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`ARTICLE OF FOOTWEAR
`WITH EXTRUDED COMPONENTS
`
`Inventors:
`
`Brian Christensen
`Paul Davis
`Ricardo Vestuti
`Henry Hardigan
`Dennis Gaboriault
`
`CROSS-REFERENCE TO RELATED APPLICATION
`
`[0001]
`
`This application is a divisional of U.S. Patent Application No. 15/644,463, filed July
`
`7, 2017 and entitled, “Article of Footwear with Extruded Components,” the disclosure of
`
`which is incorporated herein in its entirety by reference thereto.
`
`BACKGROUND
`
`Field
`
`[0002]
`
`Embodiments of the present invention relate generally to articles of footwear; and
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`more specifically to articles of footwear with extruded (e.g., dispensed) components.
`
`Background
`
`[0003]
`
`Individuals can be concerned with the amount of cushioning an article of footwear
`
`provides, as well as the aesthetic appeal of the article of footwear. This is true for articles
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`of footwear worn for non-performance activities, such as a leisurely stroll, and for
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`performance activities, such as running, because throughout the course of an average day,
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`the feet and legs of an individual are subjected to substantial impact forces. When an
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`article of footwear contacts a surface, considerable forces may act on the article of
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`footwear and, correspondingly, the wearer's foot.
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`[0004]
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`The human foot
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`is a complex and remarkable piece of machinery, capable of
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`withstanding and dissipating many impact forces. The natural padding of fat at the heel
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`and forefoot, as well as the flexibility of the arch, help to cushion the foot. Although the
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`human foot possesses natural cushioning and rebounding characteristics, the foot aloneis
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`incapable of effectively overcoming many of the forces encountered during every day
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`activity. Unless an individual
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`is wearing footwear that provides proper cushioning,
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`support, and flexibility, the soreness and fatigue associated with every day activity is
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`more acute, and its onset accelerated. The discomfort for the wearer that results may
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`diminish the incentive for further activity. Also,
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`inadequate cushioning, support, or
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`flexibility in an article of footwear can lead to injuries such as blisters; muscle, tendon,
`
`and ligament damage; and bonestress fractures. Improper footwear can also lead to other
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`ailments, including back pain.
`
`BRIEF SUMMARY
`
`[0005]
`
`Articles of footwear with extruded (e.g., dispensed) components are disclosed. The
`
`components may be formed via an automated dispensing process that is done robotically.
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`In some embodiments, an upper for an article of footwear includes a first upper panel, a
`
`second upper panel, and an extruded component. In some embodiments, the extruded
`
`componentis disposed along a border between the first upper panel and the second upper
`
`panel. In some embodiments, the extruded componentjoins the first upper panel to the
`
`second upperpanel.
`
`[0006]
`
`In some embodiments, the extruded component is polyurethane (or another suitable
`
`polymeric material). In some embodiments, a material of the first upper panelis different
`
`than a material of the second upper panel. In some embodiments, the extruded component
`
`forms a portion of a closure system for the article of footwear. In some embodiments, the
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`upper also includes a seam joiningthe first upper panel and the second upperpanel.
`
`[0007]
`
`In some embodiments, the extruded component is disposed on an exterior surface of
`
`the first upper panel and the second upper panel. In some embodiments, the extruded
`
`component forms an exterior surface of the upper.
`
`[0008]
`
`In some embodiments, the upper also includes a third upper panel and an additional
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`extruded component.
`
`In some embodiments,
`
`the additional extruded component
`
`is
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`disposed along a border between the first upper panel and the third upper panel. In some
`
`embodiments, the additional extruded componentjoins the first upper panel to the third
`
`upper panel.
`
`[0009]
`
`In some embodiments, an article of footwear includes a sole, an upper having a
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`plurality of panels, and an upper extruded component joining two adjacent panels of the
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`plurality of panels together. In some embodiments, the two adjacent panels are joined
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`together only by the upper extruded component.
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`[0010]
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`In some embodiments, the upper extruded component joins each of the plurality of
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`panels to adjacent panels. In some embodiments, each of the plurality of panels are joined
`
`together only by the upper extruded component.
`
`[0011]
`
`In some embodiments,
`
`the sole includes a sole extruded component.
`
`In some
`
`embodiments, the sole extruded component is a ground-contacting surface of the article
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`of footwear. In some embodiments, the sole extruded component extends from a heel area
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`of the article of footwear to a toe area of the article of footwear. In some embodiments,
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`the sole extruded component may be discontinuous (e.g., separate heel and forefoot
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`extruded components). In some embodiments,
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`the sole extruded component may be
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`positioned only in a portion of the article of footwear (e.g., heel area only, midfoot area
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`only, forefoot area only, or a combination thereof).
`
`In some embodiments,
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`the sole
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`extruded component extends above the sole to form a closure system for the article of
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`footwear.
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`[0012]
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`In some embodiments, the plurality of panels includes at least ten panels. In some
`
`embodiments, at least one panel of the plurality of panels is a heel counter.
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`[0013]
`
`In some embodiments, a method of making an upperincludes shapinga first panel to
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`form part of the upper, shaping a second panel to form another part of the upper, placing
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`the first panel adjacent to the second panel, and extruding a component along a border
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`between the first panel and the second panel to join the first panel and the second panel
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`together.
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`[0014]
`
`In some embodiments, placing the first panel adjacent to the second panel includes
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`abutting the first panel against the second panel. In some embodiments, the method also
`
`includes shaping additional panels to form parts of the upper and extruding the
`
`component along borders between the additional panels, the first panel, and the second
`
`panel to join each of the panels to form the entire upper. In some embodiments, the first
`
`panel completely surrounds the second panel.
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`BRIEF DESCRIPTION OF THE DRAWINGS
`
`[0015]
`
`The accompanying drawings, which are incorporated herein and form a part of the
`
`specification, illustrate the present invention and, together with the description, further
`
`serve to explain the principles of the invention and to enable a person skilled in the
`
`pertinent art to make and use the invention.
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`[0016]
`
`FIG.
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`1 shows a perspective view of an article of footwear according to some
`
`embodiments.
`
`[0017]
`
`[0018]
`
`[0019]
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`FIG. 2 showsa front view ofan article of footwear according to some embodiments.
`
`FIG. 3 shows a back view ofan article of footwear according to some embodiments.
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`FIG. 4 shows a medial side view of an article of footwear according to some
`
`embodiments.
`
`[0020]
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`FIG. 5 shows a lateral side view of an article of footwear according to some
`
`embodiments.
`
`[0021]
`
`[0022]
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`FIG. 6 showsa top view ofan article of footwear according to some embodiments.
`
`FIG.
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`7 shows a bottom view of an article of footwear according to some
`
`embodiments.
`
`[0023]
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`FIG. 8 shows a top view of an upper layout for an article of footwear according to
`
`some embodiments.
`
`[0024]
`
`FIG. 9 showsa bottom view of an upper layout for an article of footwear according to
`
`some embodiments.
`
`[0025]
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`FIG. 10 shows a top view of an upper layout for an article of footwear according to
`
`some embodiments.
`
`[0026]
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`FIG. 11 shows a bottom view of an upper layout for an article of footwear according
`
`to some embodiments.
`
`[0027]
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`FIG. 12 shows a bottom view of a sole for an article of footwear according to some
`
`embodiments.
`
`[0028]
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`FIG. 13 shows a top view of a sole for an article of footwear according to some
`
`embodiments.
`
`[0029]
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`FIG. 14 showsa side view of a sole for an article of footwear according to some
`
`embodiments.
`
`[0030]
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`FIGS. 15A—15I show portions of an upper with an extruded component according to
`
`some embodiments.
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`[0031]
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`FIG. 16 shows an article of footwear having an upper support element with an
`
`extruded component according to some embodiments.
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`[0032]
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`FIG. 17 shows an upper support element for an article of footwear made with an
`
`extruded component according to some embodiments.
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`[0033]
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`FIG. 18 shows an upper support element for an article of footwear made with an
`
`extruded component according to some embodiments.
`
`[0034]
`
`FIG. 19 shows an upper support element for an article of footwear made with an
`
`extruded component according to some embodiments.
`
`[0035]
`
`FIG. 20 shows an upper support element for an article of footwear made with an
`
`extruded component according to some embodiments.
`
`[0036]
`
`FIG. 21 shows an upper support element for an article of footwear made with an
`
`extruded component according to some embodiments.
`
`[0037]
`
`FIG. 22 shows an upper support element for an article of footwear made with an
`
`extruded component according to some embodiments.
`
`[0038]
`
`FIG. 23 shows an upper support element for an article of footwear made with an
`
`extruded component according to some embodiments.
`
`[0039]
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`FIG. 24 showsa portion of a sole during the process of creating the sole for an article
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`of footwear according to some embodiments.
`
`[0040]
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`FIG. 25 showsa portion of a sole during the process of creating the sole for an article
`
`of footwear according to some embodiments.
`
`[0041]
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`FIG. 26 showsa portion of a sole during the process of creating the sole for an article
`
`of footwear according to some embodiments.
`
`[0042]
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`FIG. 27 showsa portion of a sole during the process of creating the sole for an article
`
`of footwear according to some embodiments.
`
`[0043]
`
`[0044]
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`FIG. 28 showsa sole for an article of footwear according to some embodiments.
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`FIG. 29 shows an upper support element and an upper layout for an article of
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`footwear according to some embodiments.
`
`[0045]
`
`FIG. 30 shows an upper support element and an upper layout for an article of
`
`footwear according to some embodiments.
`
`[0046]
`
`FIG. 31 shows an upper support element and an upper layout for an article of
`
`footwear according to some embodiments.
`
`[0047]
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`FIG. 32 shows an upper support element and an upper layout for an article of
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`footwear according to some embodiments.
`
`[0048]
`
`FIG. 33 showsan article of footwear with an extruded component according to some
`
`embodiments.
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`[0049]
`
`FIG. 34 shows an upper support element for an article of footwear made with an
`
`extruded component according to some embodiments.
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`DETAILED DESCRIPTION
`
`[0050]
`
`The present invention will now be described in detail with reference to embodiments
`
`thereofas illustrated in the accompanying drawings, in which like reference numerals are
`
`used to indicate identical or
`
`functionally similar elements. References
`
`to “one
`
`embodiment”, “an embodiment”, “an example embodiment”, etc.,
`
`indicate that
`
`the
`
`embodiment described may include a particular feature, structure, or characteristic, but
`
`every embodiment may not necessarily include the particular feature, structure, or
`
`characteristic. Moreover,
`
`such phrases are not necessarily referring to the same
`
`embodiment. Further, when a particular feature, structure, or characteristic is described in
`
`connection with an embodiment, it is submitted that it is within the knowledge of one
`
`skilled in the art to affect such feature, structure, or characteristic in connection with other
`
`embodiments whether or not explicitly described.
`
`[0051]
`
`The term “invention”or “present invention” as used herein is a non-limiting term and
`
`is not
`
`intended to refer to any single embodiment of the particular invention but
`
`encompassesall possible embodiments as described in the application.
`
`[0052]
`
`The following examples are illustrative, but not limiting, of the present invention.
`
`Other suitable modifications and adaptations of the variety of conditions and parameters
`
`normally encountered in the field, and which would be apparent to those skilled in theart,
`
`are within the spirit and scope of the invention.
`
`[0053]
`
`Embodiments of the present invention provide articles of footwear having one or
`
`more extruded components created by an automated dispensing process. It is understood
`
`that while the term “extruded”is generally used herein to refer to certain materials, these
`
`materials may also be “dispensed,” for example, dispensed from a mechanical device.
`
`Thus,
`
`the term “extruded component” includes components that are extruded and
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`componentsthat are dispensed.
`
`[0054]
`
`In some embodiments, an upper and/or a sole of the article of footwear may have one
`
`or more extruded components. In some embodiments, an upper and/or a sole, or portions
`
`thereof, can be formed from one or more extruded components. In some embodiments,
`
`the extruded component can be a single, continuous piece of solid material. An extruded
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`footwear component can have advantages overtraditionally-formed components, such as
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`those made by casting, pouring, injection molding, screen-printing, or thermo-plastically
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`forming. For example, an extruded component can be customized without having to
`
`machine a new, expensive mold. The use of extruded components can also allow for the
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`use of shapes and geometries that are difficult to achieve using conventional upper or
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`bottom molding techniques. Moreover, the data and knowledge to make an extruded
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`component can be quickly deployed to any location that houses equipment and material
`
`suitable for processing.
`
`[0055]
`
`Various physical properties of the extruded component can be manipulated, adjusted,
`
`altered, and/or modified. For example, in some embodiments, the width, length, shape,
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`wall thickness, color, density, elasticity, material, viscosity, hardness, etc. of the extruded
`
`component can vary along the extruded component or between a first and second
`
`extruded component. As an example, an extruded component on an upper maybeless
`
`viscous than an extruded component on a sole, which can help the extruded component
`
`on the upperlay flat. As another example, an extruded upper component maybe rigid in a
`
`first portion, flexible in a second portion that is continuous with the first portion, and rigid
`
`in a third portion that is continuous with the first portion. The extruded upper component
`
`may similarly vary in other characteristics, such as color.
`
`[0056]
`
`In some embodiments, the extruded component can be made of rubber, foam (e.g.,
`
`dispensed
`
`polyurethane
`
`foam),
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`silicone,
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`plastic
`
`including
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`thermoplastic
`
`(e.g.,
`
`polyurethane (such as TPU), nylon, or polypropylene), or any other suitable material. In
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`some embodiments, the extruded component can be made of a composite material. In
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`some embodiments, the cross-section of the extruded component can be substantially
`
`circular, oval, rectangular, triangular, square, or any other suitable shape or design (e.g.,
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`star-shaped). In some embodiments, the cross-section of the extruded component can be
`
`relatively flat G.e., low profile). Moreover, the cross-section of the extruded component
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`may be adjusted dynamically and may vary throughout the automated dispensing process.
`
`[0057]
`
`In some embodiments, the extruded component can be extruded directly onto the
`
`article of footwear, such as directly onto the sole (e.g., insole, midsole, and/or outsole) or
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`the upper. For example, the extruded component can be extruded or dispensed directly
`
`onto a formed upper onalast (e.g., a flat knit upper, a circular knit upper, a formed three-
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`dimensional knit, a sock, a fully-finished traditionally-lasted upper, etc.). The upper may
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`be made ofa textile fabric, leather, synthetic, or film product. In some embodiments, the
`
`extruding or dispensing is done automatically (i.e., robotically). In some embodiments, a
`
`scanner may scan the upper and then robotically dispense the extruded component onto
`
`the upper based on the scan.
`
`[0058]
`
`In some embodiments, the extruded component can be usedto partially or completely
`
`join a plurality of panels together to form the upper. In some embodiments, the extruded
`
`component can be extruded along the border between twopanels. In some embodiments,
`
`the extruded component may bond (e.g., by thermal fusion, chemical adhesion, or
`
`mechanical locking) to a portion of the article of footwear (e.g., one or more panels). In
`
`some embodiments, a portion of the extruded component may bond to the article of
`
`footwear, while another portion of the extruded component does not bondto the article of
`
`footwear.
`
`[0059]
`
`In some embodiments, the extruded component may form an upper support element
`
`for the article of footwear. In some embodiments, the extruded component may be used as
`
`part of a closure system for the article of footwear. For example, the extruded component
`
`may support laces or other securement straps for securing the article of footwear to the
`
`wearer.
`
`[0060]
`
`In some embodiments,
`
`the article of footwear may include or utilize any of the
`
`extruded components or other features disclosed in U.S. Application No. 14/455,650,
`
`filed August 8, 2014, and/or U.S. Application 14/945,077, filed November 18, 2015, the
`
`disclosures of which are incorporated herein in their entireties by referencethereto.
`
`[0061]
`
`In some embodiments, extruded components may be extruded directly onto other
`
`portions of an article of footwear, such as article of footwear 100 shown in FIGS. 1-7. In
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`some embodiments, article of footwear 100 may include a sole 110 and an upper 120. In
`
`some embodiments, sole 110 and/or upper 120 include an extruded component. The
`
`component may beextruded onto a surface so as to provide an extruded componentthat
`
`extends abovethe surface at a certain width and height profile. In some embodiments, the
`
`height, width, or geometry or physical appearance/characteristic of the extruded
`
`components may be dynamically changed as the components are extruded onto article of
`
`footwear 100, such as onto upper 120. In some embodiments, the geometry or physical
`
`appearance/characteristics of the extruded components may be changed by dynamically
`
`changing the height of the nozzle (relative to the dispensing surface or substrate) from
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`which the material, used to form the component, is extruded. In some embodiments, the
`
`geometry or physical appearance/characteristics of the extruded components may be
`
`changed by dynamically changing the speed at which the nozzle is moving as the material
`
`is extruded and the component is formed. In some embodiments, the geometry or physical
`
`appearance/characteristics of the extruded components may be changed by dynamically
`
`changing the flow rate of the material that is extruded. Other parameters may be changed
`
`to dynamically change the height, width, or other characteristic of the extruded
`
`components. In some embodiments, the density or viscosity of the extruded components
`
`may be changed. For example, a low density extruded component may be used to form a
`
`collar of the upper 120.
`
`[0062]
`
`In some embodiments, upper 120 has one or more panels 130 and one or more upper
`
`extruded components 140 that define all or a portion of the area of the upper. In some
`
`embodiments, panels 130 comprise individual
`
`textile pieces.
`
`In some embodiments,
`
`panels 130 may be made of leather, synthetic leather, plastic (e.g., thermoplastic film),
`
`mesh, textile, knit-goods, woven-goods, non-woven, or other suitable materials. In some
`
`embodiments, panels 130 may be made of a knitted or woven fabric.
`
`In some
`
`embodiments, panels 130 may be made of a non-knitted or non-woven fabric. In some
`
`embodiments, upper 120 is a knit upper. In some embodiments, upper 120 is a circular
`
`knit upper. For example, a portion or the entirety of upper 120 may be circular knit. In
`
`some embodiments, upper 120 is a 360 degree circular knit upper. In some embodiments,
`
`upper 120is a flat knit upper. For example, a portion or the entirety of upper 120 may be
`
`flat knit.
`
`[0063]
`
`In some embodiments, upper 120 comprises at
`
`least five panels 130.
`
`In some
`
`embodiments, upper 120 comprises at least ten panels 130. In some embodiments, panels
`
`130 may differ from one another in size, shape, material, and/or other characteristics. In
`
`some embodiments,
`
`the characteristics vary based on desired functions of article of
`
`footwear 100 at particular locations. For example,
`
`in some embodiments, upper 120
`
`comprises one or more panels 132 configured to provide additional support, such as in a
`
`heel region of upper 120. In some embodiments, panels 132 comprise a heel counter (see
`
`FIG. 3). In some embodiments, upper comprises one or more panels 134 madeofa first
`
`material and one or more panels 136 made of a second material. In some embodiments,
`
`panels 134 are made of a knitted fabric and panels 136 are made of a non-knitted fabric.
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`[0064]
`
`In some embodiments, upper extruded components 140 are extruded directly onto
`
`upper 120 (e.g., panels 130 of upper 120) to form a portion of upper 120. In some
`
`embodiments, upper extruded components 140 may have a lower viscosity than other
`
`extruded components (e.g., extruded components in sole 110). Accordingly, upper
`
`extruded components 140 may berelatively flat on upper 120 (see, e.g., FIG. 2). In some
`
`embodiments, upper extruded components 140 are disposed on an exterior portion of
`
`article of footwear 100. In some embodiments, upper extruded components 140 form an
`
`exterior portion of article of footwear 100.
`
`[0065]
`
`In some embodiments, upper extruded components 140 provide aesthetic and
`
`functional features of article of footwear 100. In some embodiments, upper extruded
`
`components 140 may form a pattern on upper 120. In some embodiments, upper extruded
`
`components 140 may be a single, continuous element. In some embodiments, upper
`
`extruded components 140 may include a plurality of continuous elements.
`
`In some
`
`embodiments, upper extruded components 140 include one or more extruded components
`
`142 that are disposed along a border (..e., transition) between two or more panels 130 or
`
`an area of overlap between two or more panels 130, one or more extruded components
`
`144 that are disposed across (but not along a border between) one or more panels 130,
`
`and one or more extruded components 146 that completely surround a panel 130 along
`
`the border of panel 130. In some embodiments, a single upper extruded component 140
`
`may form both an extruded component 142 and an extruded component 144. In some
`
`embodiments, a single upper extruded component 140 may form both an extruded
`
`component 142 and an extruded component 146. In some embodiments, a single upper
`
`extruded component 140 may form both an extruded component 144 and an extruded
`
`component 146.
`
`[0066]
`
`In some embodiments, upper extruded components 140 form part of a closure system
`
`for article of footwear. For example, as shown in FIG. 1, laces 150 extend through upper
`
`120 between portions of upper extruded component 144. This may strengthen the hole
`
`that receives laces 150. In some embodiments, upper extruded components 140 may
`
`provide a loop to receive laces 150. In some embodiments, extruded components may
`
`support other components configured to receive laces 150.
`
`[0067]
`
`In some embodiments, upper extruded components 140 (e.g., extruded component
`
`142, extruded component 144, or extruded component 146) join two or more panels 130
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`together. In some embodiments, upper extruded components 140 are the only means for
`
`joining panels 130 together (.e., panels 130 are not sewn, joined with an adhesive, joined
`
`with low-melt film,
`
`laser-welded, ultrasonically welded, radio-frequency welded, or
`
`otherwise joined together except by upper extruded components 140).
`
`In some
`
`embodiments, panels 130 are joined together by upper extruded components 140 as well
`
`as being sewn, joined with an adhesive, laser-welded, ultrasonically welded, or radio-
`
`frequency welded.
`
`[0068]
`
`In some embodiments, two or more panels 130 are joined together or coupled at a
`
`seam.
`
`In some embodiments,
`
`the seam may include one or more of upper extruded
`
`component 140, adhesive, stitching, or another suitable redundant joining method. In
`
`some embodiments, the seam is a stitchless seam. In some embodiments, the seam is a
`
`stitchless seam with an overlay. In some embodiments, the seam is a butt seam. In some
`
`embodiments, the seam is a hidden seam (e.g., closed seam). In some embodiments, the
`
`seam is covered with seam tape. For example, the seam may include upper extruded
`
`component 140 on an outer surface of upper 120 and seam tape on an inner surface of
`
`upper 120. In some embodiments, the seam comprises an area of overlap between the two
`
`panels 130.
`
`[0069]
`
`For example, a layout for an upper 120 is shown in FIGS. 8 and 9. The various panels
`
`130 making up upper 120 (including panels 132, panels 134, and panels 136) are joined
`
`together by upper extruded components 140. Some of upper extruded components 140
`
`extend along the border between panels 130 (i.e., extruded components 142). Some of
`
`upper extruded components 140 extend across multiple panels 130, but not along a border
`
`between panels 130 (i.e., extruded components 144). Some of upper extruded components
`
`140 extend to completely surround a panel 130 (i.e., extruded components 146). As
`
`shown on the innerside of upper 120 (see FIG. 9), no additional element or means (other
`
`than upper extruded components 140) joins panels 130 together.
`
`[0070]
`
`The placement of upper extruded components 140is not limited to a particular design
`
`or configuration. Instead, upper extruded components 140 may be dispensed in a desired
`
`location to provide a desired function or aesthetic. An additional example of upper 120is
`
`provided in FIGS. 10 and 11. In some embodiments, as shown in FIGS. 10 and 11, all
`
`upper extruded components 140 are extruded components 142 (1.e., all upper extruded
`
`components 140 extend along a border between panels 130). As shown on the innerside
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`-12-
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`of upper 120 (see FIG. 11), no additional element or means (other than upper extruded
`
`components 140) joins panels 130 together.
`
`[0071]
`
`In some embodiments, upper 120 is made by shapinga plurality of panels 130 to form
`
`parts of the upper. In some embodiments,a first panel 130 may be shaped to form part of
`
`upper 120. For example, the first panel 130 may be cut to a particular shape. In some
`
`embodiments, a second panel 130 may also be shaped to form another part of upper 120,
`
`for example, by cutting. In some embodiments, the first and second panels 130 may be
`
`placed adjacent to each other. For example, the first panel 130 may be abutted against the
`
`second panel 130 to form a border. In some embodiments, a component 140 is extruded
`
`along a border between the first and second panels 130. As extruded component 140
`
`hardens, extruded component 140 bonds with first and second panels 130 and thus joins
`
`first and second panels 130 together. In some embodiments, component 140 is extruded
`
`onto panels 130 in a flat configuration. In some embodiments, component140 is extruded
`
`onto panels 130 in a three dimensional configuration (e.g., onto a contoured surface). For
`
`example, component 140 may be extruded onto panels 130 when panels 130 are on a shoe
`
`last, a foot form, or any other three-dimensional form suitable for holding panels 130.
`
`While only two panels 130 are discussed here, additional panels 130 may be shaped to
`
`form other parts of upper 120 and components 140 may be extruded along each of the
`
`borders between panels 130 to join panels 130 together to form the entire upper 120. In
`
`some embodiments, one panel 130 may completely surround another panel 130.
`
`[0072]
`
`In some embodiments, as shown, for example, in FIGS. 1-7, sole 110 comprises
`
`various layers of extruded components. In some embodiments, sole 110 can provide the
`
`desired ride and feel characteristics to the wearer. In some embodiments, sole 110 can
`
`minimize the weight of article of footwear 100; control
`
`the flexion, resilience, and
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`support of article of footwear 100; and provide customized desired cushioning and shape
`
`for an article of footwear 100. In some embodiments, sole 110 comprises an extruded
`
`component 112. In some embodiments, extruded component 112 is disposed at the
`
`junction between sole 110 and upper 120. In some embodiments, extruded component
`
`112 forms an outer edge of sole 110 and/or upper 120. In some embodiments, extruded
`
`component 112 is one continuous componentthat surroundsarticle of footwear 100.
`
`[0073]
`
`In some embodiments, extruded component 112 provides a base componentor layer
`
`around which the rest of sole 110 is made (see FIGS. 24-28). For example, in some
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`embodiments, additional layers of extruded component(s) may be deposited adjacent to
`
`extruded component 112 to form a portion of sole 110, such as a midsole. For example,
`
`one or more layers 114 of extruded component may be deposited adjacent to extruded
`
`component 112. In some embodiments, layers 114 provide a midsole of sole 110. In some
`
`embodiments, layers 114 are formed from one continuous extruded component. In some
`
`embodiments, each layer 114 is formed from a separate continuous extruded component.
`
`In some embodiments, as shown in FIGS. 4 and 5, the numberof layers 114 varies along
`
`a length of the article of footwear 100. In some embodiments, the extruded component of
`
`layers 114 may be extruded in a pattern, such as a loop-forming pattern back and forth
`
`across article of footwear 100 (e.g., in a longitudinal direction, a transverse direction, or
`
`an angled direction between a longitudinal direction and a transverse direction). In some
`
`embodiments, the extruded componentof layers 114 extends from a heel area ofarticle of
`
`footwear 100 to a toe area ofthe article of footwear 100.
`
`[0074]
`
`In some embodiments, the extruded component of layers 114 is discontinuous such
`
`that there are separate heel and forefoot extruded components. In some embodiments, the
`
`extruded component of layers 114 is positioned only in a portion of sole 110 (e.g., heel
`
`area only, midfoot area only, forefoot area only, or a combination thereof). In some
`
`embodiments, other portions of sole 110 may be made of foam. For example, article of
`
`footwear 100 may include the extruded componentof layers 114 only in the heel of sole
`
`110 with foam in the forefoot of sole 110. As another example, article of footwear 100
`
`may include the extruded component of layers 114 only in the forefoot of sole 110 with
`
`foam in the heel of sole 110. In some embodiments, there may be more layers 114 in the
`
`heel of sole 110 than in the forefoot of sole 110 to create a heel
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`lift.
`
`In some
`
`embodiments, a heel lift may be created with the same numberof layers 114 in the heel of
`
`sole 110 andin the forefoot of sole 110, but with the nozzle running faster in the forefoot
`
`and slowerin the heel.
`
`[0075]
`
`In some embodiments, one or more layers 116 of extruded component are deposited
`
`adjacent to layers 114 (i.e., underneath layers 114). In some embodiments, layers 116
`
`provide an outsole of sole 110. In some embodiments, layers 116 are formed from one
`
`continuous extruded component. In some embodiments, each layer 116 is formed from a
`
`separate continuous extruded component. In some embodiments, the extruded component
`
`of layers 116 may be extruded in a pattern, such as an undulating pattern back and forth
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`across article of footwear 100 (e.g., in a longitudinal direction, a transverse direction, or
`
`an angled direction between a longitudinal direction and a transverse direction). For
`
`example, as shownin FIG. 7, sole 110 includes a layer 116 of an extruded componentthat
`
`extends back and forth in a transverse direction across article of footwear 100 in an
`
`undulating pattern and a layer 116 of an extruded component that extends back and forth
`
`in an angled direction (between the longitudinal and transverse directions) across article
`
`of footwear 100 in an undulating pattern. In some embodiments, layers 116 differ from
`
`layers 114 in at
`
`least one characteristic (e.g., color, density, shape, size, material
`
`composition, etc.).
`
`In some embodiments,
`
`layers 116 comprise a gro