SENSORY SOLE STRUCTURE FOR AN ARTICLE OF FOOTWEAR

Abstract

An article of footwear can include an upper and a sole member coupled to the upper, where the sole member comprises a plurality of spaced apart apertures extending through the sole member. The article of footwear can further include a plurality of individual sensory nodes, where each sensory node has a first end coupled directly to the upper and an opposite, second end configured to engage with a ground surface. Each sensory node is configured to translate freely within a respective aperture of the sole member.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Patent Application No. 63/660,700, filed Jun. 17, 2024. This application also claims the benefit of U.S. Provisional Patent Application Nos. 63/573,690 and 63/573,694, filed Apr. 3, 2024. This application also claims the benefit of U.S. Provisional Patent Application Nos. 63/597,182 and 63/597,184, filed Nov. 8, 2023. The related applications are incorporated by reference herein.

FIELD

This disclosure relates generally to articles of footwear and, in particular to sole structures for articles of footwear.

BACKGROUND

An article of footwear typically includes two main components: a sole structure and an upper. The sole structure is configured for supporting the wearer's foot and providing cushioning between the wearer's foot and the ground. The sole structure may include an outsole that is adapted to contact the ground. The upper is coupled to the sole structure and is configured for securing the wearer's foot to the sole structure.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a lateral side view of an article of footwear including a sole member and sensory node assembly coupled to an upper.

FIG. 2 is a bottom view of the article of footwear of FIG. 1 illustrating sensory nodes of the sensory node assembly protruding outward from the sole member.

FIG. 3 is a perspective view of a sole system for the article of footwear of FIG. 1 which includes the sole member and the sensory node assembly.

FIG. 4 is a top view of the sole system of FIG. 3.

FIG. 5 is a bottom view of the sole system of FIG. 4.

FIG. 6 is a lateral side view of the sole system of FIG. 3.

FIG. 7 is a disassembled view of components of a jig system for coupling a sensory node assembly to an upper for an article of footwear.

FIG. 8 is a disassembled top view of a cutting member and sensory node holding member that make up a sensory node cutting jig of the jig system of FIG. 7.

FIG. 9 is an assembled side view of the sensory node cutting jig of FIG. 8.

FIG. 10 is a top view of a base member of the jig system of FIG. 7.

FIG. 11 is a top view of a sensory node holder received within the base member of FIG. 10, where the sensory node holder is configured to receive lower ends of sensory nodes therein.

FIG. 12 is an assembled side view of a sensory node transfer assembly of the jig system of FIG. 7, the sensory node transfer assembly including the base member and sensory node holder coupled to the sensory node holding member and a pressing member disposed on top of the sensory node holding member.

FIG. 13 is a flow chart of a method for coupling a sensory node assembly to an upper to form an article of footwear.

FIG. 14 is a flow chart of a method for arranging a sensory node assembly within a sole member and coupling the sensory node assembly and sole member to an upper to form an article of footwear with a jig system.

FIG. 15 depicts a sensory node assembly with sensory nodes connected by connecting bridges disposed within the sensory node holding member of FIG. 8, with bottom ends of the sensory nodes extending outward from the sensory node holding member.

FIG. 16 depicts the cutting member of FIG. 8 disposed over the sensory node assembly and coupled to the sensory node holding member, and the assembled sensory node cutting jig disposed within a press apparatus.

FIG. 17 depicts the sensory node cutting jig after being pressed with the press apparatus to cut the connecting bridges from the sensory nodes of the sensory node assembly.

FIG. 18 depicts removal of the cutting member from the sensory node holding member.

FIG. 19 depicts the cut sensory nodes within the sensory node holding member, with the connecting bridges being removed from between the sensory nodes.

FIG. 20 depicts the sensory node holding member flipped over and coupled to the base member so that the lower ends of the sensory nodes can be received within the sensory node holder.

FIG. 21 depicts placing the pressing member over the outer side of the sensory node holding member to form the sensory node transfer assembly of FIG. 12.

FIG. 22 depicts pressing together the sensory node transfer assembly within the press apparatus in order to transfer the lower ends of the sensory nodes of the sensory node assembly to the sensory node holder.

FIG. 23 depicts the sensory node assembly coupled to the sensory node holder such that upper ends of the sensory nodes are free and extending away from the sensory node holder.

FIG. 24 depicts inserting the sensory node holder with the coupled sensory nodes into a base receptacle.

FIG. 25 depicts positioning a sole member around the sensory nodes within the base receptacle.

FIG. 26 depicts activating an adhesive on the upper ends of the sensory nodes and/or sole member.

FIG. 27 depicts positioning an upper over the sensory node assembly and the sole member.

FIG. 28 depicts pressing the upper into the sensory node assembly and the sole member to attach the upper ends of the sensory nodes directly to the upper and couple the upper to the sole member.

FIG. 29 depicts removing the base receptacle from the assembled article of footwear.

FIG. 30 depicts removing the sensory node holder from the lower ends of the sensory nodes.

FIG. 31 depicts trimming around the sensory nodes within the sole member.

FIG. 32 is a perspective view of an article of footwear including a sole member and sensory node assembly coupled to an upper.

FIG. 33 is a bottom perspective view of the article of footwear of FIG. 33 illustrating sensory nodes of the sensory node assembly protruding outward from the sole member.

FIG. 34 is a lateral side view of an article of footwear including a sole member and sensory node assembly coupled to an upper.

FIG. 35 is a bottom view of the article of footwear of FIG. 34 illustrating sensory nodes of the sensory node assembly protruding outward from the sole member.

FIG. 36 illustrates an exemplary computing system for implementing a portion of the disclosed methods.

FIG. 37A is a top view of a web assembly comprising sensory nodes that are interconnected by a web, or in a sheet of material, following the molding process.

FIG. 37B is a bottom view of the web assembly of FIG. 37A.

FIG. 38 is a perspective view of an exemplary cutting member for a cutting jig of a jig system for coupling a sensory node assembly to an upper for an article of footwear, such as the sensory node assembly of FIGS. 37A and 37B.

FIG. 39 is a perspective view of an exemplary sensory node holding member configured to interface with the cutting member of FIG. 38 and form the cutting jig.

FIG. 40 is a perspective view of the web assembly of FIG. 37B held within the sensory node holding member of FIG. 39.

FIG. 41 is a perspective view of cut sensory nodes transferred to a node holder of the jig system, which is held within a base member.

FIG. 42 is a lateral view of an exemplary article of footwear including a sole member and sensory node assembly coupled to an upper.

FIG. 43A is a first cross-sectional view of the article of footwear of FIG. 42 taken along a forefoot portion of the article.

FIG. 43B is a second cross-sectional view of the article of footwear of FIG. 42 taken along a midfoot portion of the article.

FIG. 43C is a third cross-sectional view of the article of footwear of FIG. 42 taken along a heel portion of the article.

FIG. 44 is a schematic cross-sectional view of an exemplary strobel with a sensory node connected thereto.

FIG. 45 is a perspective view of an exemplary article of footwear including a sole member, a fabric layer of an upper, and individual sensory nodes arranged within the sole member and attached to the fabric layer.

FIG. 46 is a top view of the article of footwear of FIG. 45, showing articles for both a right and left foot.

FIG. 47 is a top perspective view of the article of footwear of FIG. 45 with the fabric layer removed.

FIG. 48 is a top view of the article of footwear of FIG. 45 with a last arranged within a foot cavity of the article.

FIG. 49 is a lateral side view of the article of footwear of FIG. 48.

FIG. 50 is a medial side view of the article of footwear of FIG. 48.

FIG. 51 is a bottom view of the article of footwear of FIG. 48.

FIG. 52 is a front view of the article of footwear of FIG. 48.

FIG. 53 is a rear view of the article of footwear of FIG. 48.

FIG. 54 depicts arranging a jig across a fabric layer for an upper of an article of footwear.

FIG. 55 depicts connecting edges of the fabric layer to the jig of FIG. 54.

FIG. 56 depicts inserting the assembled fabric layer and jig of FIG. 55 into a foot cavity of the article of footwear and attaching the fabric layer to the sole member using the jig.

FIG. 57 depicts removing the jig to reveal the fabric layer arranged across the sole member of the article of footwear.

FIG. 58 depicts inserting sensory nodes into respective apertures of the sole member of the article of footwear and attaching the sensory nodes to the fabric layer of FIG. 57.

FIG. 59 depicts attaching a tongue to an upper of an article of footwear.

FIG. 60 is a top view of the article of footwear of FIG. 48 with a wavy V-shaped elongate channel in a top of the upper.

FIG. 61 is a top view of the article of footwear of FIG. 48 with a smaller U-shaped elongate channel in a top of the upper.

FIG. 62 is a bottom view of the article of footwear of FIG. 48 having a sensory node assembly with two separated regions of sensory nodes having a circular cross-section.

FIG. 63 is a bottom view of the article of footwear of FIG. 48 having a sensory node assembly with sensory nodes having a square cross-section.

FIG. 64 is a bottom view of the article of footwear of FIG. 48 having a sensory node assembly with sensory nodes having a triangular cross-section.

DETAILED DESCRIPTION

General Considerations

The systems and methods described herein, and individual components thereof, should not be construed as being limited to the particular uses or systems described herein in any way. Instead, this disclosure is directed toward all novel and non-obvious features and aspects of the various disclosed examples, alone and in various combinations and subcombinations with one another. For example, any features or aspects of the disclosed examples can be used in various combinations and subcombinations with one another, as will be recognized by an ordinarily skilled artisan in the relevant field(s) in view of the information disclosed herein. In addition, the disclosed systems, methods, and components thereof are not limited to any specific aspect or feature or combinations thereof, nor do the disclosed things and methods require that any one or more specific advantages be present or problems be solved.

As used in this application the singular forms “a,” “an,” and “the” include the plural forms unless the context clearly dictates otherwise. Additionally, the term “includes” means “comprises.” Further, the term “coupled” or “secured” encompasses mechanical and chemical couplings, as well as other practical ways of coupling or linking items together, and does not exclude the presence of intermediate elements between the coupled items unless otherwise indicated, such as by referring to elements, or surfaces thereof, being “directly” coupled or secured. Furthermore, as used herein, the term “and/or” means any one item or combination of items in the phrase.

Although the operations of some of the disclosed methods are described in a particular, sequential order for convenient presentation, it should be understood that this manner of description encompasses rearrangement, unless a particular ordering is required by specific language set forth below. For example, operations described sequentially may in some cases be rearranged or performed concurrently. Moreover, for the sake of simplicity, the attached figures may not show the various ways in which the disclosed things and methods can be used in conjunction with other things and methods. Additionally, the description sometimes uses terms like “provide,” “produce,” “determine,” and “select” to describe the disclosed methods. These terms are high-level descriptions of the actual operations that are performed. The actual operations that correspond to these terms will vary depending on the particular implementation and are readily discernible by one of ordinary skill in the art having the benefit of this disclosure.

For purposes of this disclosure, portions of an article of footwear (and the various component parts thereof) may be identified based on regions of the foot located at or near that portion of the article of footwear when the footwear is worn on the properly sized foot. For example, an article of footwear and/or a sole structure may be considered as having a “forefoot region” at the front of the foot, a “midfoot” region at the middle or arch area of the foot, and a “heel region” at the rear of the foot. Footwear and/or sole structures also include a “lateral side” (the “outside” or “little toe side” of the foot) and a “medial side” (the “inside” or “big toe side” of the foot). The forefoot region generally includes portions of the footwear corresponding to the toes and the joints connecting the metatarsals with the phalanges. The midfoot region generally includes portions of the footwear corresponding with the arch area of the foot. The heel region generally corresponds with the rear portions of the foot, including the calcaneus bone. The lateral and medial sides of the footwear extend through the forefoot, midfoot, and heel regions and generally correspond with opposite sides of the footwear (and may be considered as being separated by a central longitudinal axis). These regions and sides are not intended to demarcate precise areas of footwear. Rather, the terms “forefoot region,” “midfoot region,” “heel region,” “lateral side,” and “medial side” are intended to represent general areas of an article of footwear and the various components thereof to aid the in discussion that follows.

For purposes of this disclosure, directional adjectives may be employed which correspond to the illustrated example. For example, the term “longitudinal” as used herein refers to a direction extending a length of an article. In some cases, the longitudinal direction may extend from a forefoot portion to a heel portion of the article. Also, the term “lateral” as used herein refers to a direction extending a width of an article. In other words, the lateral direction may extend between a medial side and a lateral side of an article. Furthermore, the term “vertical” as used herein refers to a direction generally perpendicular to a lateral and longitudinal direction. For example, in cases where an article is planted flat on a ground surface, the vertical direction may extend from the ground surface upward. It will be understood that each of these directional adjectives may be applied to individual components of an article, such as an upper and/or a sole structure.

As used herein, the term “exemplary” means serving as a non-limiting example, instance, or illustration. As used herein, the terms “e.g.,” and “for example,” introduce a list of one or more non-limiting examples, instances, and/or illustrations.

As used herein, the term “sole structure” refers to any combination of materials that provides support for a wearer's foot and bears the surface that is in direct contact with the ground or playing surface, such as, for example, a single sole; a combination of an outsole and an inner sole; a combination of an outsole, a midsole, and an inner sole; and a combination of an outer covering, an outsole, a midsole and an inner sole.

As used herein, the terms “attached” and “coupled” generally mean physically connected or linked, which includes items that are directly attached/coupled and items that are attached/coupled with intermediate elements between the attached/coupled items, unless specifically stated to the contrary.

As used herein, the terms “articles of footwear” or “articles” mean any type of footwear, including, for example, basketball shoes, volleyball shoes, tennis shoes, running shoes, soccer shoes, football shoes, rugby shoes, baseball shoes, sneakers, hiking boots, sandals, socks, etc.

Although the figures may illustrate an article of footwear intended for use on only one foot (e.g., a right foot) of a wearer, one skilled in the art and having the benefit of this disclosure will recognize that a corresponding article of footwear for the other foot (e.g., a left foot) would be a mirror image of the right article of footwear.

Unless explained otherwise, all technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which this disclosure belongs. Although methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present disclosure, suitable methods and materials are described below. The materials, methods, and examples are illustrative only and not intended to be limiting. Other features of the disclosure are apparent from the detailed description, claims, abstract, and drawings.

The Disclosed Technology

An article of footwear typically includes two main components: a sole structure and an upper. The sole structure is configured for supporting the wearer's foot and providing cushioning between the wearer's foot and the ground (e.g., the surface on which they are moving, walking, running, etc.). The upper is coupled to the sole structure and forms a foot-receiving cavity. The upper is configured for securing the wearer's foot to the sole structure and/or can protect the wearer's foot.

While articles of footwear can be designed to provide support and increased performance for the wearer for certain activities (e.g., running, walking, playing court sports, and the like), they may not provide overall increased wellness. It may be beneficial for articles of footwear to provide feedback to a wearer (e.g., tactile feedback) and/or enhance a wearer's overall health.

Disclosed herein are articles of footwear, and methods for forming such articles of footwear, that comprise a sole system (which may be referred to as a multi-part sole structure) which provides tactile feedback or enhanced tactile sensation to the sole of the foot of the person wearing the article of footwear (“the wearer”). For example, the sole system can include features that provide a tactile response to the wearer's sole, as the wearer moves along a ground surface, and in response to variations in the ground surface. In some examples, the sole system can be configured to improve balance and positional awareness or proprioception of the wearer through stimulation of the wearer's foot by the sole system.

More specifically, described herein are sole systems that can include a sole member and a sensory node assembly (which can also be referred to as a protruding member assembly or column assembly) that is configured to be received within the sole member. The sole member can form a ground-facing surface of the article of footwear, and the sensory node assembly can comprise a plurality of individual sensory nodes that are configured to protrude out the ground-facing surface of the sole member. For example, the sensory nodes can extend through and out respective apertures in the sole member, such that the sensory nodes interact with a ground surface on which the wearer is walking, running, or the like. Upper ends of the sensory nodes can be attached directly to an upper of the article of footwear, and the sole member can be coupled to the upper. As a result, the sensory nodes can be individually movable (up and down within the apertures of the sole member) relative to a remainder of the sole system (and relative to one another). For example, as a wearer moves across the ground surface, the sensory nodes that hit the ground surface can be pushed inward through the sole system and against the upper and the wearer's foot, thereby applying pressure to (and stimulating) the wearer's foot.

Also described herein are systems and methods for forming articles of footwear comprising a sensory node assembly where the sensory nodes are directly attached to an upper of the article of footwear. Such methods can include holding a plurality of sensory nodes together in a sensory node assembly. In some examples, the sensory nodes can be interconnected within a sheet of material. As a result, the sensory nodes can be connected to one another via connectors (formed by connecting portions or a web of the sheet of material). In such examples, the method can further include cutting around each sensory node to remove the web from the sensory nodes while the sensory nodes are held together in the sensory node assembly. A sole member can be arranged around the sensory node assembly such that each sensory node extends through a respective aperture in the sole member with lower ends of the sensory nodes extending out of the respective apertures. The method can include attaching upper ends of the sensory nodes directly to an upper (e.g., a strobel of the upper) and coupling the sole member to the upper. The resulting formed article of footwear can include sensory nodes extending out of the sole member, wherein the sensory nodes are configured to individually translate (or move) within the respective apertures in the sole member as the article of footwear interacts with a ground surface.

In some examples, a system for forming the article of footwear comprising the sensory node assembly can include a jig system comprising one or more members that are couplable to one another around a sensory node assembly. In some examples, the jig system can comprise a sensory node holding member configured to hold upper ends of the sensory nodes such that the sensory nodes are held in a sensory node assembly. A cutting member be coupled to and pressed against the sensory node holding member such that connectors (or the web) between adjacent sensory nodes are cut away from the sensory nodes and can be removed from the sensory node assembly. The sensory node holding member can be flipped over and placed over a base member and node holder such that lower ends of the sensory nodes are received within depressions in the node holder. In some examples, the jig system includes a pressing member used to press-fit the lower ends of the nodes into the depressions of the node holder. As a result, the sensory nodes can be held securely within the node holder in a sensory node assembly which can then be assembled within a sole member and attached to an upper of an article of footwear. In this way, a sensory node assembly including individually movable sensory nodes (which are not directly connected to one another and not directly coupled to a sole member) can be efficiently assembled within a sole member (such as an outsole) and attached to an upper to form an article of footwear.

In some examples, an article of footwear comprises an upper and a sole member coupled to the upper, where the sole member comprises a plurality of spaced apart apertures extending through the sole member. The article of footwear further comprises a plurality of individual sensory nodes, where each sensory node has a first end coupled directly to the upper and an opposite, second end configured to engage with a ground surface. Each sensory node is configured to translate freely within a respective aperture of the sole member.

In some examples, an article of footwear comprises an upper and a sole member attached to the upper and comprising an outward-facing surface, an inward-facing surface, and a plurality of spaced apart apertures extending though the sole member, between the inward-facing surface and the outward-facing surface. The article of footwear further comprises a sensory node assembly comprising a plurality of spaced apart sensory nodes, where each sensory node is vertically movable within a corresponding aperture of the plurality of apertures, and where each sensory node is directly attached to the upper and spaced apart from the sole member.

In some examples, a sole structure for an article of footwear comprises a sole member comprising a plurality of spaced apart apertures extending through the sole member, and a plurality of sensory nodes. Each sensory node extends through a respective aperture of the plurality of spaced apart apertures. The sensory nodes of the plurality of sensory nodes are not attached to the sole member and are freely movable relative to each other and the sole member.

In some examples, a method for forming an article of footwear comprises attaching a fabric layer directly to a foot facing surface of a sole member of the article of footwear. The method further comprises holding a plurality of sensory nodes together in a sensory node assembly and arranging a sole member around the sensory node assembly such that each sensory node extends through a respective aperture in the sole member with lower ends of the sensory nodes extending out of the respective apertures. The method further comprises attaching upper ends of the plurality of sensory nodes directly to the fabric layer, thereby forming the article of footwear with the plurality of sensory nodes, wherein each sensory node extends out of the sole member and is configured to translate within the respective aperture in the sole member.

In some examples, an article of footwear comprises a sole member comprising a plurality of spaced apart apertures extending through the sole member, a fabric layer arranged across a foot facing surface of the sole member, and a plurality of individual sensory nodes. Each sensory node has a first end coupled directly to the fabric layer and an opposite, second end configured to engage with a ground surface. Each sensory node is configured to translate freely within a respective aperture of the sole member.

Additional examples of the disclosed technology are described below with reference to the accompanying drawings.

EXAMPLES OF THE DISCLOSED TECHNOLOGY

FIGS. 1 and 2 show an article of footwear 100 (lateral side and bottom views, respectively) which can also be referred to simply as the article 100. The article 100 comprises an upper 102 and a sole system 104. The sole system 104, which includes a sole member 106 and a sensory node assembly 110, is shown alone in the different view of FIGS. 3-6 (perspective, top, bottom, and lateral side views, respectively).

The article 100 may be configured for use with various kinds of footwear including, but not limited to: hiking boots, soccer shoes, football shoes, sneakers, running shoes, cross-training shoes, rugby shoes, basketball shoes, baseball shoes as well as other kinds of shoes. Moreover, in some examples the article 100 may be configured for use with various kinds of non-sports related footwear, including, but not limited to: slippers, sandals, high heeled footwear, loafers as well as any other kinds of footwear, apparel and/or sporting equipment (e.g., gloves, helmets, etc.).

Generally, the upper 102 may be any type of upper. In particular, the upper 102 may have any design, shape, size and/or color. For example, in examples where the article 100 is a basketball shoe, the upper 102 could be a high top upper that is shaped to provide high support on an ankle. In examples where the article 100 is a running shoe, the upper 102 could be a low top upper.

In some examples, as shown in FIG. 1, the upper 102 includes provisions for fastening the article 100 to a foot, such as a lacing region 108.

The sole system 104 is secured to the upper 102 and extends between the foot and the ground when the article 100 is worn by an individual. In different examples, the sole system 104 can include different components. For example, the sole system 104 can include an outsole, a midsole, and/or an insole. In some cases, one or more of these components may be optional.

The sole system 104 (which can also be referred to herein as a “sole structure”) may provide one or more functions for the article 100. For example, in some examples, the sole system 104 may be configured to provide traction for the article 100. In addition to providing traction, the sole system 104 may attenuate ground reaction forces when compressed between the foot and the ground during walking, running or other ambulatory activities. The configuration of the sole system 104 may vary in different examples to include a variety of conventional or non-conventional structures. In some cases, the configuration of the sole system 104 can be selected according to one or more types of ground surfaces on which the sole system 104 may be used. Examples of ground surfaces include, but are not limited to natural turf, synthetic turf, dirt, cement, as well as other surfaces.

As described in further detail below, in some examples, the sensory node assembly 110 of the sole system 104 can include sensory nodes 112 that enhance tactile sensation at the sole of the foot. For example, the sensory node assembly 110 can include sensory nodes 112 that provide a tactile response to variations in a ground surface and/or as different parts of the sole system engage the ground surface when worn by an individual.

Referring to FIGS. 1-6, for purposes of reference, the sole system 104 can be divided into a forefoot portion 114, a midfoot portion 116 and a heel portion 118 (as labeled in FIG. 5). In addition, the sole system 104 may include a lateral side 117 (the side shown in FIG. 6) and a medial side 119 (the side shown in the perspective view of FIG. 3). In particular, the lateral side 117 and the medial side 119 are opposing sides of article 100. Furthermore, both the lateral side 117 and the medial side 119 may extend through the forefoot portion 114, midfoot portion 116, and heel portion 118.

As shown in FIGS. 1-6, the sole system 104 includes the sole member 106 (which can also be referred to as a carrier) and the sensory node assembly 110 (which can also be referred to as a protruding member assembly or column assembly). The sensory node assembly 110 comprises a plurality of sensory nodes 112 (which can also be referred to as protruding members or columns). The sole member 106 is adapted to receive the sensory node assembly 110, as described in further detail below. In some examples, the sole member 106 can be a midsole. In some examples, the sole member 106 can be an outsole.

The sensory nodes 112 of the sensory node assembly 110 are individual sensory nodes 112 that are not directly connected to one another or the sole member 106. Said another way, each sensory node 112 is unattached and spaced away from the sole member 106 (e.g., spaced away from walls or sidewalls defining the apertures 120 such that there is clearance between an outer perimeter of each sensory node 112 and the respective aperture 120). As such, each sensory node 112 can be received within and configured to translate vertically (e.g., up and down relative to a ground surface) within a respective aperture 120 in the sole member 106 (as shown in FIGS. 2-5). In this way, as described further below, the sensory nodes 112 can extend through the sole member 106 and provide tactile feedback to the foot of a wearer as they interact with a ground surface.

In some examples, the sensory nodes 112 can be cleat members, lugs, or other traction elements that are configured to engage a ground surface and provide increased traction between the sole system 104 and the ground surface. In some examples the sensory nodes 112 may provide enhanced tactile sensation. In some examples, at least some of the sensory nodes 112 of the sensory node assembly 110 can be configured as cleat members or lugs that improve traction and facilitate enhanced tactility and sensation on the bottom of the foot of the wearer.

In some examples, the sole member 106 can comprise one or more stationary nodes 122 (which can also be referred to as fixed nodes since the stationary nodes can be fixed or immobile relative to a remainder of the sole member), as shown in FIGS. 2, 5, and 6. The one or more stationary nodes 122 can be configured as lugs, cleats, or other traction elements that are configured to engage the ground surface. The stationary nodes 122 can have various sizes and shapes and be arranged on the sole member 106 in locations that do not include apertures 120. For example, each stationary node 122 can be offset (laterally and/or longitudinally) from adjacent apertures 120.

Thus, in some examples, the stationary nodes 122 extend outward from a base surface of the sole member 106 without extending through the sole member 106.

Each sensory node 112 has a first end 124 (shown in FIGS. 3 and 4) and a second end 126 (shown in FIGS. 5 and 6). As described further below, the first end 124 of each sensory node 112 can be directly attached to the upper 102 (e.g., a strobel of the upper, as explained further below), and thus can be referred to herein as an upper end 124 of the sensory node 112. The second end 126 of each sensory node 112 forms a ground-contacting surface of the sensory node 112, and thus can be referred to herein as a bottom or lower end 126 of the sensory node 112.

The first ends 124 of the sensory nodes 112 can be disposed at or adjacent to an inward-facing surface 128 of the sole member 106 (as shown in FIGS. 3 and 4). The inward-facing surface 128 can face and/or couple to the upper 102 (e.g., a strobel of the upper).

In some examples, the first ends 124 of the sensory nodes 112 can be flush with the inward-facing surface 128 when the second ends 126 are not interacting with the ground surface and being pushed upward into the upper 102 (when the article 100 is being worn).

The second ends 126 of the sensory nodes 112 can be disposed adjacent to and/or protrude outward from an outward-facing surface 130 of the sole member 106 (as shown in FIGS. 5 and 6). The outward-facing surface 130 can face the ground surface.

In some examples, the second ends 126 of the sensory nodes 112 can extend outward from the outward-facing surface 130 when not being pressed into the ground surface and can move closer to the outward-facing surface 130 when being pressed into the ground surface.

In some examples, the first end 124 of each of or one or more of the sensory nodes 112 can be relatively planar or have a relatively flat or level surface (which faces the wearer's foot). In some instances, the surface of the first end 124 of each or one or more of the sensory nodes 122 can be slanted, sloped, or tapered (e.g., as shown in FIG. 23). As a result, the first ends 124 of the sensory nodes 112 can better follow or conform to a shape of the wearer's foot (or sole) and/or the footbed of the article 100.

In some examples, the second end 126 of each of or one or more of the sensory nodes 112 can be curved, rounded, or spherical (as shown in FIGS. 1, 2, 5, and 6). In this way, the ground-facing or interacting surfaces of the sensory nodes 112 can be rounded or spherical. This shape of the second ends 126 can allow for a same pressure to be applied to the wearer's foot, when the sensory nodes 112 are pressed into the sole member 106 and the wearer's foot (due to interacting with the ground surface), no matter what angle the sole system 104 hits the ground.

In alternate examples, the second end 126 of one or more sensory nodes 112 can be more flat or less rounded than shown in FIGS. 1, 2, 5, and 6.

In some examples, the sensory nodes 112 can have various shapes (other than or in addition to the cylindrical and domed or spherical-tipped shapes shown in FIGS. 1-6), such as being spherical, conical, domed, cylindrical, spiked, and the like. In some examples, the sensory node assembly 110 can have sensory nodes 112 having a variety of shapes and/or sizes, such as conical protruding members, and spherical or domed-tipped cylindrical protruding members having a constant or varying diameter (e.g., a decreasing or increasing diameter) along their length (which is measured between their first end 124 and second end 126). In different examples, the sensory nodes 112 can have a variety of geometries commonly associated with cleats, lugs, and traction elements for footwear.

In some examples, the sensory nodes 112 can have varying sizes and/or dimensions, such as different diameters, widths, lengths, or the like. The dimensions (e.g., diameter and/or length) of the sensory nodes 112 can be selected according to factors including, but not limited to, location in the sole member 106, materials used, desired tactile properties, target stimulation points on a wearer's foot, user comfort, a gender of the intended wearer, a weight or weight range of the intended wearer, a height or height range of the intended wearer, and/or the like.

In some examples, the spacing between adjacent sensory nodes 112 can be made as small as possible, in order to allow for a greater number of sensory nodes 112 and increased sensation for a wearer.

In different examples, the geometric pattern formed by the sensory nodes 112 could vary. For example, the relative spacing between adjacent sensory nodes 112, the number of sensory nodes 112 in the sensory node assembly 110, the placement of the sensory nodes 112 across or in different regions of the sole member 106, as well as other general geometric features of the arrangement could be varied. These geometric features could be selected to achieve desired levels of tactile sensation across different regions of the foot.

For example, in some instances the sole system 104 can comprise some fixed or stationary nodes 122 and some movable sensory nodes 112.

In some examples, the sole system 104 may only include sensory nodes 122 and does not include stationary nodes 122.

The number of sensory nodes 112 and/or the arrangement of sensory nodes in and/or across the sole member 106 can be determined based on an intended use (e.g., sport) for the article of footwear 100, a type of ground surface on which the article of footwear 100 is to be used, and/or the like. For example, in some instances, instead of being arranged across a majority of the sole system 104, the sensory nodes 112 may be disposed only in the forefoot portion 114, only in the heel portion 118, only in the midfoot portion 118, or in two of the forefoot portion 114, midfoot portion 116, and heel portion 118 of the sole system 104.

FIGS. 32 and 33 and FIGS. 34 and 35 show additional examples of articles of footwear with a sensory node assembly having a different arrangement of sensory nodes and/or stationary nodes, or a differently configured upper and/or sole member, as described in more detail below.

In some examples, the sole systems and articles of footwear described herein, such as the article 100 and the article 500 can be formed with a jig system 200 (components of which are depicted in FIGS. 7-12). A disassembled view of the various components of the jig system 200 is shown in FIG. 7. The jig system 200 can comprise a plurality of members that are couplable to one another (in various combinations) around a sensory node assembly. The jig system 200 shown in FIGS. 7-12 is exemplary, and in some instances, the articles of footwear described herein can be formed using all or a subset of the components of the jig system 200, or with different jig system components than those shown in FIGS. 7-12.

It should be noted that the configuration of sensory nodes for the node assembly depicted in FIGS. 7-12, as well as the method of making images shown in FIGS. 15-30 does not correspond to the node arrangement of FIGS. 1-6, and instead shows an alternative node arrangement for the node assembly. In this way, the components of the jig system 200 described herein can be modified to accommodate node assemblies having different numbers, arrangements, and sizes of sensory nodes.

As shown in FIG. 7, the jig system 200 can include (from left to right) a base 202, a node base 204, a node holder 206, a cutting member 208, a sensory node holding member 210, and a pressing member 212. The components of the jig system 200 are configured to stack with and/or couple to one another at various stages in fabricating the sole system and article of footwear.

For example, as shown in greater detail in FIGS. 8 and 9, the cutting member 208 and sensory node holding member 210 can be configured to couple to one another via protruding pins 214 in the cutting member 208 and complementary channels 216 (or slots or holes) in the perimeter of the sensory node holding member 210. Together, the cutting member 208 and the sensory node holding member 210 form a cutting jig 218 of the jig system 200. The cutting jig 218 is shown disassembled in FIG. 8 and assembled in FIG. 9 (without a sensory node assembly disposed therebetween).

The sensory node holding member 210 comprises a plurality of spaced apart cavities 220 (or holes) that are configured to receive respective sensory nodes therein (as shown in FIG. 8). Each cavity can be shaped to receive and hold therein a portion of a sensory node that includes the upper end of the sensory node (e.g., the first end 124 of the sensory node 112). Thus, the arrangement of the cavities 220 in the sensory node holding member 210, such as the spacing between adjacent cavities 220 and the size (e.g., width, diameter, and/or depth) of each cavity, can be specified based on a desired arrangement of sensory nodes in a sensory node assembly for a sole system of an article of footwear.

The cutting member 208 can, in some examples, comprise spaced apart node-receiving regions 222 that correspond to the locations of the cavities 220 in the sensory node holding member 210. When the sensory nodes are coupled to the sensory node holding member 210 and the cutting member 208 is coupled to the sensory node holding member 210 (with the pins 214 engaging the channels 216), lower ends of the sensory nodes can be disposed adjacent to respective node-receiving regions 222. As described further below, after pressing together the cutting member 208 and the sensory node holding member 210 during the cutting process, lower ends of the sensory nodes may touch and/or press against the respective node-receiving regions 222.

In some examples, the node-receiving regions 222 can have a concave or inwardly curved shape that is complementary to the shape or contour of the lower ends of the sensory nodes (e.g., curved or spherical).

The cutting member 208 can comprise cutting features 224 disposed between adjacent node-receiving regions 222. In some examples, the cutting features 224 can comprise a cavity 226 and blade 228 (or other sharp edge) that are configured to cut connectors (which can also be referred to as bridges or connecting bridges) that are initially disposed between and connect adjacent sensory nodes of a sensory node assembly (e.g., as shown in FIG. 15, which is described in more detail below). As described further below, the connectors can be configured to hold the sensory nodes together in one or more groups or lines of sensory nodes. In some examples, the connectors are formed during the molding process of the sensory nodes and are removed using the cutting jig 218 during the process of forming the sole system, as described further below. When the sensory nodes are arranged in the cavities 220 of the sensory node holding member 210 and the cutting member 208 is coupled to the sensory node holding member 210, the connectors can extend across the cutting features 224.

Thus, when the cutting member 208 is pressed against the sensory node holding member 210 with the sensory nodes disposed therebetween, the cutting features 224 can cut the ends of the connectors that connect to the sensory nodes, thereby allowing the connectors to be removed from sensory node assembly (e.g., as described further below with reference to FIGS. 17-19.

In some examples, the node-receiving regions 222 and the cutting features 224 can be disposed in a raised portion 230 (or platform) of the cutting member 208. The raised portion 230 can be spaced from a perimeter of the cutting member 208 and be raised relative to a base portion 232 of the cutting member 208.

In some examples, the base portion 232 of the cutting member 208 can comprise protruding columns 234 with central depressions configured to received complementary pins 236 in the sensory node holding member 210. In some examples, these features can serve as stops during the pressing process described below (e.g., as shown in FIG. 17).

Turning to FIGS. 10-12, the components of the jig system 200 can also be configured to form a sensory node transfer assembly 238 (shown assembled in FIG. 12). The sensory node transfer assembly 238 can include the node base 204 disposed within a complementary-shaped cavity 240 in the base 202 (shown in FIG. 7), thereby forming a base member 242, as shown in FIG. 10.

The node base 204 is shaped to receive the node holder 206 therein, as shown in FIG. 11. For example, as shown in FIG. 10, the node base 204 comprises spaced apart depressions 244 that are shaped to receive protruding portions of the node holder 206 which are formed by complementary depressions 246 in the node holder 206. The depressions 246 in the node holder 206 are shaped and arranged to receive lower ends of respective sensory nodes of the sensory node assembly.

In some examples, at one or more or each of the depressions 246 of the node holder 206, a collar 248 can extend around and protrude outward from the respective depression 246. Each collar 248 can be configured to interface with and hold a respective sensory node within the respective depression 246 (e.g., as shown in FIG. 24).

The base 202 can comprise one or more protruding pins 250 spaced apart around a perimeter of the base 202. Each pin 250 is configured to be received within a respective channel 216 of the sensory node holding member 210, thereby coupling the sensory node holding member 210 to the base 202 and forming the sensory node transfer assembly 238, as shown in FIG. 12. As described further below, the sensory node transfer assembly 238 can be configured to transfer and couple the lower ends of the sensory nodes to the node holder 206 such that the sensory nodes are maintained in the arrangement of the sensory node assembly and upper ends of the sensory nodes can be attached to an upper of an article of footwear.

Turning now to FIG. 13, a method 300 for coupling a sensory node assembly to an upper of an article of footwear is shown. In particular, the method 300 can include forming a sole system for an article of footwear including a sensory node assembly and attaching the sole system to the upper to form the article of footwear. In some examples, the sensory node assembly is one of the sensory node assemblies described herein, such as the sensory node assembly 110 or the sensory node assembly 510. Any of the articles of footwear described herein can be formed with method 300. However, method 300 can also be used to form other articles of footwear having sensory node assemblies and uppers, such as articles with differently shaped sole members, uppers, and/or different configurations of sensory nodes within a sensory node assembly.

The method 300 begins at 302 and includes holding a plurality of sensory nodes together in a sensory node assembly. In some examples, the holding at 302 can include coupling upper ends of the plurality of sensory nodes to a sensory node holding member to form a sensory node assembly that is held together with the sensory node holding member (e.g., as shown in FIG. 15 which is described below). The upper ends of the sensory nodes can include ends of the sensory nodes that are configured to be attached to the upper of the article of footwear (e.g., the first ends 124 shown in FIGS. 3 and 4). In some examples, the node holding member can be the sensory node holding member 210 shown in FIGS. 7-9 and 12, as described above.

At 304, the method optionally includes removing connectors (or bridges or connecting bridges) from between the sensory nodes (e.g., if connectors are present between the sensory nodes). As introduced above, in some examples, during the molding process or process for forming the sensory nodes, one or more groups of sensory nodes can be connected via connectors or bridges. In some examples, all the sensory nodes of the sensory node assembly can be interconnected by connectors. In some examples, portions of the sensory nodes of the sensory node assembly can be connected by connectors. In this way, in some instances, each sensory node is connected to at least one other sensory node of the sensory node assembly by a connector. These connectors can be removed prior to attaching the sensory nodes to the upper by the method at 304.

In some examples, the method at 304 can include manually cutting the connectors from where they attach to the adjacent sensory nodes and removing the cut connectors from the sensory node assembly.

In some examples, the method at 304 can include cutting the connectors away from the sensory nodes using a cutting jig, such as the cutting jig 218 shown in FIGS. 8 and 9, as described above (e.g., as shown in FIGS. 16-19, as described in more detail below). For example, a cutting member can be coupled to and pressed against the sensory node holding member to cut the connectors from the sensory nodes (e.g., as described further below with reference to the method of FIG. 14). In some examples, the pressing the cutting member against or together with the sensory node holding member can be performed by activating a pressing apparatus (e.g., the pressing apparatus 260 of FIG. 16, as described in further detail below).

The method at 306 includes arranging a sole member around the sensory node assembly (e.g., as shown in FIGS. 25 and 26, and described in greater detail below with reference to the method of FIG. 14). For example, the method at 306 can include arranging a sole member (such as the sole member 106 or the sole member 506) around the sensory node assembly such that each sensory node of the sensory node assembly extends through a respective aperture in the sole member with lower ends of the sensory nodes extending out of the respective apertures. In this way, the method at 306 can include arranging the sensory node assembly within the sole member.

As introduced above, the sensory nodes can be arranged within the respective apertures of the sole member such that each sensory node is individually movable within the respective aperture. In this way, in some examples, the sensory node assembly is not directly coupled to any part of the sole member.

The method at 308 includes coupling the sole member to an upper for an article of footwear and attaching the upper ends of the sensory nodes directly to the upper (e.g., as shown in FIGS. 26-28).

In some examples, the sole member can be attached to the upper first and then the upper ends of the sensory nodes can be attached to the upper (e.g., the strobel). For instance, it could be advantageous to first attach the sole member to the upper first since the upper ends of the sensory nodes can, in some instances, be slanted, sloped, or tapered (e.g., as shown in FIG. 23). Thus, attaching the sole member to the upper first can allow the sole member to be more easily attached to the outer edges of the upper before attaching the tapered upper ends of the sensory nodes to the upper (e.g., to the strobel).

For example, the upper could include a strobel, sockliner, or insole. Thus, in some examples, the method at 308 can include attaching the upper ends of the sensory nodes directly to a strobel, sockliner, or insole.

The upper, or at least the portion of the upper to which the upper ends of the sensory nodes are attached (e.g., the strobel of the upper) can comprise a material that is configured to effectively transmit sensation (or tactile feedback) from the sensory nodes (as they are depressed) to the foot of the wearer. In some examples, the upper, or at least the portion of the upper to which the upper ends of the sensory nodes are attached (e.g., the strobel of the upper) can comprise a material that is stretchable, water deterrent (or water resistant or waterproof), or both stretchable and water deterrent.

Such materials can include materials that are abrasion resistant/tear resistant and that have a relatively high amount of stretch in one or more directions (e.g., four-way stretch) (such as in the ranges discussed further below). By having higher amounts of stretch (as compared to a more standard strobel for a traditional article of footwear, for example), a larger tactile response or sensation from the sensory nodes being depressed can be transferred to the wearer's foot. For example, less stretchable materials and/or materials having a greater thickness than described below may dampen or not effectively transfer the sensation from the sensory nodes to the wearer's foot.

Such materials for the strobel can have a z height distention of greater than 10 mm at 200 kPa load with a 30.5 mm diaphragm (as tested with a pneumatic bursting strength tester, e.g., TruBurst). In some examples, the material can have a z height distention of greater than 12 mm or in a range of 12-25 mm. The z height distension can be a measure of stretch of the material, with a higher z height distention providing more stretch and more transmission of tactile feedback from the sensory nodes to the wearer's foot.

In some examples, the material for the strobel (or the insole, sockliner, or bottom surface of the upper to which the sensory nodes are directly attached) can be a stretchable fabric (or knit), such as double layer circular knit (interlock). Such a knit can comprise cationic dyeable polyester (CDP) and spandex (elastane). In some examples, the knit material can be 60-81% CDP and 19-40% spandex. In some examples, the material can be 68-72% CDP and 28-32% spandex.

In some examples, the double layer circular knit can be formed from a first yarn comprising CDP, a second yarn comprising CDP, and a third yarn comprising elastane.

In some examples, the material for the strobel of the upper can include a surface coating and/or layer that provides the strobel with water resistance. For example, the water resistance surface coating or layer can be added to the double layer circular knit described above. By having a coating or layer that is resistant to or deters water, the strobel can reduce and/or prevent water from being transferred from the sensory nodes to the upper and/or an interior of the article of footwear.

Such surface coatings or layers can include a polyurethane layer with a TPU hot melt. The polyurethane and TPU hot melt layer can form the surface of the strobel (or the insole, sockliner, or bottom surface of the upper) that directly contacts (and adheres to) the sensory nodes (e.g., the surface 866 of the strobel of the upper 852 shown in FIGS. 43A-43C, as described further below). In some examples, the TPU hot melt forms an adhesive layer for bonding the polyurethane to the double layer circular knit.

For example, FIG. 44 shows an exemplary strobel 900 of an upper with such a configuration. The strobel 900 can be part of and/or form a surface of any upper (e.g., upper 102, 502, 702, or 852) described herein that the sensory nodes couple to. The strobel 900 comprises a stretchable fabric layer 902 (or knit, such as the double layer circular knit described above), a polyurethane layer 904, and a TPU hot melt layer 906 that bonds the polyurethane layer 904 to the fabric layer 902. Together, the polyurethane layer 904 and TPU hot melt layer 906 can form the water deterrent layer of the strobel 900. A sensory node 910 (which can be any of the sensory nodes described herein, such as sensory nodes 112) is directly attached to a bottom or ground-facing surface 912 of the strobel 900 which is defined by the polyurethane layer 904. The ground-facing surface 912 is opposite a surface 914 of the strobel 900, defined by the fabric layer 902, that faces a wearer's foot.

In some examples, the outer water deterrent layer can comprise about 50 μm polyurethane (e.g., polyurethane layer 904 shown in FIGS. 44) and 100-150 μm TPU hot melt (e.g., TPU hot melt layer 906 shown in FIG. 44). Thus, in some examples, the water deterrent layer can have a thickness of about 0.15-0.2 mm.

In some examples, the material for the strobel may not include a water deterrent layer, and thus, may include only the double circular knit described above.

The material for the strobel (or the insole, sockliner, or bottom surface of the upper to which the sensory nodes are directly attached) can have a total thickness in a range of 1.15-1.3 mm, 1.15-1.2 mm, or 1.15-1.18 mm.

Any of the uppers (or strobels of the uppers) described herein (e.g., upper 102) can comprise or at least partially comprise one or a combination of the materials described above.

In some examples, the article of footwear can comprise a strobel and omit a sockliner or insole. As such, the wearer's foot and/or sock can directly contact the strobel thereby increasing the tactile sensitivity and/or sensation between the wearer's foot and the sensory nodes because only the strobel is disposed therebetween.

Returning to the method at 308, in some examples, the sole member and the upper ends of the sensory nodes can be attached to the upper at the same time (e.g., during a same pressing operation, as shown in FIGS. 26-28).

In some examples, the upper ends of the sensory nodes can be attached to the upper first and then the sole member can be attached to the upper.

As described further below with reference to the method of FIG. 14, in some examples attaching the upper ends of the sensory nodes to the upper and coupling the sole member to the upper can include adhering the upper to the upper ends of the sensory nodes and the sole member via an adhesive (e.g., an activated adhesive).

Thus, the sensory nodes can be suspended from the upper, within the sole member. Further, the sensory nodes can be spaced away from the sole member so that they can individually translate within respective apertures of the sole member.

The method at 310 includes removing any holders and/or forms used to assemble the sole system and the article of footwear from the article of footwear (e.g., as shown in FIGS. 29 and 30).

FIG. 14 shows a more detailed exemplary method 400 for coupling a sensory node assembly to an upper of an article of footwear. In particular, the method 400 can include arranging a sensory node assembly within a sole member and coupling the sensory node assembly and sole member to an upper to form an article of footwear with a jig system. In some examples, the jig system can be the jig system 200 of FIGS. 7-12. In some examples, the jig system can be an alternate jig system.

In some examples, one or more portions of the method 400 can be automated and performed using a computing system, such as the computing system 602 shown in FIG. 36.

The method 400 is described below with reference to the examples shown in FIGS. 15-31. However, the method 400 can be applied to a variety of sole systems, sensory node assemblies, uppers, jig systems, and/or the like. Thus, the method 400 can be applied to systems and components that are different than those shown in FIGS. 15-31.

The method 400 begins at 402 by inserting sensory nodes into a sensory node holding member. For example, as shown in FIG. 15, a plurality of sensory nodes 112 can be inserted into respective cavities 220 of a sensory node holding member 210. The sensory nodes 112 can be inserted into the cavities 220 such that their lower ends (e.g., second ends 126) extend outward and away from the sensory node holding member 210.

In some examples, sensory nodes 112 can be press-fit into the cavities 220 such that they do not easily fall out of the sensory node holding member 210.

In some examples, as shown in FIG. 15, each sensory node 112 can be connected to at least one adjacent sensory node by a connector 140 (or connecting bridge).

The method at 404 includes coupling a cutting member to the sensory node holding member, around the sensory nodes, and pressing the cutting member and sensory node holding member together to cut the connectors away from the sensory nodes.

For example, as shown in FIG. 16, the cutting jig 218, which includes the coupled together cutting member 208 and sensory node holding member 210 with the sensory nodes 112 disposed therein, can be placed in a pressing apparatus 260 (or press). The pressing apparatus 260 can be configured to apply pressure to the cutting member 208 and/or the sensory node holding member 210, thereby pressing the cutting member 208 and sensory node holding member 210 toward one another.

As a result, the cutting member 208 is moved closer to the sensory nodes 112 and sensory node holding member 210 and the cutting features 224 of the cutting member 208 score and/or cut between ends of the connectors 140 and the sensory nodes 112, as shown in FIG. 17.

The method at 406 includes removing (or uncoupling) the cutting member 208 from the sensory node holding member 210 and removing the cut connectors from between the sensory nodes. For example, as shown in FIG. 18, the cutting jig 218 can be removed from the pressing apparatus 260 and the cutting member 208 can be uncoupled and removed from the sensory node holding member 210. The cut connectors 140 can be removed (e.g., by hand) from the exposed sensory node assembly 110, as shown in FIG. 19.

The methods at 408 and 410 can collectively include transferring the sensory nodes from the sensory node holding member to a node holder, where lower ends of the sensory nodes are received in the node holder (e.g., as shown in FIGS. 20-23).

More specifically, in some examples, the method at 408 includes flipping over the sensory node holding member (with the sensory nodes disposed therein) and placing it on top of the base member and node holder such that lower ends of the sensory nodes are received in (and/or disposed adjacent) the node holder, and placing a pressing member over the open end of the sensory node holding member. For example, as shown in FIG. 20, the sensory node holding member 210 is flipped over so that the lower ends of the sensory nodes are received in or disposed adjacent to the depressions of the node holder 206 which is disposed in the base member 242. As such, open ends of the cavities 220 of the sensory node holding member 210 are on the outside of the assembly in FIG. 20.

As shown in the example of FIG. 21, the pressing member 212 can be arranged over the open ends of the cavities 220 of the sensory node holding member 210. As a result, protruding columns 211 of the pressing member 212 (shown in FIG. 7) can extend into respective cavities 220 of the sensory node holding member 210.

The method at 410 can include pressing together the pressing member 212, the sensory node holding member 210, and the base member 242 and removing the pressing member and the sensory node holding member to reveal upper ends of the sensory nodes with lower ends of the sensory nodes coupled to the node holder. For example, as shown in FIG. 22, the sensory node transfer assembly 238 (which includes the base member 242, the sensory node holding member 210, and the pressing member 212) can be inserted into the pressing apparatus 260 and pressed together. As a result, the protruding columns 211 of the pressing member 212 force the lower ends of the sensory nodes 112 into engagement with the depressions 246 in the node holder 206. As a result, the sensory nodes can be press-fit and/or held in position within the node holder 206 (e.g., by the collars 248 of the node holder 206) with their upper ends 124 extending outward and away from the base member 242, as shown in FIG. 23.

The method at 412 includes placing the node holder with the sensory nodes coupled thereto into a base receptacle and positioning a sole member around the sensory nodes inside the base receptacle. For example, as shown at FIG. 24, the node holder 206, with the sensory nodes 112 coupled to the node holder 206, is placed into a bottom of a base receptacle 262 (or tray or holder). The base receptacle 262 can have an open top, a bottom, and sidewalls that form a cavity configured to receive the node holder 206 and sensory nodes 112 therein.

The cavity of the base receptacle 262 can also be configured to receive a sole member and/or an intermediate receptacle holding a sole member. In some examples, the method at 412 can include positioning the sole member into an intermediate receptacle (or tray or holder) and inserting the intermediate receptacle into the base receptacle, over the sensory nodes. For example, as shown at FIGS. 25, the sole member 106 is inserted into a cavity of an intermediate receptacle 264. The intermediate receptacle 264 can be configured to hold the sole member 106 therein and couple to and inside the base receptacle 262. For example, as shown in FIG. 26, the intermediate receptacle 264 with the sole member 106 disposed therein is positioned within the base receptacle 262 such that the sole member 106 is disposed around the sensory nodes 112 of the sensory node assembly 110. For example, each sensory node 112 is disposed within a respective aperture 120 in the sole member.

The upper ends 124 of the sensory nodes 112 can be disposed flush or adjacent to the inward-facing surface 128 of the sole member 106, as shown in FIG. 26. As a result, an upper can be attached to both the inward-facing surface 128 and the upper ends 124 of the sensory nodes 112.

The method at 414 includes activating (and/or applying) an adhesive to the faces of the upper ends of the sensory nodes and positioning an upper over the upper ends of the sensory nodes. In some examples, the method at 414 can include applying and/or activating an adhesive on the upper ends of the sensory nodes and/or the inward-facing surface of the sole member and positioning the upper above the inward-facing surface of the sole member and the upper ends of the sensory nodes. For example, as shown at FIG. 27, the upper 102 is positioned over the sensory nodes 112 and sole member 106, which are arranged within the intermediate receptacle 264 and base receptacle 262.

The method at 416 includes pressing the upper into the sole member to attach the upper to the sole member and the upper ends of the sensory nodes, thereby forming an article of footwear. In some examples, the pressing at 416 can include manually pressing the upper into the sole member and sensory nodes. In some examples, the pressing at 416 can include pressing the upper into the sole member and sensory nodes with a press or press apparatus. For example, as shown in FIG. 28, the upper 102 can be pressed into the sole member 106 and the sensory nodes 112, while the sole member 106 is held within the intermediate receptacle 264 and base receptacle 262, with a first pressing arm 266 and a second pressing arm 268 of a press apparatus. In some examples, a last 270 can be disposed within the upper 102 (as shown in FIGS. 27 and 28) to provide the upper 102 with structure during the pressing process. Thus, in some examples, the second pressing arm 268 can press against the last 270, thereby pressing the upper 102 into the sole member 106 and the sensory nodes 112 (as shown in FIG. 28).

The method at 418 includes removing the formed article of footwear, which includes the upper attached directly to the sole member and the sensory nodes of the sensory node assembly, from the receptacle(s) and removing the node holder from the sensory node assembly. For example, as shown in FIG. 29, the article of footwear 100 can be taken out of the base receptacle 262, and the intermediate receptacle 264 can be removed (by pulling off or away) from the sole member 106 of the article 100. The node holder 206 can be removed from the sensory node assembly 110 (e.g., by pulling it away from the sensory nodes 112), as shown in FIG. 30. The resulting article 100 is shown in FIGS. 1 and 2, as described above.

In some examples, instead of using a jig system to cut bridges from between sensory nodes in preparation for attaching the sensory nodes (e.g., sensory nodes 112) to the upper, a siping process can be used. For example, in some instances, a sensory node assembly (such as any of the sensory node assemblies described herein or similar sensory node assemblies) and the sole member can be molded (e.g., injection molded) as a single, unitary component.

In some instances, there may be a layer or segments of material (e.g., foam) interconnecting the sensory nodes and the sole member which completely circumscribes the sensory nodes. In some instances, there may be a layer or segments of material (e.g., foam) interconnecting the sensory nodes and the sole member which less than completely circumscribes the sensory nodes.

The unitary sole member and sensory nodes (or sensory node assembly) can be attached to the upper similar to as described above for the methods at 306, 308, and 310 of method 300 and/or the methods at 412, 414, 416, and/or 418 of method 400. The siping process can include cutting and/or trimming (or siping) around the sensory nodes within the sole member, thereby separating the sensory nodes from one another and from the sole member such that they can each move freely within a respective aperture of the sole member. In this way, the connectors or strips of material formed during the molding process can be siped out of the assembly.

For example, as shown in FIG. 31, a siping or trimming apparatus 272 can comprise a cutting blade or needle 274 attached to a robotic arm, where the needle 274 is used to trim and/or cut around each sensory node 112, between the sensory node 112 and its respective aperture 120 in the sole member 106. As a result, each sensory node 112 can be separated from the respective aperture 120 so it can freely translate (e.g., up and down) within the aperture 120. In this way, the sensory nodes 112 are not directly coupled to the sole member 106.

In some examples, instead of automatically trimming the sensory nodes within the sole member with the trimming apparatus 272, the sensory nodes can be manually trimmed within the sole member (e.g., with a blade or needle operated by hand).

FIGS. 32 and 33 show another exemplary article of footwear 500 (referred to as “article 500) comprising a sole system 504 including a sole member 506 and a sensory node assembly 510 which are each directly attached to the upper 502. The article 500 can be formed using any of the methods described herein, such as method 300 and/or 400. The article 500 can be similar to the article 100, except it has a different arrangement of sensory nodes 512 that make up the sensory node assembly 510. For example, the sensory node assembly 510 can have a greater number of sensory nodes 512 than the sensory node assembly 110 of the article 100. However, the sensory nodes 512 can function similarly to the sensory nodes 112, as described above. For example, each sensory node 512 can comprise an upper end directly attached to the upper 502 and configured to move individually and freely within a respective aperture 520 in the sole member. Each sensory node 512 can have an opposite, lower end 526 that extends outward and away from the sole member 506.

FIGS. 34 and 35 show another exemplary article of footwear 700 (referred to as “article 700) comprising a sole system 704 including a sole member 706 and a sensory node assembly 710 which are each directly attached to the upper 702. The article 700 can be formed using any of the methods described herein, such as method 300 and/or 400. The article 700 can be similar to the article 100, except the sole member 706 does not include stationary (or fixed) nodes, and a shape of the sole member 706 and/or upper 702 may be slightly different than in the article 100. The sensory node assembly 710 and its sensory nodes 712 may be substantially the same as the sensory node assembly 110 and the sensory nodes 112, as described above. The sole member 706 comprises apertures 720, where each sensory nodes can be spaced away from and translate within a respective aperture 720 in the sole member. Each sensory node 712 has a lower end 726 that extends outward and away from the sole member 706.

The sensory nodes, or sensory node assembly, can be formed (e.g., molded) in different ways. For example, in some instances, a sensory node assembly 804 can be formed by a molding process that results in a plurality of sensory nodes 806 being interconnected by a web 802 or in a sheet of material, as shown in FIGS. 37A and 37B (instead of bridges, as shown in FIG. 15). FIGS. 37A and 37B show a top view and bottom view, respectively, of a web assembly 800 comprising the sensory nodes 806 and web 802. The web assembly 800 is formed during the molding process, before being cut by a cutting member (of a cutting jig) of a jig system and can comprise a continuous sheet of material. The web 802 can extend between and surround each sensory node 806 of the sensory node assembly 804. Thus, in some examples, the web 802 of material can be referred to as a connecting portion or as connectors (e.g., connectors that are continuous with one another) that connect the sensory nodes 806 to one another.

In some examples, the sensory node assembly 804 and sensory nodes 806 are the same or similar to the sensory node assembly 110 and sensory nodes 112 described above, except for any artifacts that are left over from the web 802 after cutting with a cutting jig, as described in more detail below with reference to FIGS. 42-43C.

For example, each sensory node 806 has a first end 808 (shown in FIG. 37A) and a second end 810 (shown in FIG. 37B). As described above for the sensory nodes 112, the first end 808 of each sensory node 806 can be directly attached to the upper of an article of footwear (e.g., upper 102), and thus can be referred to herein as an upper end 808 of the sensory node 806. In some examples, the upper end 808 of each sensory node 806 is directly coupled to a bottom (or ground-facing) surface 866 of the strobel or upper 852 (as depicted in FIGS. 43A-43C).

The second end 810 of each sensory node 806 forms a ground-contacting surface of the sensory node 806, and thus can be referred to herein as a bottom or lower end 810 of the sensory node 806.

The sensory nodes 806 can be removed from the web 802 using a cutting jig, which includes a cutting member 820 (FIG. 38) and a sensory node holding member 822. The cutting member 820 can be similar to the cutting member 208 and the sensory node holding member 822 can be similar to the sensory node holding member 210, as described above, except for the configuration of the cutting features 824 of the cutting member 820 and an aperture 826 of the sensory node holding member 822 that is configured to interface with the web assembly 800, as described in further detail below.

For example, as shown in FIG. 38, the cutting member 820 of the cutting jig can include protruding pins 828 (which can be similar to pins 214, as described above) spaced apart around a perimeter of the cutting member 820. The cutting member 820 can also include spaced apart node-receiving regions 830 that are each configured to receive the second end 810 of a respective sensory node 806 therein during cutting with the cutting jig.

In some examples, the node-receiving regions 830 can have a concave or inwardly curved shape that is complementary to the shape or contour of the second ends 810 of the sensory nodes 806 (e.g., curved or spherical).

The cutting member 820 can comprise cutting features 824 disposed around each node-receiving region 830. For example, as shown in FIG. 38, each cutting feature 824 can surround (for example, extend around an entire circumference of) a respective node-receiving region 830. Further, each cutting feature 824 can comprise a blade or sharp surface that is configured to cut through the web 802 of the web assembly 800. As such, each cutting feature 824 is configured to cut around a perimeter of a respective sensory node 806 that is received in the respective node-receiving region 830, thereby cutting the web 802 away from the sensory nodes 806 (which results in individual sensory nodes 806 that are separated from one another, as shown in FIG. 41).

In some examples, the node-receiving regions 830 and the cutting features 824 can be disposed in a raised portion 832 (or platform) of the cutting member 820. The raised portion 832 can be spaced from a perimeter of the cutting member 820 and be raised relative to a base portion 834 of the cutting member 820.

The base portion 834 of the cutting member 820 can comprise the protruding pins 828.

In some examples, the base portion 834 can include protruding columns 836 with central depressions configured to received complementary pins 838 in the sensory node holding member 822. In some examples, these features can serve as stops during the pressing process described herein (e.g., as shown in FIG. 17).

As shown in FIG. 39, the sensory node holding member 822 comprises channels 842 (or slots or holes) disposed in the perimeter of the sensory node holding member 822. Similar to the cutting jig 218 described above, the cutting member 820 and the sensory node holding member 822 can be configured to couple to one another via the protruding pins 828 in the cutting member 820 and complementary channels 842 in the sensory node holding member 822.

The sensory node holding member 822 comprises a plurality of spaced apart cavities 840 (or holes) that are configured to receive respective sensory nodes 806 therein (as shown in FIG. 40). Each cavity 840 can be shaped to receive and hold therein a portion of a sensory node that includes the upper or first end of the sensory node (e.g., the first end 808 of the sensory node 806). Thus, the arrangement of the cavities 840 in the sensory node holding member 822, such as the spacing between adjacent cavities 840 and the size (e.g., width, diameter, and/or depth) of each cavity 840, can be specified based on a desired arrangement of sensory nodes in a sensory node assembly for a sole system of an article of footwear.

As mentioned above, in some examples, the sensory node holding member 822 can comprise an aperture 826 (or slot or channel) that is configured to receive a protrusion 812 of the web assembly 800. As shown in FIG. 40, when the web assembly 800 is coupled to the sensory node holding member 822, with the nodes 806 arranged in the respective cavities 840, the protrusion 812 of the web assembly 800 extends into the aperture 826, thereby helping to orient the web assembly 800 in place on the sensory node holding member 822.

The locations of the cavities 840 correspond to the locations of the node-receiving regions 830 of the cutting member 820 such that when the sensory nodes are coupled to the sensory node holding member 822 and the cutting member 820 is coupled to the sensory node holding member 822 (with the pins 828 engaging the complementary channels 842), lower ends of the sensory nodes can be disposed adjacent to respective node-receiving regions 830. As described herein, after pressing together the cutting member 820 and the sensory node holding member 822 during the cutting process, lower ends of the sensory nodes may touch and/or press against the respective node-receiving regions 830.

It should be noted that the cutting member 820 and sensory node holding member 822 can couple or fit together to form the cutting jig, similar to as described above for the cutting jig 218. Further, the cutting member 820 and sensory node holding member 822 can be used in the methods 300 and 400 of FIGS. 13 and 14, respectively, as described above (in lieu of the cutting member 208 and sensory node holding member 210).

For example, the cutting jig, which includes the coupled together cutting member 820 and sensory node holding member 822 with the sensory nodes 806 disposed therein (as shown in FIG. 40), can be placed in the pressing apparatus 260 (or press). As described above with reference to the method at 404, the pressing apparatus 260 can be configured to press the cutting member 820 and sensory node holding member 822 toward one another.

As a result, the cutting features 824 of the cutting member 820 cut around each sensory node 806, thereby decoupling the web 802 from the sensory nodes 806. The web 802 can then be removed from the sensory nodes 806 held within the sensory node holding member 822.

The cut sensory nodes can then be transferred to a node holder, where lower ends of the sensory nodes (e.g., second ends 810 of the nodes 806) are received in the node holder. FIG. 41 shows the cut sensory nodes 806 transferred to the node holder 844 (which can be the same or similar to the node holder 206, as described above), which is held within a base member 846.

In some examples, the node holder 844 (and the other node holders described herein) can comprise one or more pieces or sections.

For example, in some instances, the node holder 844 can comprise two pieces, as shown by the dashed line 853 in FIG. 41.

In some examples, the node holder 844 can comprise three pieces, four pieces, or the like.

In some instances, a node holder made up of multiple pieces can make assembly with the apertures of the sole member easier (e.g., easier alignment).

The base member 846 can be the same as or similar to the base member 242 (as described above with reference to FIGS. 10-12), except the base 849 of the base member 846 can include protruding columns 848 with central depressions configured to receive the complementary pins 838 in the sensory node holding member 822.

The base 849 can be used in lieu of the base 202 in the methods described herein.

FIG. 42 depicts an exemplary article of footwear 850 (“article”) including a sole system 854 including a sole member 856 and the sensory node assembly 804 which are each directly attached to the upper 852. The article 850 can be formed using the web assembly 800, cutting jig, and node holder shown in FIGS. 37A-41 and using any of the methods described herein, such as method 300 and/or 400. The article 850 can be similar to the article 100, except the sensory nodes 806 are cut from a web assembly, which can result in differences in a contour of the outer surface of the sensory nodes 806. Apart from the contour differences, which result from cutting around each sensory node in the web assembly, the sensory node assembly 804 and its sensory nodes 806 may be substantially the same as the sensory node assembly 110 and the sensory nodes 112, as described above.

The sole member 856 comprises apertures 858, where each sensory node 806 can be spaced away from and translate within a respective aperture 858 in the sole member 856. The lower or second end 810 of each sensory node extends outward and away from the sole member 856, as shown in FIG. 42.

FIGS. 43A-43C are cross-sectional views of the article 850 shown in FIG. 42, taken along a forefoot portion of the article (FIG. 43A), a midfoot portion of the article (FIG. 43B), and a heel portion of the article (FIG. 43C).

As shown in FIGS. 43A-43C, due to cutting around a circumference of each node 806 within the web assembly 800, one or more (or each of) the nodes 806 can have a flange 860 (or skirt) around its outer surface (which makes the sensory nodes 806 appear to have an upside-down cupcake shape in FIGS. 43A-43C). This can be an artifact of cutting the sensory nodes 806 away from the web 802, around an entire circumference of the sensory node 806.

In some examples, the flange 860 can be wider or narrower than shown, based on how closely the cutting feature 824 of the cutting member 820 cut through the web 802 around the sensory nodes 806.

In some examples, a portion of the sensory nodes 806 may not include the flange 860.

As mentioned above, in some examples, the upper ends 808 of the sensory nodes 806 can have a varying contour, slope, or taper in order to better follow or conform to a shape of the wearer's foot 864 (or sole) and/or the footbed of the article of footwear. For example, as shown in FIGS. 43A-43C, the upper or first ends 808 of the sensory nodes 806 can have different surface contours, at least partially based on where they are located within the article 850. Thus, if a heel portion of a wearer's footbed has more contour (curvature) than the forefoot or midfoot portions, then the sensory nodes 806 in the heel portion of the article 850 can have a first end 808 (or surface) that tapers or curves to a greater extend (e.g., greater angle) than the sensory nodes 806 located in the forefoot portion and midfoot portions of the article 850.

For example, looking at FIGS. 43A-43C, the first end 808 of the sensory nodes 806 in the forefoot portion (FIG. 43A) and midfoot portion (FIG. 43B) are flatter or more planar that the first end 808 of the sensory nodes 806 in the heel portion (FIG. 43C).

As another example, the first end 808 of the sensory nodes 806 positioned closer to a central longitudinal axis 862 of the article 850 (which separates the lateral and medial sides of the article) can have less curvature (and thus be more planar or flat) than the sensory nodes 806 positioned farther away from the central longitudinal axis 862 (as shown in FIG. 43A).

As shown in FIG. 43C, the first end 808 of the sensory nodes 806 in the heel portion of the article 850 can curve outward and upward from their sides located closest to the central longitudinal axis 862 to their sides located closer to the respective medial and lateral sides of the article. As a result, this larger taper or curvature follows a natural shape of the wearer's heel of their foot 864.

It should be noted that the other sensory nodes of the various sensory node assemblies described herein can have similar contours at their upper surfaces, as described above.

FIGS. 45-53 depict various views of an exemplary article of footwear 1000 (referred to as “article 1000”) comprising a sole system 1004 (which can also be referred to herein as a “sole structure”) including a sole member 1006 and a sensory node assembly 1010. The article 1000 further comprises an upper 1002.

In FIGS. 48-53 the article 1000 is depicted around a last 1050 (a foot-shaped form). In FIGS. 45-47 the last is not present and an interior, or foot cavity 1032 (which can also be referred to as a “foot receiving cavity”), of the article 1000 is visible.

In some examples, the upper 1002 and the sole member 1006 are separate parts (e.g., molded separately) which are coupled together.

In some examples, the upper 1002 and the sole member 1006 are formed as one piece (a single part, e.g., molded together as one piece or part by injection molding or another form of molding). For example, as shown in the example of FIGS. 45-53, the upper 1002 and the sole member 1006 are not distinct.

In some examples, the article 1000 can be referred to as a “mule” (i.e., it does not have a back or constraint around a heel of a foot when being worn by a user). For example, the article 1000 can have a foot cavity 1032 defined by an inward or foot facing surface of the fabric layer 1008 and an inward facing surface of the upper 1002. In this way, the foot cavity 1032 is defined by inner or inward facing surfaces of the upper 1002. The upper 1002 defines a foot opening 1034 into the foot cavity 1032.

The sole member 1006 has a foot facing surface 1028 (or inward facing surface) (shown in FIG. 47) and a ground facing surface 1030 (or outward facing surface) (shown in FIG. 51) which are arranged opposite one another.

The sole member 1006 comprises a plurality of apertures 1020 spaced apart from one another across the sole member 1006. Each aperture 1020 can extend through an entire thickness (defined in a superior-to-inferior direction) of the sole member, between the foot facing surface 1028 and the ground facing surface 1030.

Each aperture 1020 can be shaped and/or sized to receive a sensory node 1012 therethrough, as explained in detail herein (e.g., as explained above with reference to the article 100).

As noted above, the upper 1002 at least partially defines the foot opening 1034 and foot cavity 1032. The upper 1002 has an outward facing surface 1036 (facing away or outward from the foot cavity 1032) and an inward facing surface 1038 (or foot facing surface, or inner surface). The foot opening 1034 can extend from the sole member 1006, forward toward a toe portion (or toe 1042) and upward toward a top portion 1041 (or a top-most or peak) of the upper 1002. In this way, the foot opening 1034 can be large as compared to articles with a heel portion included in the upper (such as the article 100).

In some examples, as shown in FIGS. 47, 48, and 52, the upper 1002 can comprise an elongate channel 1040. The channel 1040 extends from the foot opening 1034 in the top portion 1041 of the upper 1002 toward a toe 1042 of the upper 1002. However, the channel 1040 can be spaced away from the end of the toe 1042.

By extending the channel 1040 as far as possible toward the toe 1042 of the upper 1002, a larger opening covering a majority of a length of the foot facing surface 1028 of the sole member is provided by the combination of the channel 1040 and foot opening 1034. This larger opening enables easier insertion and more precise placement of the fabric layer 1008 onto the foot facing surface 1028.

In this way, when the tongue 1048 is unattached to the upper 1002, the elongate opening or channel 1040 (as shown in FIGS. 47 and 48) can enable the fabric layer 1008 to be more easily and accurately inserted into and attached to the sole member 1006 (for example, by using a jig, as described further below with reference to FIGS. 54-57).

In some examples, the channel 1040 can comprise a groove 1044 that steps down from an outer edge 1046 of the channel 1040.

A tongue 1048 can be attached to the upper 1002 such that it covers the channel 1040 (as shown in FIGS. 45 and 46).

In some examples, the tongue 1048 can have a complementary shape to the channel 1040 such that the tongue 1048 is received within the groove 1044 of the channel 1040.

In some examples, the tongue 1048 can be press fit to the channel 1040 such that it locks in place in the channel 1040.

In some examples, the tongue 1048 can be adhered to the channel 1040 and/or the outward facing surface 1036 of the upper 1002 via an adhesive.

In some examples, the tongue 1048 is removably attached to the upper 1002.

The tongue 1048 can be interchangeable with other tongues comprising different materials, colors, textures, patterns, or the like. For example, tongues comprising different materials can be interchangeable and used for the different seasons of the year.

For example, in some instances, one tongue could comprise mesh. In some instances, another tongue could comprise rubber. In some instances, yet another tongue could comprise plush knit fabric or fleece.

In some examples, the tongue could comprise one or more openings (e.g., for increased airflow).

In some examples, the channel 1040 can have a different shape, while still be elongated (for example, the channel 1040 can extend a majority of the distance from the foot opening 1034 to the toe 1042). FIGS. 60 and 61 show exemplary alternative configurations (e.g., shapes) for the channel 1040 in the article 1000. Tongues, similar to the tongue 1048, can be complementary shaped to fit with the different shapes of the channels 1040 shown in FIGS. 60 and 61.

For example, in some instances, as shown in FIG. 60, the channel 1040 can have an overall V-shape with a wavy edge between an opening 1041 to the channel 1040 and the tip 1043 of the channel 1040.

In some instances, as shown in FIG. 61, the channel can have a narrower U-shape. As shown in FIG. 61, a width of the channel 1040 near the tip 1043 is smaller than a width of the channel 1040 at the opening 1041.

In some examples, the upper 1002 includes a fabric layer 1008 (as shown in FIG. 46). In some examples, the fabric layer 1008 may be considered a strobel or an alternative to a strobel. Thus, in some examples, the fabric layer 1008 can be the same or similar to the other strobels described herein (such as strobel 900). For example, the fabric layer 1008 can comprise the same materials and/or layers of materials as described herein with reference to strobels for articles of footwear.

The fabric layer 1008 is arranged across the foot facing surface 1028 of the sole member 1006.

In some examples, the fabric layer 1008 is attached to the foot facing surface 1028 of the sole member 1006 with an adhesive.

In some examples, an inward (or foot) facing surface of the fabric layer 1008 can comprise indicators 1024 (e.g. circles) that are outlined, colored, or textured and indicate a location of the sensory node 1012 attached to the opposite, ground facing surface of the fabric layer 1008.

In some examples, the fabric layer may not include the indicators 1024.

The sensory node assembly 1010 is directly attached to the fabric layer 1008. The sensory node assembly 1010 comprises a plurality of individual sensory nodes 1012 (not directly attached to one another in the article 1000). Thus, each individual sensory node 1012 is directly attached to the fabric layer 1008. The article 1000 can be formed using any of the methods described herein, such as method 300 and/or 400, as well as the methods described below with reference to FIGS. 54-59. For example, the sensory nodes 1012 can be attached to the fabric layer 1008 the same or similar to as described herein for attaching sensory nodes to a strobel of an upper.

The sensory node assembly 1010 can be the same or similar to the other sensory node assemblies described herein (such as sensory node assembly 110 or 804), except, in some examples, it may have a different number, sizes, and/or arrangement of sensory nodes 1012 that make up the sensory node assembly 1010.

The sensory nodes 1012 can function similarly to the sensory nodes 112 and/or 806, as described above. For example, each sensory node 1012 can comprise an upper end (which would be directly below the indicators 1024 shown on the inward facing surface of the fabric layer 1008 in FIG. 46) directly attached to the fabric layer 1008 and configured to move individually and freely within a respective aperture 1020 in the sole member 1006.

Each sensory node 1012 can have an opposite, lower end 1026 that extends outward and away from the sole member 1006 (as shown in FIGS. 45 and 49-53). As described herein, the lower ends 1026 interact with a ground surface as the article 1000 is worn by a wearer.

Nodes having a circular cross-section and domed or spherical-tipped shape may be particularly suited for transferring enhanced vibrational sensation, 360 degrees around the node, to a wearer of the article (such as nodes 1012, for example). However, as noted herein, it is possible for a sensory node assembly for any of the articles described herein to have nodes having different shapes, sizes, and/or arrangements.

FIGS. 62-64 depict alternate arrangements of sensory nodes in a sensory node assembly for the article 1000 (or any of the other articles described herein, or similar articles). As one example, FIG. 62 shows a sensory node assembly 1060 comprising a plurality of sensory nodes 1012. The sensory nodes 1012 can have a circular cross-section, as discussed herein. However, the sensory nodes 1012 can have varying diameters and placements across the sole member. For example, the sensory nodes 1012 can be grouped into two or more regions, such as a first region 1062 closer to a toe of the article 100 and a second region 1064 closer to a heel of the article 1000. Various other groupings of sensory nodes 1012 is also possible.

FIG. 63 shows a sensory node assembly 1070 comprising a plurality of sensory nodes 1072 with a square-shaped cross-section. The square-shaped nodes 1072 can function similarly to the round sensory nodes 1012, as described herein. However, in some instances, the apertures 1074 in the sole member can have a square shape as well.

FIG. 64 a sensory node assembly 1080 comprising a plurality of sensory nodes 1082 with a triangular-shaped cross-section. The triangular-shaped nodes 1082 can function similarly to the round sensory nodes 1012, as described herein. However, in some instances, the apertures 1084 in the sole member can have a triangular shape as well.

Further, as shown in the exemplary assemblies of FIGS. 62-64, the sensory nodes of a sensory node assembly can have varying sizes and be placed at different locations across the sole member.

FIGS. 54-59 depict additional images for methods for forming the articles of footwear described herein. The methods shown in FIGS. 54-59 may be particularly tailored to forming the article 1000 (or similar articles) described above. For example, FIGS. 54-59 can be described below as utilizing components of the article 1000 described above; however, the methods described below can be applied to other articles of footwear having a fabric layer to be attached to a sole member.

In some examples, the methods described below with reference to FIGS. 54-59 can be part of the methods 300 and/or 400 described above.

FIG. 54 depicts arranging a jig 1100 across the fabric layer 1008 (or another fabric layer for another article of footwear) for an upper of an article of footwear, such as the article 1000 shown in FIGS. 45-53.

The jig 1100 can comprise an elongate base 1102 and two raised T-shaped structures 1104 that each have pegs or pins 1106 for attaching notches 1009 of the fabric layer 1008 thereto. In some examples, additional pins 1106 can be located at and extend upward from a front or toe region of the elongate base 1102.

In some examples, instead of pins 1106, the jig can comprise clips, hooks, or other elements that can receive a portion of the edge of the fabric layer 1008 and hold it thereto.

As shown in FIG. 54, the base 1102 of the jig 1100 is centered along an inward facing surface of the fabric layer 1008.

The edges of the fabric layer 1008 including the notches 1009 are then folded upward (as illustrated by arrow 1110 in FIG. 54) toward the T-shaped structure 1104 to attach the notches 1009 to respective pins 1106, as shown in FIG. 55.

In some examples, an adhesive is applied to the ground facing surface of the fabric layer 1008 and/or the foot facing surface of the sole member.

The jig 1100 with the fabric layer 1008 fastened thereto is then inserted into the foot cavity 1032 of the upper 1002 and the jig 1100 is used to align the fabric layer 1008 across the ground facing surface of the sole member 1006.

This process is made easier, with more precise placement of the fabric layer 1008 against the sole member 1006, by the open elongate channel 1040 which provides a larger opening for inserting the jig 1100.

The jig 1100 can be used to press the ground facing surface of the fabric layer 1008 into the foot facing surface of the sole member 1006, thereby attaching the fabric layer 1008 to the sole member of the article 1000.

Once the fabric layer 1008 is attached and in place against the sole member 1006, the fabric layer 1008 can be decoupled from jig 1100 and the jig 1100 is removed, as shown in FIG. 57.

As noted above, in some examples, the upper 1002 and the sole member 1006 of the article 1000 can be separate parts (e.g., molded separately) which are coupled together. In such example, the fabric layer 1008 can be attached to the foot facing surface of the sole member 1006 prior to attaching the remainder of the upper 1002 to the sole member 1006. After the fabric layer 1008 is attached to the sole member 1006, the body of the upper 1002 can be attached to the sole member 1006. Thus, in some instances, the upper 1002 may not need an opening for a tongue (for example, channel 1040).

Methods for forming the sensory node assembly (such as sensory node assembly 1010) can follow any of the methods outlined herein (such as the methods at 302 of method 300 and the methods at 402, 404, 406, 408, and/or 410 of the method 400).

After forming the sensory node assembly, as described herein, one or more pieces of a node holder holding the individual sensory nodes (such as node holder 844 shown in FIG. 41) can be used to arrange the sensory nodes within the apertures 1020 of the sole member 1006.

For example, as shown in FIG. 58, a first node holder portion 844a of the node holder 844 can be used to insert the sensory nodes 1012 into the respective apertures 1020 in the sole member 1006.

Remaining node holder portions can then be used to insert the remaining sensory nodes 1012 into the respective apertures 1020 of the sole member 1006.

The ground facing surface of the fabric layer 1008 can be seen through the apertures 1020 in FIG. 58. In some examples, the upper ends of the sensory nodes 1012 can have an adhesive applied thereto and the method shown at FIG. 58 can include pressing the upper ends of the sensory nodes 1012 against the ground facing surface of the fabric layer 1008, thereby attaching each sensory node 1012 individually to the fabric layer 1008 of the upper 1002.

FIG. 59 depicts attaching the tongue 1048 to the upper 1002 of the article 1000, after the fabric layer 1008 has been secured to the sole member 1006. As described above, in some examples the tongue can be removably coupled to the upper 1002.

In this way, the methods and jig systems described herein can be utilized to form a variety of articles of footwear comprising a sole system including a sensory node assembly disposed within a sole member, and where the sensory nodes of the sensory node assembly are individually attached (directly attached) to the upper of the article. The sole member is also attached to the upper and the sensory nodes translate freely within the sole member as they interact with a ground surface when the article is worn by an individual. Thus, articles including a sensory node assembly can be more efficiently and precisely formed. In some examples, portions of the method of forming such articles can be automated, thereby further simplifying the manufacturing process.

Exemplary Control Systems and Computing Systems

In some examples, one or more portions of the methods for forming an article of footwear comprising a sensory node assembly may be implemented with a computing system, in conjunction with inputs from a user. For example, as described above with reference to FIGS. 13 and/or 14, one or more portions of the methods can be performed manually or automatically, and in some cases with a computing system.

FIG. 36 depicts a generalized example of a suitable computing system 602 in which a portion the above-described innovations may be implemented. The computing system 602 is not intended to suggest any limitation as to scope of use or functionality, as the innovations may be implemented in diverse general-purpose or special-purpose computing systems. For example, the computing system 602 can be used to implement hardware and software.

With reference to FIG. 36, the computing system 602 includes one or more processing units 620, 622, non-volatile memory 624, and memory 626. In FIG. 36, this basic configuration of a computing environment 628 is included within a dashed line. The processing units 620, 622 execute computer-executable instructions, including instructions for operating a pressing apparatus, trimming apparatus, or the like, as disclosed herein (e.g., as described above with reference to FIGS. 13 and 14). A processing unit can be a general-purpose central processing unit (“CPU”), processor in an application-specific integrated circuit (“ASIC”), or any other type of processor. In a multi-processing system, multiple processing units execute computer-executable instructions to increase processing power. For example, FIG. 36 shows a central processing unit 620 as well as a graphics processing unit (“GPU”) or co-processing unit 622. The tangible memory 626 may be volatile memory (e.g., registers, cache, RAM), non-volatile memory (e.g., ROM, EEPROM, flash memory, etc.), or some combination of the two, accessible by the processing unit(s). The memory 626 stores software 630 implementing one or more innovations described herein, in the form of computer-executable instructions suitable for execution by the processing unit(s).

A computing system may have additional features. For example, the computing system 602 includes storage 632, one or more input devices 634, one or more output devices 636, and one or more communication connections 638. An interconnection mechanism (not shown) such as a bus, controller, or network interconnects the components of the computing system 602. Typically, operating system software (not shown) provides an operating environment for other software executing in the computing system 602, and coordinates activities of the components of the computing system 602.

The tangible storage 632 may be removable or non-removable, and includes magnetic disks, magnetic tapes or cassettes, CD-ROMs, DVDs, or any other medium which can be used to store information, and which can be accessed within the computing system 602. The storage 632 stores instructions for the software 630 for implementing one or more innovations described herein.

The input device(s) 634 may be a touch input device such as a keyboard or other devices that provides input to the computing system 602 (e.g., a mouse or imaging device). For video encoding, the input device(s) 634 may be a camera with an image sensor, video card, TV tuner card, or similar device that accepts video input in analog or digital form, or a CD-ROM, CD-RW, DVD, or Blu-Ray that reads video samples into the computing system 602.

The output device(s) 636 may be any device that receives an output or that is controlled by the computing system 602 by instructions, or a series of instructions, from the computing system 602 (such as the pressing apparatus 260, pressing arms 266, 268, and the trimming apparatus 272). For example, the output device(s) 636 could include the pressing apparatus 260 or pressing arms 266, 268, wherein these components are controlled via signals received from the computing system 602 (rather than being manually controlled by a user).

The communication connection(s) 638 enable communication over a communication medium (e.g., a connecting network) to another computing entity. The communication medium conveys information such as computer-executable instructions, compressed graphics information, video, or other data in a modulated data signal. The communication connection(s) 638 are not limited to wired connections (e.g., megabit or gigabit Ethernet, Infiniband, Fibre Channel over electrical or fiber optic connections) but also include wireless technologies (e.g., RF connections via Bluetooth, WiFi (IEEE 802.11a/b/n), WiMax, cellular, satellite, laser, infrared) and other suitable communication connections for providing a network connection for the disclosed agents, bridges, and agent data consumers. In a virtual host environment, the communication(s) connections can be a virtualized network connection provided by the virtual host.

Some examples of the disclosed methods can be performed using computer-executable instructions implementing all or a portion of the disclosed technology in a computing cloud 640. For example, disclosed computer-readable instructions can be executed by processors located in the computing environment 628, or the disclosed computer-readable instructions can be executed on servers located in the computing cloud 640.

Computer-readable media are any available media that can be accessed within a computing environment 628. By way of example, and not limitation, with the computing environment 628, computer-readable media include memory 624 and/or storage 631. As should be readily understood, the term computer-readable storage media includes the media for data storage such as memory 624 and storage 632 but does not include transmission media such as modulated data signals or other transitory signals.

The innovations can be described in the general context of computer-executable instructions, such as those included in program modules, being executed in a computing system on a target real or virtual processor. Generally, program modules include routines, programs, libraries, objects, classes, components, data structures, etc. that perform particular tasks or implement particular data types. The functionality of the program modules may be combined or split between program modules as desired in various examples. Computer-executable instructions for program modules may be executed within a local or distributed computing system.

ADDITIONAL EXAMPLES OF THE DISCLOSED TECHNOLOGY

Additional examples of the disclosed technology are enumerated below.

Example 1. An article of footwear comprising an upper; a sole member coupled to the upper, wherein the sole member comprises a plurality of spaced apart apertures extending through the sole member; and a plurality of individual sensory nodes, wherein each sensory node has a first end coupled directly to the upper and an opposite, second end configured to engage with a ground surface, and wherein each sensory node is configured to translate freely within a respective aperture of the sole member.

Example 2. The article of footwear of any example herein, particularly example 1, wherein the sensory nodes of the plurality of sensory nodes are unattached to one another and spaced away from the sole member.

Example 3. The article of footwear of any example herein, particularly either example 1 or example 2, wherein the first end of each sensory node is attached to a strobel of the upper.

Example 4. The article of footwear of any example herein, particularly any one of examples 1-3, wherein the sole member comprises one or more stationary nodes that are fixed relative to a remainder of the sole member and that are configured to engage with the ground surface and that are spaced apart from the plurality of sensory nodes.

Example 5. The article of footwear of any example herein, particularly any one of examples 1-3, wherein the sole member does not include any nodes.

Example 6. The article of footwear of any example herein, particularly any one of examples 1-5, wherein the sensory nodes of the plurality of sensory nodes are spaced apart across a majority of the sole member.

Example 7. The article of footwear of any example herein, particularly any one of examples 1-5, wherein the sensory nodes of the plurality of sensory nodes are spaced apart across a portion of the sole member.

Example 8. The article of footwear of any example herein, particularly any one of examples 1-7, wherein a larger number of sensory nodes of the plurality of sensory nodes are disposed in a forefoot portion than a heel portion of the sole member.

Example 9. The article of footwear of any example herein, particularly any one of examples 1-8, wherein the sole member is a midsole.

Example 10. The article of footwear of any example herein, particularly any one of examples 1-9, wherein the upper and the sole member are formed as one piece.

Example 11. An article of footwear comprising an upper; a sole member attached to the upper and comprising an outward-facing surface, an inward-facing surface, and a plurality of spaced apart apertures extending though the sole member, between the inward-facing surface and the outward-facing surface; and a sensory node assembly comprising a plurality of spaced apart sensory nodes, wherein each sensory node is vertically movable within a corresponding aperture of the plurality of apertures, and wherein each sensory node is directly attached to the upper and spaced apart from the sole member.

Example 12. The article of footwear of any example herein, particularly example 11, wherein the sole member comprises one or more stationary nodes extending outward from the outward-facing surface, and wherein each stationary node is fixed to the outward-facing surface.

Example 13. The article of footwear of any example herein, particularly either example 11 or example 12, wherein each sensory node is directly attached to the upper at its upper end and has a lower end that extends out of the corresponding aperture.

Example 14. The article of footwear of any example herein, particularly example 13, wherein the upper end of at least one sensory node of the plurality of sensory nodes is sloped.

Example 15. The article of footwear of any example herein, particularly any one of examples 11-14, wherein the upper includes a strobel, and wherein each sensory node is directly attached to the strobel.

Example 16. The article of footwear of any example herein, particularly example 15, wherein the strobel comprises a knit material having a z height distention of greater than 10 mm at 200 kPa load.

Example 17. The article of footwear of any example herein, particularly example 16, wherein the strobel comprises a polyurethane layer on the knit material that forms a surface of the strobel to which each sensory node is attached.

Example 18. The article of any example herein, particularly any one of examples 15-17, wherein the strobel is attached to the inward-facing surface of the sole member.

Example 19. The article of any example herein, particularly any one of examples 11-18, wherein the upper and the sole member are molded together as one part.

Example 20. A sole structure for an article of footwear, comprising a sole member comprising a plurality of spaced apart apertures extending through the sole member; and a plurality of sensory nodes, wherein each sensory node extends through a respective aperture of the plurality of spaced apart apertures, and wherein the sensory nodes of the plurality of sensory nodes are not attached to the sole member and are freely movable relative to each other and the sole member.

Example 21. The sole structure of any example herein, particularly example 20, wherein the sole member comprises one or more fixed nodes that are not freely movable relative to a remainder of the sole member.

Example 22. The sole structure of any example herein, particularly either example 20 or example 21, wherein a first end of each sensory node is planar and an opposite, second end of each sensory node is spherical, and wherein the second end of each sensory node is configured to engage a ground surface.

Example 23. An assembly comprising the sole structure of any example herein, particularly any one of examples 20-22, and further comprising an upper, wherein the sole member and the plurality of sensory nodes are attached to the upper, and wherein each sensory node of the plurality of sensory nodes is directly and individually attached to a strobel of the upper.

Example 24. The assembly of any example herein, particularly example 23, wherein the strobel comprises a double layer circular knit comprising cationic dyeable polyester and elastane.

Example 25. An article of footwear comprising a sole member comprising a plurality of spaced apart apertures extending through the sole member; a fabric layer arranged across a foot facing surface of the sole member; and a plurality of individual sensory nodes, wherein each sensory node has a first end coupled directly to the fabric layer and an opposite, second end configured to engage with a ground surface, and wherein each sensory node is configured to translate freely within a respective aperture of the sole member.

Example 26. The article of footwear of any example herein, particularly example 25, wherein the fabric layer is attached to the foot facing surface of the sole member with an adhesive.

Example 27. The article of footwear of any example herein, particularly either example 25 or example 26, further comprising an upper, and wherein the fabric layer forms a strobel of the upper.

Example 28. The article of footwear of any example herein, particularly example 27, wherein the upper and the sole member are formed as a single part.

Example 29. The article of footwear of any example herein, particularly either example 27 or example 28, wherein the upper defines a foot receiving cavity of the article and a foot opening into the cavity, and wherein the foot opening extends from the sole member, forward toward a toe portion of the article, and upward toward a top portion of the upper.

Example 30. The article of footwear of any example herein, particularly any one of examples 27-29, wherein the upper includes an elongate channel, and further comprising a tongue that is attached to the upper such that it covers the elongate channel.

Example 31. The article of footwear of any example herein, particularly example 30, wherein the tongue is removably attached to the upper.

Example 32. The article of footwear of any example herein, particularly either example 30 or example 31, wherein the elongate channel extends from a foot opening at a top portion of the upper toward a toe of the upper.

Example 33. The article of footwear of any example herein, particularly any one of examples 25-32, wherein the sole member comprises a ground facing surface that is arranged opposite the foot facing surface, and wherein the foot facing surface faces a foot receiving cavity of the article of footwear.

Example 34. The article of footwear of any example herein, particularly example 33, wherein each aperture of the plurality of spaced apart apertures of the sole member extends between the foot facing surface and the ground facing surface of the sole member.

Example 35. The article of footwear of any example herein, particularly any one of examples 25-34, wherein the fabric layer is arranged across the entirety of the foot facing surface of the sole member.

Example 36. The article of footwear of any example herein, particularly any one of examples 25-35, wherein the sensory nodes of the plurality of sensory nodes are unattached to one another and spaced away from the sole member.

Example 37. The article of footwear of any example herein, particularly any one of examples 25-36, wherein the sole member comprises one or more stationary nodes that are fixed relative to a remainder of the sole member and that are configured to engage with the ground surface and that are spaced apart from the plurality of sensory nodes.

Example 38. The article of footwear of any example herein, particularly any one of examples 35-36, wherein the sole member does not include any nodes.

Example 39. A method for forming an article of footwear, comprising holding a plurality of sensory nodes together in a sensory node assembly; arranging a sole member around the sensory node assembly such that each sensory node extends through a respective aperture in the sole member with lower ends of the sensory nodes extending out of the respective apertures; and coupling the sole member to an upper and attaching upper ends of the plurality of sensory nodes directly to the upper, thereby forming the article of footwear with the plurality of sensory nodes, wherein each sensory node extends out of the sole member and is configured to translate within the respective aperture in the sole member.

Example 40. The method of any example herein, particularly example 39, wherein holding the plurality of sensory nodes together in the sensory node assembly includes inserting upper ends of the plurality of sensory nodes into a sensory node holding member such that the sensory nodes of the plurality of sensory nodes are spaced apart from one another in a specified arrangement.

Example 41. The method of any example herein, particularly example 40, wherein the plurality of sensory nodes are interconnected by a connecting web that surrounds and extends between each sensory node of the plurality of sensory nodes, and further comprising, prior to arranging the sole member around the sensory node assembly, removing the connecting web from around and between the plurality of sensory nodes of the sensory node assembly.

Example 42. The method of any example herein, particularly example 41, wherein removing the connecting web includes cutting around each sensory node of the plurality of sensory nodes with a cutting member of a cutting jig by pressing the cutting member and the sensory node holding member together.

Example 43. The method of any example herein, particularly any one of examples 39-42, further comprising, prior to arranging the sole member around the sensory node assembly, transferring the sensory node assembly from the sensory node holding member to a node holder by attaching lower ends of the plurality of sensory nodes to the node holder.

Example 44. The method of any example herein, particularly any one of examples 39-43, further comprising, following attaching the upper ends of the plurality of sensory nodes and the sole member to the upper, removing the node holder from the sensory node assembly to reveal the formed article of footwear.

Example 45. The method of any example herein, particularly any one of examples 39-44, wherein coupling the sole member to the upper and attaching the upper ends of the sensory nodes directly to the upper includes directly attaching an inward-facing surface of the sole member and upper ends of the sensory nodes to the upper via an adhesive.

Example 46. The method of any example herein, particularly any one of examples 39-45, wherein coupling the sole member to the upper and attaching the upper ends of the sensory nodes directly to the upper includes first attaching the sole member to the upper and then attaching the upper ends of the sensory nodes directly to the upper.

Example 47. The method of any example herein, particularly any one of examples 39-46, wherein attaching the upper ends of the sensory nodes directly to the upper includes directly attaching the upper ends of the sensory nodes to a strobel of the upper.

Example 48. The method of any example herein, particularly any one of examples 39-46, wherein attaching the upper ends of the sensory nodes directly to the upper includes directly attaching the upper ends of the sensory nodes to an insole or sockliner of the upper.

Example 49. The method of any example herein, particularly any one of example 39-48, wherein attaching the upper ends of the sensory nodes directly to the upper includes attaching each sensory node of the plurality of sensory nodes individually to only the upper such that each sensory node is individually movable within a respective aperture of the sole member as the formed article of footwear interacts with a ground surface.

Example 50. The method of any example herein, particularly any one of examples 39-49,wherein the sensory nodes of the plurality of sensory nodes of the sensory node assembly are unattached to one another and spaced away from the sole member.

Example 51. A method for forming an article of footwear, comprising inserting sensory nodes interconnected by connectors into a sensory node holding member to form a sensory node assembly; coupling a cutting member to the sensory node holding member, around the sensory nodes, and pressing the cutting member and sensory node holding member toward one another to cut the connectors away from the sensory nodes; transferring the sensory nodes from the sensory node holding member to a node holder, wherein lower ends of the sensory nodes are received in the node holder; arranging a sole member around the sensory node assembly such that each sensory node extends through a respective aperture in the sole member; attaching an upper directly to upper ends of the sensory nodes and to the sole member; and removing the node holder from the sensory node assembly to reveal the formed article of footwear comprising the upper, sole member, and sensory nodes extending out of the sole member, wherein the sensory nodes are configured to translate within respective apertures in the sole member.

Example 52. The method of any example herein, particularly example 51, wherein the transferring includes coupling the sensory node holding member to a base member with the node holder disposed therein, wherein lower ends of the sensory nodes disposed adjacent to the node holder; placing a pressing member comprising protruding columns over open ends of the sensory node holding member such that the protruding columns are aligned with the sensory nodes; and pressing the pressing member against the sensory nodes in the sensory node holding member such that lower ends of the sensory nodes are coupled to the node holder.

Example 53. The method of any example herein, particularly either example 51 or example 52, further comprising, prior arranging the sole member around the sensory node assembly, placing the node holder with the coupled sensory nodes into a base receptacle and positioning the sole member around the sensory nodes inside the base receptacle.

Example 54. The method of any example herein, particularly any one of examples 51-53, wherein attaching the upper directly to upper ends of the sensory nodes and to the sole member includes activating an adhesive on the upper ends of the sensory nodes, and pressing the upper into an inward-facing surface of the sole member and the upper ends of the sensory nodes.

Example 55. The method of any example herein, particularly any one of examples 51-54, wherein the pressing the cutting member and sensory node holding member toward one another to cut the connectors away from the sensory nodes includes activating a pressing apparatus to press the cutting member and sensory node holding member toward one another.

Example 56. The method of any example herein, particularly any one of examples 51-55, wherein following the attaching the upper directly to the upper ends of the sensory nodes, the sensory nodes are suspended from the upper within the respective apertures of the sole member.

Example 57. The method of any example herein, particularly any one of examples 51-55, wherein the upper includes a strobel, wherein attaching the upper directly to upper ends of the sensory nodes and to the sole member includes attaching the strobel to an inward-facing surface of the sole member and attaching the upper ends of the sensory nodes directly to the strobel.

Example 58. A system for forming an article of footwear, comprising a sensory node holding member comprising spaced apart cavities, wherein each cavity is configured to receive a first end of a respective sensory node of a sensory node assembly for a sole system of the article of footwear; a cutting member comprising a plurality of spaced apart cutting features, wherein each cutting feature aligns with a space surrounding a respective cavity of the sensory node holding member when the cutting member is coupled to the sensory node holding member; a node holder comprising spaced apart depressions, wherein each depression is configured to receive a second end of a respective sensory node of the sensory node assembly; and a pressing member comprising a plurality of spaced apart protruding columns, wherein the pressing member is configured to couple to the sensory node holding member such that each protruding column extends into an open end of a respective cavity of the sensory node holding member.

Example 59. The system of any example herein, particularly example 58, further comprising a base member configured to receive the node holder, wherein the base member is configured to couple to the sensory node holding member.

Example 60. The system of any example herein, particularly either example 58 or example 59, further comprising a pressing apparatus, and wherein the pressing apparatus is configured to press the sensory node holding member and the cutting member toward one another to cut around each sensory node of the sensory node assembly such that a web of material interconnecting the sensory nodes is detached from the sensory node assembly.

Example 61. The system of any example herein, particularly any one of examples 58-60, further comprising a pressing apparatus, and wherein the pressing apparatus is configured to press the pressing member into the sensory node holding member such that the sensory nodes of the sensory node assembly are transferred to the depressions of the node holder.

Example 62. A method for forming an article of footwear, comprising attaching a fabric layer directly to a foot facing surface of a sole member of the article of footwear; holding a plurality of sensory nodes together in a sensory node assembly; arranging a sole member around the sensory node assembly such that each sensory node extends through a respective aperture in the sole member with lower ends of the sensory nodes extending out of the respective apertures; and attaching upper ends of the plurality of sensory nodes directly to the fabric layer, thereby forming the article of footwear with the plurality of sensory nodes, wherein each sensory node extends out of the sole member and is configured to translate within the respective aperture in the sole member.

Example 63. The method of any example herein, particularly example 62, wherein attaching the fabric layer directly to the foot facing surface of the sole member includes attaching edges of the fabric layer to a jig and using the jig to align the fabric layer within a foot cavity of the article of footwear and against the foot facing surface of the sole member.

Example 64. The method of any example herein, particularly either example 62 or example 63, wherein attaching the fabric layer directly to the foot facing surface of the sole member includes attaching the fabric layer to the foot facing surface with an adhesive.

Example 65. The method of any example herein, particularly any one of examples 62-64, wherein the fabric layer forms a strobel of an upper of the article of footwear.

Example 66. The method of any example herein, particularly example 65, wherein the upper is formed as one piece with the sole member.

Example 67. The method of any example herein, particularly either example 65 or example 66, further comprising attaching a tongue to an elongate channel of the upper.

Example 68. The method of any example herein, particularly example 67, wherein attaching the tongue to the elongate channel includes fitting the tongue to the channel such that the tongue is removable coupled to the upper and can be interchangeable with additional tongues comprising a different material, color, or design.

In view of the many possible examples to which the principles of the disclosed technology may be applied, it should be recognized that the illustrated examples are only preferred examples of the disclosed technology and should not be taken as limiting the scope of the claimed subject matter. Rather, the scope of the claimed subject matter is defined by the following claims and their equivalents.

Claims

1. An article of footwear comprising:

an upper;

a sole member coupled to the upper, wherein the sole member comprises a plurality of spaced apart apertures extending through the sole member; and

a plurality of individual sensory nodes, wherein each sensory node has a first end coupled directly to the upper and an opposite, second end configured to engage with a ground surface, and wherein each sensory node is configured to translate freely within a respective aperture of the sole member.

2. The article of footwear of claim 1, wherein the sensory nodes of the plurality of sensory nodes are unattached to one another and spaced away from the sole member.

3. The article of footwear of claim 1, wherein the first end of each sensory node is attached to a strobel of the upper.

4. The article of footwear of claim 3, wherein the strobel comprises a knit material having a z height distention of greater than 10 mm at 200 kPa load.

5. The article of footwear of claim 1, wherein the sensory nodes of the plurality of sensory nodes are spaced apart across a majority of the sole member.

6. The article of footwear of claim 1, wherein the sensory nodes of the plurality of sensory nodes are spaced apart across a portion of the sole member.

7. The article of footwear of claim 1, wherein the first end of at least one sensory node of the plurality of sensory nodes is sloped.

8. The article of footwear of claim 1, wherein the upper and the sole member are formed as one piece.

9. A sole structure for an article of footwear, comprising:

a sole member comprising a plurality of spaced apart apertures extending through the sole member; and

a plurality of sensory nodes, wherein each sensory node extends through a respective aperture of the plurality of spaced apart apertures, and wherein the sensory nodes of the plurality of sensory nodes are not attached to the sole member and are freely movable relative to each other and the sole member.

10. The sole structure of claim 9, wherein the sole member comprises one or more fixed nodes that are not freely movable relative to a remainder of the sole member.

11. The sole structure of claim 9, wherein a first end of each sensory node is planar and an opposite, second end of each sensory node is spherical, and wherein the second end of each sensory node is configured to engage a ground surface.

12. An assembly comprising the sole structure of claim 9, and further comprising an upper, wherein the sole member and the plurality of sensory nodes are attached to the upper, and wherein each sensory node of the plurality of sensory nodes is directly and individually attached to a strobel of the upper.

13. The assembly of claim 12, wherein the strobel comprises a double layer circular knit comprising cationic dyeable polyester and elastane.

14. An article of footwear comprising:

a sole member comprising a plurality of spaced apart apertures extending through the sole member;

a fabric layer arranged across a foot facing surface of the sole member; and

a plurality of individual sensory nodes, wherein each sensory node has a first end coupled directly to the fabric layer and an opposite, second end configured to engage with a ground surface, and wherein each sensory node is configured to translate freely within a respective aperture of the sole member.

15. The article of footwear of claim 14, wherein the fabric layer is attached to the foot facing surface of the sole member with an adhesive.

16. The article of claim 14, further comprising an upper, and wherein the fabric layer forms a strobel of the upper.

17. The article of footwear of claim 16, wherein the upper and the sole member are formed as a single part.

18. The article of footwear of claim 16, wherein the upper defines a foot receiving cavity of the article and a foot opening into the cavity, and wherein the foot opening extends from the sole member, forward toward a toe portion of the article, and upward toward a top portion of the upper.

19. The article of footwear of claim 14, wherein the upper includes an elongate channel, and further comprising a tongue that is attached to the upper such that it covers the elongate channel.

20. The article of footwear of claim 19, wherein the elongate channel extends from a foot opening at a top portion of the upper toward a toe of the upper.