ARTICLE OF FOOTWEAR WITH SIPES

Abstract

The present disclosure is directed to articles of footwear having a sole structure comprising a pair of curvilinear sipes extending from the forefoot region to a midfoot region or heel region. The curvilinear sipes may have a profile that is a consistent distance from the edge of the outsole. The curvilinear sipes may be carved into the ground-facing surface of an outsole and extending into the midsole. A carved sipe may comprise a first sidewall, a second sidewall, and a cavity defined by the sidewalls and a plane defined by the ground-facing surface. Systems and methods for forming sipes in accordance with the present disclosure by using a reciprocating blade with a non-heated and plain (non-serrated) cutting edge are also discussed.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This non-provisional patent application claims priority to U.S. provisional patent app. No. 63/724,131, filed on Nov. 22, 2024, and titled “Article of Footwear With Sipes,” co-pending U.S. provisional patent app. No. 63/724,113, filed on Nov. 22, 2024, and titled “Article of Footwear With Sipes, ” and co-pending U.S. provisional patent app. No. 63/724,147, filed on Nov. 22, 2024, and titled “Article of Footwear With Sipes.” The entire contents of the above-referenced applications are incorporated herein by reference.

BACKGROUND

The present embodiments relate generally to articles of footwear, and in particular to articles of footwear with uppers and sole structures.

Articles of footwear generally include two primary elements: an upper and a sole structure. The upper may be formed from a variety of materials that are unitary in construction, stitched or adhesively bonded together to form a void within the footwear for comfortably and securely receiving a foot. The sole structure is secured to a lower portion of the upper and is generally positioned between the foot and the ground. In many articles of footwear, including athletic footwear styles, the sole structure often incorporates a midsole and an outsole.

In some articles of footwear, the sole structure may include one or more sipes extending through the sole structure. The sipes may improve the grip of the sole structure with the ground and may also provide the sole structure with additional flexibility.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 illustrates a top perspective view of a first example of an article of footwear in accordance with the present disclosure.

FIG. 2 illustrates a bottom view of the sole structure of the article of footwear of FIG. 1.

FIG. 3 illustrates a bottom perspective view of the sole structure of FIG. 2.

FIG. 4 illustrates a cross-sectional view of the sole structure of FIG. 2 along cut line 4-4.

FIG. 5A illustrates a cross-sectional view of the sole structure of FIG. 2 along cut line 5-5 in a relaxed and un-flexed state.

FIG. 5B illustrates a cross-sectional view of the sole structure of FIG. 5A in a flexed-state.

FIG. 6A illustrates an enlarged view of the carved sipe in FIG. 5A.

FIGS. 6B and 6C illustrate the first sidewall and the second sidewall of the carved sipe of FIG. 6A.

FIGS. 7A and 7B illustrate side and top views of a blade for use in manufacturing a sole structure in accordance with the present disclosure.

FIGS. 7C and 7D illustrates the positions of a blade and a sole structure prior to and during a cut being made in accordance with the present disclosure.

FIG. 8 illustrates an example of a path of a reciprocating blade cutting through a sole structure in accordance with the present disclosure.

FIG. 9A is a schematic plan view of a footwear component manufacturing system in a first configuration, in accordance with aspects hereof.

FIG. 9B is a schematic plan view of a footwear component manufacturing system in a second configuration, in accordance with aspects hereof.

FIG. 10 is a perspective bottom view of a second example of a sole structure in accordance with the present disclosure.

FIG. 11 is a flow chart of a method of manufacturing a sole structure in accordance with the present disclosure.

FIGS. 12A-C illustrates different examples of carved sipes in accordance with the present disclosure having different cross-sectional profiles.

DETAILED DESCRIPTION

The present disclosure relates to an article of footwear comprising an upper attached to a sole structure having a pair of longitudinally-oriented curvilinear sipes extending through a ground-facing surface of the outsole into the midsole. The sipes each have a curvilinear profile that includes an apex (relative to a longitudinal midline) in a forefoot region of the sole structure. In an example, a medial sipe has a medial edge that is offset from and corresponding to a medial edge of the sole structure in at least a portion of the forefoot region, and a lateral sipe has a lateral edge that is offset from and corresponding to a lateral medial edge of the outsole in at least a portion of the forefoot region. In examples, the sole structure further comprises a plurality of transverse sipes extending through the first curvilinear sipe and the second curvilinear sipe. In examples, each of the sipes comprises a first side wall and a second side wall that extend from the ground-facing surface of the outsoles and converge in the midsole. The first side wall may extend through the outsole at the ground-facing surface at a first angle and the second side wall may extend through the outsole at the ground-facing surface at a second angle.

The sipes may be formed by slicing into the sole structure with a reciprocating blade, which cuts the material of the sole structure without removing or melting any significantly measurable amount of material. The resulting cut creates no appreciable gap in the material (e.g., kerf width) between the opposite sides of the cut. Stated differently, the material of the sole structure is divided along the path of the cut but since no material is removed or melted by the cutting process itself the design of the sipe is not required to incorporate the kerf width in its design. Accordingly, a sipe may be designed and manufactured with greater design flexibility, e.g., a sipe may have sharp angles or vertexes that were previously unable to be manufactured in a practical way. The reciprocating cutting action used to form sipes in accordance with the present disclosure may leave, in examples, characteristic striations across the faces of the sidewalls formed on either side of the sipe. It is noted that in other examples, however, the cutting action of the blade may not leave visible striations on the face of one or more sidewalls or portions of a sidewall.

In examples, the sole structure further comprises a plurality of transverse sipes extending through the first curvilinear sipe and the second curvilinear sipe. The plurality of sipes may also be carved into the sole structure or may be slit sipes that comprises a slit in the sole structure material where no intervening material between the sidewalls has been removed. A first transverse sipe of the plurality of transverse sipes may have a first distance between a first side of the first transverse sipe and a second side of the first transverse sipe at the ground-facing surface and a second distance between the first side and the second side at the foot-facing surface, wherein the first distance is greater than the second distance. In examples, each of the plurality of transverse sipes may extend through the medial side and the lateral side of the sole structure. Each of the plurality of transverse sipes may be curvilinear, and may have a heelward facing apex between the first curvilinear sipe and the second curvilinear sipe. A transverse sipe may also have a medial end or a lateral end that is heelward than an intersection of the transverse sipe with an adjacent longitudinal curvilinear sipe.

The edge of each longitudinal sipe may be curved to correspond to the adjacent outer perimeter of the sole structure. Thus, the sole elements that are defined between the perimeter and the sipe have a consistent transverse width, so that the sole elements provide a more consistent feel and response to forces experienced during movement (e.g., running, jumping or sideways cutting actions). The longitudinal curvilinear sipes, in combination with a cross-rocker sole structure, allow the sole structure to more easily conform to an individual user's specific foot anatomy and movement patterns. This allows for a better fit and feeling without individual customization of each shoe structure. In other words, the curvilinear longitudinal sipes facilitate the shoe being more adaptive to a user's foot and movement patterns, while providing a certain level of consistency in terms of traction, flexibility and support. The profile of the curved longitudinal sipes, either alone or in combination with the plurality of transverse sipes, may also enhance a consumer's visual perception of the reactive nature of the sole structure.

Turning now to FIG. 1, an example article of footwear (hereinafter referred to as article 100) in accordance with the present disclosure is provided. In the examples described herein, the article 100 has the form of a general purpose athletic shoe. However, in other examples, the article 100 may be another type of athletic footwear including, but not limited to, basketball shoes, hiking boots, soccer shoes, football shoes, sneakers, running shoes, cross-training shoes, rugby shoes, baseball shoes as well as other kinds of shoes. Moreover, in examples, the present disclosure is contemplated to be applicable to various other kinds of non-sports-related footwear, including, but not limited to, slippers, rain boots, sandals, high-heeled footwear, and loafers.

For consistency and convenience, directional adjectives are employed throughout this detailed description corresponding to the illustrated examples. The term “longitudinal” as used throughout this detailed description and in the claims refers to a direction oriented along a length of a component (e.g., an upper or sole component). In some cases, a longitudinal direction may be parallel to a longitudinal axis that extends between a forefoot region and a heel region of the component. The term “transverse” as used throughout this detailed description and in the claims refers to a direction oriented along a width of a component. In some cases, a transverse direction may be parallel to a transverse axis that extends between a medial side and a lateral side of a component. Furthermore, the term “vertical” as used throughout this detailed description and in the claims refers to a direction generally perpendicular to a transverse and longitudinal direction. For example, in cases where an article is planted flat on a ground surface, a vertical direction may extend from the ground surface upward. Additionally, the term “inner” refers to a portion of an article disposed closer to an interior of an article, or closer to a foot when the article is worn. Likewise, the term “outer” refers to a portion of an article disposed further from the interior of the article or from the foot. Thus, for example, the inner surface of a component is disposed closer to an interior of the article than the outer surface of the component. The terms “heelward” refers to being in the direction of or being closer towards the heel of the article, and the term “toeward” refers to being in the direction of or being closer towards the toe of the article. This detailed description makes use of these directional adjectives in describing an article and various components of the article, including an upper and a sole structure.

Article 100 may be characterized by a number of different regions or portions. For example, the article 100 of FIG. 1 may be divided into a forefoot region 10, midfoot region 12, and heel region 14. In addition, article 100 may include lateral side 16 and medial side 18 on opposing sides of article 100. It is to be understood that these regions are not intended to demarcate precise areas of article 100. Rather, forefoot region 10, midfoot region 12, heel region 14, lateral side 16, and medial side 18 are intended to represent general areas of article 100 that provide a frame of reference during the following discussion.

Article 100 may comprise an upper 102 and a sole structure 104. Generally, the upper 102 may be any type of upper and can be secured to the sole structure 104 by adhesives, bonding, mechanical fasteners, or via a strobel. The upper 102 may be formed from a variety of different manufacturing techniques, resulting in various kinds of upper structures. For example, in examples, an upper could have a braided construction, a knitted (e.g., warp-knitted or weft-knitted) construction, or some other woven or nonwoven construction. The upper 102 may be formed from a variety of materials, such as organic or synthetic materials in the form of textiles, yarns, fibers, sheets, films, and the like. The upper 102 may be formed as a unitary construction or as a plurality of components joined together to form the upper 102.

The sole structure 104 of FIG. 1 comprises an outsole 110 and a midsole 120. The inner surface 114 of the outsole 110 and the ground-facing surface 122 of the midsole 120 are adjacent to each other along an interface 125. The outsole 110 and the midsole 120 may be attached to each other along the interface 125 via adhesives, heat bonding, co-molding, vulcanization, or other methods.

The outsole 110 may include a ground-facing surface 112 configured to provide traction for article 100 and also provide a durable, wear-resistant component for attenuating ground reaction forces and absorbing energy as article 100 impacts the ground. The outsole 110 may be manufactured from a variety of different materials, which may include, but are not limited to, rubber (e.g., carbon rubber or blown rubber), polymers, thermoplastics (e.g., thermoplastic polyurethane), as well as possibly other materials. It is understood that the sole structure 104, in an example, may omit one of the outsole 110 or the midsole 120. Similarly, it is contemplated that the outsole 110 and midsole 120 are substantially monolithic in structure and/or composition.

In examples, the outsole 110 may extend from forefoot region 10 through midfoot region 12 and to heel region 14, and from the lateral side 16 to the medial side 18. Stated differently, the outsole 110 and its ground-facing surface 112 may extend substantially across the entire surface area defined by the outer perimeter 106 of the sole structure. In other examples, such as in the example sole structure 104 depicted in FIG. 1 and also as seen in FIGS. 2 and 3, the outsole 110 and its ground-facing surface 112 may only cover a portion or portions of the surface area defined by the outer perimeter 106 of the sole structure 104, exposing the ground-facing surface 122 of the midsole 120. The ground-facing surface 112 of the outsole 110 may be generally smooth, or may include features that enhance grip with the ground, such as treads formed as ridges, hemispheric protrusions, cylindrical or other geometric protrusions as well as other kinds of tread elements. The ground-facing surface 112 may be curved in the longitudinal direction, in the transverse direction, or in both. In other examples the ground-facing surface 112 may generally be flat. In examples, the outsole 110 has an outsole thickness 116 that is generally consistent. In other examples, the outsole thickness 116 may vary. For instance, the thickness may be a first thickness in the forefoot region 10 and a second thickness near the heel region 14 that is greater than the first thickness.

Midsole 120 may comprise a resilient material to attenuate ground reactions forces, absorbing and redirecting energy during walking, running, jumping or other movements and activities. In examples, the midsole 120 may extend from forefoot region 10 through midfoot region 12 and to heel region 14. In examples, the midsole 120 may be a continuous, one-piece component that extends from forefoot region 10 to heel region 14. In other examples, the midsole 120 may include multiple pieces or may include a gap or space in any of the regions. That is, in examples, the midsole 120 may be separated into two or more pieces.

In different examples, the midsole 120 may generally incorporate various provisions associated with midsoles. In examples, a midsole 120 may be formed from a polymer foam material that attenuates ground reaction forces (i.e., provides cushioning) during walking, running, and other ambulatory activities. In various examples, midsole 120 may also include one or more fluid-filled chambers, plates, moderators, or other elements that further attenuate forces, enhance stability, or influence the motions of the foot, for example. The midsole 120 may generally be manufactured from polyurethane, polyurethane foam, other kinds of foams as well as possibly other materials. In examples, the midsole 120 may utilize polymer foams, including but not limited to ethylvinylacetate (EVA), thermoplastic polyurethane (TPU) or polyurethane foams.

It may be desirable, for at least some applications, that the Shore A hardness of the outsole material be larger than the Shore A hardness of the midsole material, e.g., by at least about 20% and larger than the Shore A hardness of the insole material by at least about 50%. As a non-limiting example, the midsole material may include a polymer foam material, such as TPU foam or EVA, having a material hardness in the range of about 40 to about 60 Shore A (e.g., about 65 to about 80 Asker C). Conversely, the outsole material may include an elastic polymer material, such as polyvinylchloride (PVC), hard-compound polyurethane (PU), or a polycaprolactone (PCL) or polyester-based TPU, having a material hardness of about 75 to about 90 Shore A.

The densities of the materials forming the outsole 110 and the midsole 120 also may differ from each other. For instance, the outsole 110 may have a higher density than a midsole 120, thereby allowing for increased durability and wear resistance. In other examples, however, the density of the outsole 110 could be equal to the density of the midsole 120, or could be less than the density of the midsole 120.

Turning to the bottom view of the sole structure 104 in FIG. 2, the sole structure 104 includes a plurality of sipes that extend along the ground-facing surface 112. As used herein, the term “sipe” may refer to a slit, cut, or groove. A “carved sipe” is formed by multiple converging cuts to define opposing sidewalls and removing the intervening material between the sidewalls, which then defines a sipe cavity between them. The sole structure 104 of FIG. 2 comprises two generally longitudinally oriented carved sipes 400 and six generally transversely oriented carved sipes 450. Each of the transverse sipes 450 intersect both longitudinal sipes 400, defining the sole structure 104 into a plurality of different sole elements 230.

Turning to a further description of the two longitudinal sipes 400, a lateral sipe 410 is positioned between a longitudinal midline 20 of the sole structure and the lateral edge 107 of the perimeter 106. A first end 412 is positioned in the forefoot region 10 near the toe of the sole structure 104, and a second end 414 is positioned in the heel region 14. In between the first end 412 and the second end 414 the sipe has a curvilinear shape, with an apex 416 facing towards the lateral edge 107. The lateral sipe 410 has a first outsole edge 418 and a second outsole edge 420 at the ground-facing surface 112, with the first outsole edge 418 closer to the lateral edge 107 and the second outsole edge 420 closer to the longitudinal midline 20. On the interior of the sipe, the lateral sipe 410 has a first sidewall 150 and a second sidewall 160. The first sidewall 150 extends from the first outsole edge 418 through the thickness 116 of the outsole 110 and into the midsole 120, and the second sidewall 160 extends from the second outsole edge 420 through the thickness 116 of the outsole 110 and into the midsole 120. The first sidewall 150 and the second sidewall 160 converge in the midsole along an interior edge 170. A lateral sipe width 422 may be measured between opposing points on the first outsole edge and the second outsole edge. The lateral sipe width 422 varies along the length of the sipe, tapering to zero at the first end 412 and the second end 414 and widening closer to the middle of the sipe. In examples, the lateral sipe width 422 may be at its widest at the apex 416. In the example of FIG. 2, the first outsole edge 418 does not cross a line 22 defined by the first end 412 and the second end 414 while the second outsole edge 420 does cross line 22, but in other examples both outsole edges 418, 420 may cross line 22 one or multiple times (e.g., a sipe having a serpentine profile for at least a portion of its length), and in yet other examples neither outsole edge 418, 420 crosses line 22.

Similarly, a medial sipe 430 is positioned between the longitudinal midline 20 and the medial edge 108 of the perimeter 106. A first end 432 is positioned in the forefoot region 10 near the toe of the sole structure 104, and a second end 434 is positioned in the heel region 14. In between the first end 432 and the second end 434 the sipe has a curvilinear shape, with an apex 436 facing towards the medial edge 108. The medial sipe 430 has a first outsole edge 438 and a second outsole edge 440, with the first outsole edge 438 closer to the medial edge 108 and the second outsole edge 440 closer to the longitudinal midline 20. The medial sipe 430 has first sidewall 150 extending from the first outsole edge 438 and second sidewall 160 extending from the second outsole edge 440 that meet along an interior edge 170 within the midsole. A medial sipe width 442 may be measured between opposing points on the first outsole edge 438 and the second outsole edge 440. The medial sipe width 442 varies along the length of the sipe, tapering to zero at the first end 432 and the second end 434 and widening closer to the middle of the sipe. In examples, the medial sipe width 442 may be at its widest at the apex 436.

The lateral sipe 410 and the medial sipe 430, while similar in dimensions and profile, may not be mirror images of each other. For example, depending upon the geometry of the perimeter 106, the apex 416 of the lateral sipe 410 and the apex 436 of the medial sipe 430, may not be aligned with each other. Similarly, in the example of FIG. 2, the first outsole edge 438 does not cross a line 24 defined by the first end 432 and the second end 434, but the second outsole edge 440 does. In other examples both outsole edges 438, 440 may cross line 24 one or multiple times (e.g., a sipe having a serpentine profile for at least a portion of its length), and in yet other examples neither outsole edge 438, 440 crosses line 24.

Turning to a description of the transverse sipes 450, each transverse sipe 450 extends from the lateral edge 107 to the medial edge 108 of the perimeter. The first transverse sipe 452 is positioned close to the toe of the sole structure 104 in the forefoot region 10, and the sixth transverse sipe 462 is positioned in the midfoot region 12 close to the heel region 14. Each transverse sipe 450 has a curvilinear profile, with an apex 470 that extends towards the heel between the lateral sipe 410 and the medial sipe 430. In the example sole structure of FIG. 2, an end of a transverse sipe 450 is more heelward than an intersection of the transverse sipe 450 with the adjacent longitudinal sipe 400. For example, a lateral end 472 of third transverse sipe 456 is more heelward than intersection 474 of the third transverse sipe with the lateral sipe 410. Similarly, the medial end 476 of the third transverse sipe 456 is more heelward than intersection 478 of the third transverse sipe with the medial sipe 430.

Similar to the longitudinal sipes 400, each transverse sipe 450 may have a longitudinal width 480 between its opposing edges 482, with each opposing edge defined by an intersection of a sidewall of the sipe with the ground-facing surface 112. Each transverse sipe may also have a longitudinal width that may be consistent or may vary along the length of the sipe. For example, fifth transverse sipe 560 has a first longitudinal width 486 near the medial edge 108 that is greater than a second longitudinal width 488 near the longitudinal midline 20. The longitudinal widths of the transverse sipes may also vary from each other. For example, the longitudinal width 490 of the sixth transverse sipe is generally wider than the first transverse sipe 452, the second transverse sipe 454, the third transverse sipe 456, the fourth transverse sipe 458 and the fifth transverse sipe 460. While the example sole structure 104 of FIG. 2 shows each transverse sipe having a curvilinear profile, in other examples one or more transverse sipes may be generally straight along all or a part of its length.

In the example sole structure 104 of FIG. 2, at least a portion of the profile of the first outsole edge 418 of the lateral sipe 410 corresponds to the profile of the lateral edge 107 of the sole structure. Stated differently, the transverse width between the first outsole edge 418 and the lateral edge 107 is generally consistent along a portion of the length of the sipe. Thus, a first width 237 measured at a first location along the length of the lateral sipe 410 between the second transverse sipe 454 and the third transverse sipe 456 is about the same as a second width 238 measured at a second location along the lateral sipe 410 between the second transverse sipe 454 and the third transverse sipe 456. In the example of FIG. 2, the profile of the first outsole edge 418 generally corresponds to the lateral edge 107 from the first end 412 to the sixth transverse sipe 462.

Similarly, the profile of the first outsole edge 438 of the medial sipe 430 generally corresponds to the medial edge 108 from the first end 432 to the sixth transverse sipe 462. In examples, the transverse width between the first outsole edge 418 of the lateral sipe 410 and the lateral edge 107 is about equal to the transverse width between the first outsole edge 438 of the medial sipe 430 and the medial edge.

In the example article shown in FIGS. 2 and 3, the carved sipes (both longitudinal sipes 400 and transverse sipes 450) extend through the entire thickness 116 of the outsole 110 and into the midsole 120. In alternative examples the carved sipes may extend through only a portion of the outsole thickness 116 and do not extend into the midsole 120. In other examples the carved sipes may also be formed (either completely or partially) in a region of a sole structure where there is no outsole. In other examples, the present disclosure contemplates forming sipes with a reciprocating blade in a sole structure with only one layer (e.g., only an outsole 110 or a midsole 104).

The carved sipes (both longitudinal sipes 400 and transverse sipes 450) may improve the traction of the ground-facing surface 122 of the outsole against wet surfaces. Furthermore, regions of the sole structure 104 that have one or more carved sipes may more readily react to forces applied to the sole structure by a wearer's foot. Turning back to FIGS. 4-6, the midsole 120 in regions with longitudinal sipes 400 and/or transverse sipes 450 may comprise a connecting portion 210 and a siped portion 220. The connecting portion 210 may have a lower surface 212 and an upper surface 214, which may comprise the top surface of the sole structure 104 that is positioned adjacent to upper 102.

It is to be understood that the lower surface 212 of the connecting portion 210 is being used for descriptive purposes and not necessarily to indicate that connecting portion 210 and siped portion 220 are separate pieces; as seen in FIGS. 5A-B, the siped portion 220 and the connecting portion 210 of the midsole 120 may be formed from a single, monolithic piece of material. In examples, the lower surface 212 may be a plane defined by the interior edges 170 of the longitudinal sipes 400 and the transverse sipes 450. In examples, the thickness of the connecting portion 210 and the siped portion 220 may be consistent or may vary along the length of sole structure 104. Furthermore, in some examples the siped portion 220 may comprise only a portion of the entire sole structure 104. For example, as seen in FIG. 2, there are no sipes, and therefore no siped portion, in the heel region 14 of sole structure 104.

The thickness of the connecting portion 210 may affect the flexibility of sole structure 104. In general, areas where the connecting portion 210 is larger or thicker in a vertical direction, the sole structure 104 may have decreased flexibility relative to other portions of the sole structure where the connecting portion is smaller or thinner in the vertical direction. In other examples, the flexibility in a particular region of the sole structure may also be influenced by whether a sipe extends fully through the sole structure (e.g., from the medial to the lateral edge), or if one or both ends of the sipe do not extend all of the way to the perimeter of the sole. Further still, instead of a single sipe, two shorter unconnected sipes may be aligned, so that the sole structure remains connected in several locations to provide increased stiffness in desired locations.

As seen in FIGS. 2 and 3, the longitudinal sipes 400 intersect with the transverse sipe 450 and the outer perimeter 106 of the sole structure 104 to define the siped portion 220 of the midsole 120 and the outsole 110 into a plurality of sole elements 230. The sole elements 230 are each connected to the connecting portion 210 of the midsole. As previously noted, the ground-facing surface 112 of the outsole 110 may not correspond fully to the outer perimeter of the sole structure, so each sole element may have an outsole portion that only partially corresponds to the ground-facing surface of the sole element 230. For example, in FIG. 2 central sole element 231 is defined by the second outsole edge 420 of the lateral sipe 410, the second outsole edge 440 of the medial sipe 430, the heelward edge of the first transverse sipe 452, and the first toeward edge of the second transverse sipe 454. The outsole element 117 of the central sole element 231 fully corresponds to the ground-facing surface of the central sole element 231. However, lateral sole element 232 and medial sole element 234 have corresponding outsole elements 118, 119 that are not only defined by the sipes but also by the profile of the outsole cutout 113. Thus each of the lateral sole element 232 and the medial sole element 234 also have a portion of the midsole ground-facing surface 122 being exposed.

Turning back to FIGS. 4 and 5A-B, in the siped portion 220 of the sole structure 104, the longitudinal sipes 400 may reduce the rigidity of the sole structure in the medial-lateral direction so that the curved ground-facing surface 112 of the sole structure 104 more readily flattens when a user steps onto the ground (e.g., the outsole elements 118 and 119 touching the ground) or in response to other forces around a longitudinally-oriented axis. Similarly, the transverse sipes 450 may reduce the rigidity of the sole structure 104 in the longitudinal (heel-toe) direction to make the sole structure 104 more reactive to forces oriented around a transversely-oriented axis.

As described earlier, the edge of each longitudinal sipe may be curved to correspond to the adjacent outer perimeter of the sole structure. Thus, the sole elements that are defined between the perimeter and the sipe have a consistent transverse width, so that the sole elements on the medial and lateral edges of the sole structure provide a more consistent feel and response to forces experienced during movement (e.g., running, jumping or sideways cutting actions).

The longitudinal curvilinear sipes, in combination with a cross-rocker sole structure, allow the sole structure to more easily conform to an individual user's specific foot anatomy and movement patterns. This allows for a better fit and feeling without individual customization of each shoe structure. In other words, the curvilinear longitudinal sipes facilitate the shoe being more adaptive to a user's foot and movement patterns, while providing a certain level of consistency in terms of traction, flexibility and support. The profile of the curved longitudinal sipes, either alone or in combination with the plurality of transverse sipes, may also enhance a consumer's visual perception of the reactive nature of the sole structure.

Turning to FIG. 6A, which shows a cross section of the medial sipe 430, the first sidewall 150 is angled with respect to the ground-facing surface 112 at a first sidewall angle 158. The first sidewall 150 comprises an exposed first face 151 that extends from the first outsole edge 438 to the interior edge 170, and an overcut portion 157 that extends into the foam of the midsole 120 past the interior edge 170 and ends at a first midsole edge 156 (depicted as a dot in FIG. 3; also referred to generally as an internal edge in some examples herein). Stated differently, the first outsole edge 438 is on a first side of a plane P-P defined by the second sidewall 160 and the first midsole edge is on a second side of the plane P-P. As discussed further below, the overcut portion 157 is created by an overcut to account for differences in how the materials of the sole structure 104 (e.g., the foam of the midsole 120) react to the motions of the reciprocating blade when the sole structure 104 has been previously cut. However, because it does not have a kerf width, the overcut does not create a permanent gap in the sole structure, which might otherwise cause the material of the sole structure 104 (e.g., the foam of the midsole 120) on either side of such a gap to collapse against itself in reaction to the forces experienced when the wearer stands, walks, runs or jumps.

The first face 151 of the first sidewall 150 includes an outsole portion 152 and a midsole portion 153. The outsole portion 152 and the midsole portion 153 are adjacent each other along the interface 125 of the outsole 110 and the midsole 120. As see in FIG. 3, the outsole portion 152 and the midsole portion 153 are coplanar with each other - that is, the first face 151 does not change orientation between the outsole portion 152 and the midsole portion 153. Similarly, the second sidewall 160 is angled with respect to the ground-facing surface 112 at a second sidewall angle 168 and comprises a second outsole portion 162 and a second midsole portion 163 that are co-planar with each other. In some examples, the first sidewall angle 158 and the second sidewall angle 168 are equal to each other at corresponding points along the medial sipe 430. In other examples, the first sidewall angle 158 and the second sidewall angle 168 may be different along either a portion or the entirety of the sipe. Each of the first sidewall angle 158 and the second sidewall angle 168 may change along the length of the medial sipe 430. The medial sipe 430 may have a depth 145 measured from the plane of the ground-facing surface 112 to the interior edge 170 and a width 147 measured from the first outsole edge 438 to the second outsole edge 440. furthermore, a first distance between the first face 151 and the second face 161 at the ground-facing surface 112 of the outsole 110 (corresponding to width 147) is greater than a second distance between the first face 151 and the second face 161 at the inner surface 114 of the outsole 110.

Turning to FIG. 6B, which provides a frontal view of the first sidewall 150, a first plurality of striations 154 may be seen extending across the first face 151, with at least some of the striations 154 traversing through the interface 125 between the outsole portion 152 and the midsole portion 153 without a change in orientation. As further discussed below, the striations 154 may be created by the reciprocating cutting action of a reciprocating blade forming the first sidewall 150, which also creates an irregular profile for the first midsole edge 156 at the top of the first sidewall 150. It is noted that in other examples, however, the cutting action of the blade may not leave visible striations on the face of one or more sidewalls or portions of a sidewall. The first face 151 may also have a line of perforations 159 that are formed when the reciprocating blade cuts into the sole structure 104 to form the second sidewall 160.

Similarly, FIG. 6C, which provides a frontal view of the second sidewall 160, shows a second face 161 with a second plurality of striations 164 that do not change orientation as they traverse the interface 125 between the second outsole portion 162 and the second midsole portion 163. Because the second sidewall 160 has been formed by a different cutting pass, the first plurality of striations 154 and the second plurality of striations 164 may not match each other. A slit 167 is formed along the second sidewall 160 at the interior edge 170, which corresponds to the overcut portion 157 of the first sidewall. Because the overcut portion 157 of the first sidewall 150 is formed by a reciprocating blade that does not remove kerf or melt the midsole material, the slit 167 does not create a gap in the material of the sole structure 104 when the sole structure 104 is in a relaxed, un-flexed state, other than occurs by a release of internal tension of the material as a result of the slit. A second midsole edge 166, formed by the tip of the reciprocating cutting blade, generally aligns with the slit 167 (which defines the interior edge 170 of the medial sipe 430) but includes uncut areas 169 where the second midsole edge 166 does not reach or extend past the slit 167. As a result, the foam of the second sidewall 160 may be torn in these uncut areas 169 when the carved-out portion of the sipe between the first sidewall 150 and the second sidewall is removed in order to fully remove the carved-out portion of the sole structure 104 from the medial sipe 430. The uncut areas 169 may thus comprise a plurality of non-uniform surfaces on the second face 161.

In examples, the depth 145 of a particular carved sipe may be consistent along its length while the width of the sipe may increase from at different locations. This may be accomplished by angling the first sidewall 150 and second sidewall 160 may be angled more steeply or less steeply. In other examples, the first and second sidewalls may be cut at different angles with respect to the ground-facing surface in order to vary the depth and width of the sipe at different locations along its length. For example, a carved sipe may be created by cutting a first sidewall into the sole structure at a fixed angle relative to the ground-facing surface, and then cutting a second sidewall at a second fixed angle. The resulting sipe will have a fixed correlation between its depth and its width at any given location along its length. Such a sipe may therefore have a first end or a second end with zero depth and width—that is, it starts or ends at a point on the ground-facing surface of the outsole, and thus at least a portion of such a sipe may be formed only in the outsole of the sole structure. In other examples, such as when a sipe at a first location and a second location has the same width, a steeper angle of the sidewalls at the second location will result in a deeper sipe, with the sidewalls correspondingly having a greater length in the vertical direction. Furthermore, it is to be appreciated that if the two sidewalls are angled at different angles to the ground-facing surface, the sidewall with the shallower angle will have a greater length from the ground-facing surface to the shared interior edge. The depth of each sipe may be similar to one or more other sipes in the sole structure 104 or they may differ from each other.

The sipes of the present disclosure may be formed by a reciprocating blade slicing through the sole structure 104. Turning to FIGS. 7A and 7B, an example of a blade 700 suitable for use in accordance with the present disclosure is shown. The blade 700 may have a straight plain cutting edge 702 ending in blade tip 704, and a spine 710 opposite the cutting edge 702. As used herein, a “plain cutting edge” means a cutting edge without distinct serrations or teeth. The cutting edge 702 may be double beveled or single beveled. The blade 700 may have a cutting edge length 712 and the cutting edge 702 may be angled at a cutting edge angle 716. In examples, the cutting edge length 712 may be between 20 and 100 mm and the cutting edge angle 716 may be between 70 and 85 degrees. The blade 700 may include a tip edge 706 that is straight with a blade tip length 715 and angled at a blade tip angle 718 from the blade tip 704. In examples, the blade tip angle 718 may be between 0 and 10 degrees. The blade 700 may have an overall length 714 measured from the blade tip 704 to a base 708. In examples, the overall length of the blade 7000 may be between 30 and 100 mm. The blade 700 may taper to from a base thickness 719 to a tip thickness 717 (i.e., the thickness of the blade at the start of the bevel edges of the tip edge 706). In examples the blade may have a base thickness 719 may be between 0.5 to 1.5 mm, and the tip thickness may be between 0.3 and 0.7 mm. While the blade 700 of FIGS. 7A-B has been described with specificity, it is contemplated that blades of other shapes and dimensions may also be suitable for use in accordance with the present disclosure.

In examples, the blade 700 is mounted to a reciprocating mechanism 701 (see, e.g., FIG. 7C),, such as a piston, which may reciprocate at a frequency of between 140 and 200 hertz, or between 155 and 185 hertz, or about 170 hertz. In examples, the reciprocating mechanism 701 (and therefore the blade 700) reciprocates across a linear distance (hereinafter the reciprocating length RL), which, in examples, may be between 2 mm and 10 mm, or between 3 mm and 7 mm. The reciprocating length RL should be equal to or less than the cutting edge length 712 of the blade 700. Generally, the depth that the reciprocating blade 700 can cut into a sole structure is not dictated by the reciprocating length RL but by the cutting edge length 712. In examples, the reciprocating mechanism 701 may be pneumatically powered or electrically powered. In examples, the reciprocating motion of the blade relative to the reciprocating mechanism is linear only, but in other examples a more complex blade path (e.g., elliptical or oscillating) may be utilized.

The blade 700, driven by the reciprocating mechanism 701, is able to slice through the materials comprising the sole structure 104 (e.g., the outsole 110 and the midsole 120) without removing, destroying or melting as would happen with conventional manufacturing methods (saw, heated blade or laser).

In examples, as shown in FIG. 7C, to create a cut in the sole structure 104, the blade 700 may first be aligned to the ground-facing surface 112 of the sole structure 104 prior to cutting at the desired angle for the cut. While FIG. 7C shows the blade oriented to form a generally perpendicular cut, angled cuts are contemplated to be within the scope of the present disclosure. Initially, the material of the outsole 110, being selected for its durability and resistance to cutting or tearing, may resist being cut by the blade tip 704 or tip edge 706. Since the sole structure 104 may typically also comprise material (e.g., the foam of the midsole 120) that is intended to absorb impact, the sole structure 104 may least partially flex away or conform from the blade 700 instead of being cut through until the blade is brought close enough to the sole structure 104 so that the force applied at the blade tip 704, tip edge 706 or cutting edge 702 is sufficient to overcome the resistance of the outsole 110 to allow the blade to cut through the intended outsole thickness 116 completely. Put another way, as illustrated in FIG. 7D, the reciprocating blade 700 may initially contact and partially, but not completely, cut through the outsole 110 into the midsole 120, with the sole structure 104 instead deforming or deflecting in reaction to the reciprocating motion of the blade 700 (e.g., the a section of the midsole may be compressed so that a first length 790 measured from a fixed point in the midsole 120 to the ground-facing surface 112 is shortened to a second length 792, moving outsole 110 from its relative position in FIG. 7C (shown as 110A) until the sole structure 104 and blade 700 are brought close enough together so that blade 700 is able to puncture completely through the outsole thickness 116, with at least part of the sole structure 104 (such as the foam of the midsole 120) possibly being in a compressed state at the moment that the blade fully punctures the outsole 110. Once the outsole 110 is punctured, the sole structure 104, including the compressed foam of the midsole 120, may spring back from its compressed state, which may deepen the depth of the cut being made by the blade 700. The blade 700 can then be guided through the sole structure 104 so that the cutting edge 702 creates a cut through the sole structure 104 with the with the desired length, depth and profile, with the sole structure 104 on either side of the cut forming sidewalls with faces that are parallel to each other. In examples, the blade 700 may be moved relative to the sole structure so that it cuts through the sole structure material at a rate of between 1 to 30 mm/second when the blade 700 is cutting at a depth about 1 mm to about 10 mm. When the sole structure 104 comprises multiple layers, (e.g., the outsole 110 and midsole 120 of article 100), the portions of the sidewall face formed from the different layers will be coplanar with each other, even when the blade is angled relative to the exterior surface where the blade is entering into the sole structure. Depending upon the characteristics of the blade 700 and the sole structure 104, additional flexing of the sole structure 104 in response to the reciprocating motion of the blade 700 may also occur during the cutting action.

While FIGS. 7C and 7D show the blade being introduced into the sole structure at a generally perpendicular angle, to form a carved sipe the blade may instead be introduced at an angle. Each of the carved sipes described herein may be formed by two or more separate cuts made by the reciprocating blade 700. The sole structure 104 may be first introduced at a first angle into the blade 700 corresponding to the desired first sidewall angle 158 of the first sidewall 150, and then maneuvered so that the profile of the first sidewall 150 is formed. The blade 700 may enter the ground-facing surface 112 at the first end of the sipe and exits at the second end of the sipe, or vice versa. The sole structure 104 is then reintroduced to the blade 700 at a second angle corresponding to the second sidewall angle 168 of the second sidewall 160. For the second cut, the blade 700 may enter the ground-facing surface 112 at the same end as the first cut entered or at the other end. In other examples, the blade may enter the ground-facing surface corresponding to different points along the first outsole edge or second outsole edge, in which case multiple cuts may need to be performed to fully form a sidewall of the carved sipe. Such a cutting process may be desirable for sipe where the ends of the sipe may have sidewalls with relatively shallow angles, which may increase the difficultly that the blade may have in initially puncturing through the material of the outsole 110, and thus making it preferable to start a cut by introducing the blade into the sole structure 104 at a steeper angle at a different point along the length of the sipe.

As described above, the reciprocating motion of the blade and the sole structure's reaction during the cutting process may create striations along the faces of the material being cut (e.g., the first plurality of striations 154 on the outsole portion 152 and midsole portion 153 of the first face 151). At least some of the striations will cross the interface 125 of the outsole and the midsole without a change in orientation. When the sipe comprises a single continuous incision, both sidewall faces (e.g., first face 151 and second face 161) may have matching striations formed from the reciprocating motion of the blade 700 while the sole structure is advanced. It is noted that in other examples, however, the cutting action of the blade may not leave visible striations on the face of one or more sidewalls or portions of a sidewall.

Furthermore, depending upon the frequency of reciprocation, the profile of the cutting edge and tip, and the speed at which the blade is progressed through the sole structure, the midsole edges formed by the blade cutting though the material of the sole structure 104 may have a non-linear profile. In examples, a midsole edge may have a profile at least partially corresponding to an oscillating path that the blade tip 704 and tip edge 706 take through the sole structure material. As shown in FIG. 8, the combination of the reciprocation of the blade 700 and the motion of the sole structure 104 relative to the blade 700 during the cutting process results in the blade tip 704 taking an oscillating path 750 through the material of the sole structure 104. However, as discussed previously, the material of the sole structure 104 may also intermittently resist being cut until the pressure at the cutting edge or tip is sufficient to overcome the resistance. This phenomenon of intermittent delayed cutting may result in the profile 752 of the first midsole edge 156, instead of being a smooth oscillating wave, to be more irregular. In some examples, the profile 752 may resemble a serrated pattern. In other examples, the profile 752 may be irregular without a repeating pattern. The high points 754 and the low points 756 of the profile 752 will have a distance 758 between them that is equal to or less than the vertical oscillation distance 768 between the high points 762 and the low points 764 of the oscillating path 750 in that area of the cut. It is to be appreciated that the vertical oscillation distance 768 may not be equal to the reciprocating length RL, as the blade may be translating vertically during the lateral motion.

As noted above, in examples of the present disclosure the carved sipe may be formed with one sidewall having an overcut portion to account for the midsole material's reaction to the reciprocating motion of the blade. In particular, the foam of the midsole may compress or be pulled by the reciprocating blade to a greater extent during a second cut, since the structure of the nearby foam has been compromised by the first cut. Thus, it is preferable to form at least one of the sidewalls with an overcut to ensure that at least one of the sidewalls fully extends to the desired interior edge. While it is possible to form a carved sipe by overcutting both sidewalls past the desired interior edge, this may result in a sole structure that is more susceptible to undesired splaying or other deformation. Instead, the reciprocating blade for the second cut may be guided so that the oscillating path only partially intersects the intended interior edge, which may result in the intermittent perforations or slits in the opposing sidewall as described above.

FIG. 9A depicts a schematic plan view of a footwear component manufacturing system 200 in a first configuration in accordance with aspects hereof. The system 900 includes one or more robots, such as first robot 906 and second robot 910, to move a component, such as a sole structure 104, into proximity with various other system components, such as a scanning station 902, a first cutting station 904 and a second cutting station 908.

Each cutting station 904, 908 includes a blade mounted on a reciprocating mechanism. The blades and their reciprocating mechanisms may be the same or they may be different. It is contemplated that for each cutting station, the non-reciprocating components of the reciprocating mechanism are fixed in place, so that the blade reciprocates but otherwise remains fixed in the same spatial position, with the robot maneuvering the sole structure into contact with the blade accordingly to perform the desired siping. In other examples, the system may be configured so that the sole structure is fixed in place while the blade is maneuvered accordingly to form the desired sipes.

Each robot 906, 910 may comprise an articulated arm and a grasper to securely grasp and maneuver a sole structure into and through different orientations and position. In examples, a robot having a robot arm with six degrees of freedom (e.g., a 6-axis robotic arm) may be used. The grasper is configured to grasp the sole structure securely and in a manner that avoids the grasper potentially interfering with other manufacturing steps (e.g., the cutting of the sipes by the reciprocating blade). In examples, a sole structure 104 may include one or more features (e.g., guide holes in its upper surface 214) that the grasper (or other component of the robot arm) may interface with to better secure or more consistently position the sole structure relative to the grasper.

The scanning station 902 includes a scanner that precisely determines the positioning and orientation of a sole structure being held in the grasper of a robot arm, relative to one or more reference points on or in proximity to the grasper or other component of the robot arm. In examples, the scanner includes a physical probe that contacts one or more surfaces of the sole structure to determine its positioning and orientation. In other examples, one or more lasers or cameras are used to determine the position and orientation of the sole structure.

Thus, in example configurations, such as the configuration depicted in FIG. 9A, the use of multiple robots (906, 910) may allow multiple sole structures to be processed simultaneously by one or more of the system components. For example, first robot 906 can move a sole structure to scanning station 902 so that the positioning of the sole structure 104 relative to one or more reference points of the first robot can be determined or confirmed. The first robot 906 can then bring the sole structure 104 to a first cutting station 904 so that the sipes may be formed into the sole structure 104 while a second robot 910 brings a second sole structure 104 to the scanning station 902 for calibration. In the example shown in FIG. 9A, the system may also include one or more conveyor belts or other conveyance mechanisms for supplying sole structures for the system 900 to sipe and carrying away completed ones. For example, a first conveyor belt 912 may bring sole structures 920 to be siped within reach of the first robot 906 and the second robot 910, and a second conveyor belt 914 may carry completed (siped) sole structures 922 away.

It is to be appreciated that other system configurations in accordance with the present disclosure are also contemplated. One such alternative configuration is shown in FIG. 9B, in which both cutting stations 904, 908 are within reach of both robots 906, 910. This configuration may be advantageous when a sole structure requires being cut by two different types of blades, with the first blade being used by the first cutting station 904 and the second blade being used by the second cutting station 908. It is further contemplated that one or more system components, instead of being fixed in a particular location, may move relative to the other components, e.g., by being mounted on a conveyance. For example, the robot arms, cutting mechanisms or the scanner may be mounted on a track or a wheeled cart.

It is to be appreciated that FIGS. 9A and 9B is intended to only depict the general positioning of the components of the system, and that one of skill in the art would be able to determine the appropriate distances between these components depending upon factors such as the length of each robot arm and the working distance or radius of the grasper relative to a base of the robot arm during operation. Further, the schematic illustrations of FIGS. 9A and 9B are also not limiting as to size, location, or scale, and it is also contemplated that one or more components may be omitted from the system and/or that one or more components may be introduced to the system.

It is contemplated that alternative configurations of sipes may be used in accordance with the present disclosure. For example, FIG. 10 illustrates a second embodiment of a sole structure 104 that includes a pair of longitudinal curvilinear sipes combined with a plurality of transverse sipes 130 that are formed by a single cut through the material of the sole structure that extends through the outsole thickness and into the midsole. These slit sipes, when formed with a reciprocating blade as described herein, will have opposing sidewalls that, instead of having a permanent gap between them, will remain adjacent to and in contact with each other when the sole is in a relaxed and un-flexed state. Thus, each of these sipes will have first and second sidewalls that extend from the ground-facing surface 112 of the outsole though the inner surface 114 of the outsole, and into the midsole 120, with a first distance between a first side of the first transverse sipe and a second side of the first transverse sipe at the ground-facing surface and a second distance between the first side and the second side at the foot-facing surface, wherein the first distance is equal to the second distance.

The slit sipes may be generally straight (such as shown in FIG. 10) or curvilinear. The spacing between the slit sipes in the longitudinal direction may be generally consistent, or may be varied. For example, having less distance between slit sipes in certain regions may result in thinner section elements and thus may provide more flexibility that is more closely tailored to the bending points of an individual wearer's foot. The slit sipes 130 may also facilitate the bending or twisting of the sole structure 104 during movement that may allow for greater conformance to the user's foot, and additionally, allow the sole structure 104 to impart the feeling or sensation of barefoot running or movement to a user. While the example shown in FIG. 10 has slit sipes 130 that extend through both the lateral side 16 and the medial side 18 of the sole structure 104, in other examples one or both ends of a slit sipe 130 may not extend to the perimeter 106 of the sole structure 104 and instead be contained within the perimeter 106.

The longitudinal sipes may also be formed by a reciprocating blade as described herein, but in the example of FIG. 10 the blade may be used to form sipe ends that are more rounded than the ends of the longitudinal sipes shown in FIG. 2. Furthermore, it is contemplated that some examples of the sipes and siping configurations as described herein may be formed using conventional siping methods.

Methods for forming sipes in accordance with the present disclosure are also described herein. In a first method, as depicted in the flow chart 1100 in FIG. 11, in a first step a first robot (such as first robot 906) grasps a sole structure (or a jig holding the sole structure)and brings it in proximity to a scanner (such as the scanner in scanning station 902), where the scanner precisely determines the positioning and orientation of the sole structure relative to one or more reference points on or in proximity to the robot arm, such as a particular point on the grasper. In a second step 1104, the first robot brings the sole structure in proximity to a first cutting station (such as first cutting station 904) where a reciprocating blade cuts the sole structure to form one or more sipes, which may include carved sipes (such as carved sipes 400) as described herein. The carved portions of the sipe may then be removed, either while the sole structure is being held by the grasper or in a post-production step. Steps 1102 and 1104 can then be repeated with subsequent sole structures. In a series of optional steps, a second robot arm also performs the first step 1001 of scanning a sole structure at the scanner station, but then it may bring the sole structure in proximity to the first cutting station or a second cutting station (such as second cutting station 908) where the one or more sipes can be cut into the sole structure. A single scanner may alternate scanning sole structures held by the first robot and the second robot.

While the examples of the carved sipes described above generally show a carved sipe with two opposing sidewalls angled towards each other (e.g., at an acute angle relative to the ground-facing surface), other geometries are contemplated to be within the present disclosure. Some examples of alternative geometries are shown in FIGS. 12A-C. In FIG. 12A, a carved sipe 400 has a first sidewall 1200 a right angle 1204 to the ground-facing surface 112, while a second sidewall 1202 is angled at an acute angle 1206 relative to the plane defined by the ground-facing surface 112. In FIG. 12B, a carved sipe 400 having a first sidewall 1210 is angled at an angle 1214 greater than 90 degrees to the plane defined by the ground-facing surface 112. The resulting carved sipe 400 has an interior edge 170 that is positioned laterally over the ground-facing surface 112. As previously noted, a sole structure having multiple sipes with this geometry at different orientations to each other might result in mold undercuts that would prevent such a sole structure from being manufactured efficiently using conventional methods.

FIG. 12C illustrates a sole structure having an outsole 110, a first midsole layer 1250 and a second midsole layer 1252 adjacent to the first midsole layer 1250 along a midsole interface 1254. In examples, the first midsole layer 1250 and the second midsole layer 1252 comprise different properties, such as a difference in foam material, density, or color. A carved sipe 400 having a first sidewall 1230 may be formed by a single cut of a reciprocating blade. Thus, each of the side wall portions (first midsole portion 1232, second midsole portion 1234 and outsole portion 1236) are co-planar with each other.

A second sidewall 1222 of the carved sipe 400 of FIG. 12C comprises multiple faces at different angles formed by multiple cuts of the reciprocating blade. A second face 1224 extending from a second midsole edge 1221 and a third face 1226 extending from the second outsole edge 1240 meet at an intersection of the planes defined by the second face 1224 and the third face 1226 to define a third midsole edge 1228. In other examples, carved sipes may be formed in a sole structure that is a single layer (e.g., only an outsole or a midsole) or more than the three layers shown in FIG. 12C.

While not shown in the figures, it is contemplated that a carved sipe with the profiles shown in FIGS. 12A-C may have at least sidewall with an overcut portion as previously described above. Furthermore, it is contemplated that the cuts used to form the first, second or third faces may be performed in several different orders of operation.

The following clauses represent example embodiments of concepts contemplated herein. Any one of the following clauses may be combined in a multiple dependent manner to depend from one or more other clauses. Further, any combination of dependent clauses (clauses that explicitly depend from a previous clause) may be combined while staying within the scope of aspects contemplated herein. The following clauses are examples and are not limiting.

Clause 1. An article of footwear, comprising: an upper; and a sole structure having a medial side, a lateral side, and a longitudinal direction extending between a toe end and a heel end, the sole structure attached to the upper and comprising: an outsole having a ground-facing surface and an opposite foot-facing surface, a midsole joined to the foot-facing surface of the outsole, a first curvilinear sipe extending through the ground-facing surface, the foot-facing surface, and into the midsole, the first curvilinear sipe extending in the longitudinal direction on a medial side of a longitudinal midline of the sole structure and having a first apex that is medial-side facing, and a second curvilinear sipe extending through the ground-facing surface, the foot-facing surface, and into the midsole, the second curvilinear sipe extending in the longitudinal direction on a lateral side of the longitudinal midline of the sole structure and having a second apex that is lateral-side facing.

Clause 2. The article of footwear according to clause 1, wherein the first curvilinear sipe comprises a first sidewall and a second sidewall that converge in the midsole.

Clause 3. The article of footwear according to clause 2, wherein the first sidewall extends through the outsole at the ground-facing surface at a first angle and the second sidewall extends through the outsole at the ground-facing surface at a second angle that is different from the first angle.

Clause 4. The article of footwear according to any of clauses 1 to 3, further comprising a plurality of transverse sipes intersecting the first curvilinear sipe and the second curvilinear sipe, wherein the plurality of transverse sipes extend through a perimeter of the sole structure.

Clause 5. The article of footwear according to clause 4, wherein a first transverse sipe of the plurality of transverse sipes has a first distance between a first side of the first transverse sipe and a second side of the first transverse sipe at the ground-facing surface and a second distance between the first side and the second side at the foot-facing surface, wherein the first distance is greater than the second distance.

Clause 6. The article of footwear according to clause 5, wherein each of the plurality of transverse sipes extend through the medial side and the lateral side of the sole structure.

Clause 7. The article of footwear according to clause 6, wherein each of the plurality of transverse sipes are curvilinear.

Clause 8. The article of footwear of according to clause 7, wherein each of the plurality of transverse sipes have a heelward facing apex between the first curvilinear sipe and the second curvilinear sipe.

Clause 9. The article of footwear according to clause 8, wherein at least one of the plurality of transverse sipes comprises a medial end that is more heelward than a first intersection of the at least one of the plurality of transverse sipes and the first curvilinear sipe.

Clause 10. The article of footwear according to any of clauses 8 to 9, wherein at least one of the plurality of transverse sipes comprises a lateral end that is more heelward than a first intersection of the at least one of the plurality of transverse sipes and the second curvilinear sipe.

Clause 11. The article of footwear according to any of clauses 1 to 10, wherein along a first portion of a lateral edge of the second curvilinear sipe is offset by a consistent first transverse distance from the lateral edge and along a second portion of a medial edge of the first curvilinear sipe is offset by a consistent second transverse distance from the medial edge.

Clause 12. The article of footwear according to clause 11, wherein the first transverse distance is equal to the second transverse distance.

Clause 13. The article of footwear according to any of clauses 2 to 12, wherein the first sidewall and the second sidewall converge in a transverse direction at a first end and a second end of the first curvilinear sipe.

Clause 14. An article of footwear, comprising: an upper; and a sole structure having a medial side, a lateral side, a forefoot region, a midfoot region and a heel region, the sole structure attached to the upper and comprising: an outsole having a ground-facing surface, an opposite foot-facing surface, a medial edge and a lateral edge; a midsole joined to the foot-facing surface of the outsole; a medial sipe extending through the ground-facing surface, the foot-facing surface, and into the midsole, the medial sipe having a medial sipe edge that is offset from and corresponding to the medial edge in at least a portion of the forefoot region; and a lateral sipe extending through the ground-facing surface, the foot-facing surface, and into the midsole, the lateral sipe having a lateral sipe edge that is offset from and corresponding to the lateral edge for at least a portion of the forefoot region.

Clause 15. The article of footwear according to clause 14, wherein the medial sipe has a first end in the forefoot region, an opposing second end in the midfoot region or the heel region, and a first apex between the first end and the second end, wherein the second end is closer to a longitudinal midline of the sole structure than the first apex.

Clause 16. The article of footwear according to clause 15, wherein the lateral sipe has a third end in the forefoot region, an opposing fourth end in the midfoot region or the heel region, and a second apex between the third end and the fourth end, wherein the third end is closer to the longitudinal midline of the sole structure than the second apex.

Clause 17. The article of footwear according to clause 16, wherein the second end of both medial and lateral sipes are closer to the longitudinal midline than an apex of each in the forefoot region.

Clause 18. The article of footwear according to any of clauses 14 to 17, wherein the medial and lateral sipes each comprise a first sidewall and a second sidewall that converge in the midsole.

Clause 19. The article of footwear of according to clause 18, wherein each sidewall comprises an outsole portion and a midsole portion that are coplanar with each other and at an angle with the ground-facing surface.

Clause 20. An article of footwear, comprising: an upper; and a sole structure having a perimeter defined by a medial side, a lateral side, a toe end and a heel end, the perimeter forming a forefoot region and a heel region, the sole structure attached to the upper, the sole structure having a ground-facing surface, the sole structure comprising: a medial sipe having a first apex of a first curve in a medial direction within at least a part of the forefoot region, the medial sipe extending through the ground-facing surface and into the sole structure, wherein the medial sipe is contained within the perimeter; a lateral sipe having a second apex of a second curve in a lateral direction within at least a portion of the forefoot region, the lateral sipe extending through the ground-facing surface and into the sole structure, wherein the lateral sipe is contained within the perimeter; and a plurality of transverse sipes intersecting the medial sipe and the lateral sipe, wherein the plurality of transverse sipes extend through the perimeter.

Clause 21. A method of manufacturing an article of footwear, comprising: providing a sole structure having a medial side, a lateral side, and a longitudinal direction extending between a toe end and a heel end, the sole structure comprising an outsole having a ground-facing surface and an opposite foot-facing surface, and a midsole joined to the foot-facing surface of the outsole; forming a first curvilinear sipe extending through the ground-facing surface, the foot-facing surface, and into the midsole, the first curvilinear sipe extending in the longitudinal direction on a medial side of a longitudinal midline of the sole structure and having a first apex that is medial-side facing; and forming a second curvilinear sipe extending through the ground-facing surface, the foot-facing surface, and into the midsole, the second curvilinear sipe extending in the longitudinal direction on a lateral side of the longitudinal midline of the sole structure and having a second apex that is lateral-side facing.

Clause 22. The method according to clause 21, wherein forming the first curvilinear sipe comprises cutting a first sidewall and a second sidewall that converge in the midsole.

Clause 23. The method according to clause 22, wherein cutting the first sidewall comprises extending the first sidewall through the outsole at the ground-facing surface at a first angle and cutting the second sidewall comprises extending the second sidewall through the outsole at the ground-facing surface at a second angle that is different from the first angle.

Clause 24. The method according to any of clauses 21 to 23, further comprising forming a plurality of transverse sipes intersecting the first curvilinear sipe and the second curvilinear sipe, wherein the plurality of transverse sipes extend through a perimeter of the sole structure.

Clause 25. The method according to clause 24, wherein forming a first transverse sipe of the plurality of transverse sipes comprises creating a first distance between a first side of the first transverse sipe and a second side of the first transverse sipe at the ground-facing surface and a second distance between the first side and the second side at the foot-facing surface, wherein the first distance is greater than the second distance.

Clause 26. The method according to clause 25, wherein forming each of the plurality of transverse sipes comprises extending each transverse sipe through the medial side and the lateral side of the sole structure.

Clause 27. The method according to clause 26, wherein forming each of the plurality of transverse sipes comprises creating curvilinear transverse sipes.

Clause 28. The method according to clause 27, wherein forming each of the plurality of transverse sipes comprises creating a heelward facing apex between the first curvilinear sipe and the second curvilinear sipe.

Clause 29. The method according to clause 28, wherein forming at least one of the plurality of transverse sipes comprises creating a medial end that is more heelward than a first intersection of the at least one of the plurality of transverse sipes and the first curvilinear sipe.

Clause 30. The method according to clause any of clauses 28 to 29, wherein forming at least one of the plurality of transverse sipes comprises creating a lateral end that is more heelward than a first intersection of the at least one of the plurality of transverse sipes and the second curvilinear sipe.

Clause 31. The method according to any of clauses 21 to 30, wherein forming the second curvilinear sipe comprises positioning a lateral edge of the second curvilinear sipe to be offset by a consistent first transverse distance from a lateral edge of the sole structure along a first portion, and forming the first curvilinear sipe comprises positioning a medial edge of the first curvilinear sipe to be offset by a consistent second transverse distance from a medial edge of the sole structure along a second portion.

Clause 32. The method according to clause 31, wherein the first transverse distance is equal to the second transverse distance.

Clause 33. The method according to any of clauses 22 to 32, wherein forming the first curvilinear sipe comprises converging the first sidewall and the second sidewall in a transverse direction at a first end and a second end of the first curvilinear sipe.

Clause 34. A method of manufacturing an article of footwear, comprising: providing a sole structure having a medial side, a lateral side, a forefoot region, a midfoot region and a heel region, the sole structure comprising an outsole having a ground-facing surface, an opposite foot-facing surface, a medial edge and a lateral edge, and a midsole joined to the foot-facing surface of the outsole; forming a medial sipe extending through the ground-facing surface, the foot-facing surface, and into the midsole, the medial sipe having a medial sipe edge that is offset from and corresponding to the medial edge in at least a portion of the forefoot region; and forming a lateral sipe extending through the ground-facing surface, the foot-facing surface, and into the midsole, the lateral sipe having a lateral sipe edge that is offset from and corresponding to the lateral edge for at least a portion of the forefoot region.

Clause 35. The method according to clause 34, wherein forming the medial sipe comprises creating a first end in the forefoot region, an opposing second end in the midfoot region or the heel region, and a first apex between the first end and the second end, wherein the second end is closer to a longitudinal midline of the sole structure than the first apex.

Clause 36. The method according to clause 35, wherein forming the lateral sipe comprises creating a third end in the forefoot region, an opposing fourth end in the midfoot region or the heel region, and a second apex between the third end and the fourth end, wherein the third end is closer to the longitudinal midline of the sole structure than the second apex.

Clause 37. The method according to clause 36, wherein forming the medial and lateral sipes comprises positioning the second end of both medial and lateral sipes closer to the longitudinal midline than an apex of each in the forefoot region.

Clause 38. The method according to any of clauses 34 to 37, wherein forming the medial and lateral sipes comprises cutting a first sidewall and a second sidewall for each sipe that converge in the midsole.

Clause 39. The method according to clause 38, wherein cutting each sidewall comprises forming an outsole portion and a midsole portion that are coplanar with each other and at an angle with the ground-facing surface.

Clause 40. A method of manufacturing an article of footwear, comprising: providing a sole structure having a perimeter defined by a medial side, a lateral side, a toe end and a heel end, the perimeter forming a forefoot region and a heel region, the sole structure having a ground-facing surface; forming a medial sipe having a first apex of a first curve in a medial direction within at least a part of the forefoot region, the medial sipe extending through the ground-facing surface and into the sole structure, wherein the medial sipe is contained within the perimeter; forming a lateral sipe having a second apex of a second curve in a lateral direction within at least a portion of the forefoot region, the lateral sipe extending through the ground-facing surface and into the sole structure, wherein the lateral sipe is contained within the perimeter; and forming a plurality of transverse sipes intersecting the medial sipe and the lateral sipe, wherein the plurality of transverse sipes extend through the perimeter.

Many different arrangements of the various components depicted, as well as components not shown, are possible without departing from the scope of the claims below. Embodiments in this disclosure are described with the intent to be illustrative rather than restrictive. Alternative embodiments will become apparent to readers of this disclosure after and because of reading it. Alternative means of implementing the aforementioned can be completed without departing from the scope of the claims below. Certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations and are contemplated within the scope of the claims.

In the preceding detailed description, reference is made to the accompanying drawings which form a part hereof wherein like numerals designate like parts throughout, and in which is shown, by way of illustration, embodiments that may be practiced. It is to be understood that other embodiments may be utilized and structural or logical changes may be made without departing from the scope of the present disclosure. Therefore, the preceding detailed description is not to be taken in the limiting sense, and the scope of embodiments is defined by the appended claims and their equivalents.

Claims

1. An article of footwear, comprising:

an upper; and

a sole structure having a medial side, a lateral side, and a longitudinal direction extending between a toe end and a heel end, the sole structure attached to the upper and comprising: an outsole having a ground-facing surface and an opposite foot-facing surface, a midsole joined to the foot-facing surface of the outsole, a first curvilinear sipe extending through the ground-facing surface, the foot-facing surface, and into the midsole, the first curvilinear sipe extending in the longitudinal direction on a medial side of a longitudinal midline of the sole structure and having a first apex that is medial-side facing, and a second curvilinear sipe extending through the ground-facing surface, the foot-facing surface, and into the midsole, the second curvilinear sipe extending in the longitudinal direction on a lateral side of the longitudinal midline of the sole structure and having a second apex that is lateral-side facing.

2. The article of footwear of claim 1, wherein the first curvilinear sipe comprises a first sidewall and a second sidewall that converge in the midsole.

3. The article of footwear of claim 2, wherein the first sidewall extends through the outsole at the ground-facing surface at a first angle and the second sidewall extends through the outsole at the ground-facing surface at a second angle that is different from the first angle.

4. The article of footwear of claim 1 further comprising a plurality of transverse sipes intersecting the first curvilinear sipe and the second curvilinear sipe, wherein the plurality of transverse sipes extend through a perimeter of the sole structure.

5. The article of footwear of claim 4, wherein a first transverse sipe of the plurality of transverse sipes has a first distance between a first side of the first transverse sipe and a second side of the first transverse sipe at the ground-facing surface and a second distance between the first side and the second side at the foot-facing surface, wherein the first distance is greater than the second distance.

6. The article of footwear of claim 5, wherein each of the plurality of transverse sipes extend through the medial side and the lateral side of the sole structure.

7. The article of footwear of claim 6, wherein each of the plurality of transverse sipes are curvilinear.

8. The article of footwear of claim 7, wherein each of the plurality of transverse sipes have a heelward facing apex between the first curvilinear sipe and the second curvilinear sipe.

9. The article of footwear of claim 8, wherein at least one of the plurality of transverse sipes comprises a medial end that is more heelward than a first intersection of the at least one of the plurality of transverse sipes and the first curvilinear sipe.

10. The article of footwear of claim 8, wherein at least one of the plurality of transverse sipes comprises a lateral end that is more heelward than a first intersection of the at least one of the plurality of transverse sipes and the second curvilinear sipe.

11. The article of footwear of claim 1, wherein along a first portion of a lateral edge of the second curvilinear sipe is offset by a consistent first transverse distance from the lateral edge and along a second portion of a medial edge of the first curvilinear sipe is offset by a consistent second transverse distance from the medial edge.

12. The article of footwear of claim 11, wherein the first transverse distance is equal to the second transverse distance.

13. The article of footwear of claim 2, wherein the first sidewall and the second sidewall converge in a transverse direction at a first end and a second end of the first curvilinear sipe.

14. An article of footwear, comprising:

an upper; and

a sole structure having a medial side, a lateral side, a forefoot region, a midfoot region and a heel region, the sole structure attached to the upper and comprising: an outsole having a ground-facing surface, an opposite foot-facing surface, a medial edge and a lateral edge; a midsole joined to the foot-facing surface of the outsole; a medial sipe extending through the ground-facing surface, the foot-facing surface, and into the midsole, the medial sipe having a medial sipe edge that is offset from and corresponding to the medial edge in at least a portion of the forefoot region; and a lateral sipe extending through the ground-facing surface, the foot-facing surface, and into the midsole, the lateral sipe having a lateral sipe edge that is offset from and corresponding to the lateral edge for at least a portion of the forefoot region.

15. The article of footwear of claim 14, wherein the medial sipe has a first end in the forefoot region, an opposing second end in the midfoot region or the heel region, and a first apex between the first end and the second end, wherein the second end is closer to a longitudinal midline of the sole structure than the first apex.

16. The article of footwear of claim 15, wherein the lateral sipe has a third end in the forefoot region, an opposing fourth end in the midfoot region or the heel region, and a second apex between the third end and the fourth end, wherein the third end is closer to the longitudinal midline of the sole structure than the second apex.

17. The article of footwear of claim 16, wherein the second end of both medial and lateral sipes are closer to the longitudinal midline than an apex of each in the forefoot region.

18. The article of footwear of claim 14, wherein the medial and lateral sipes each comprise a first sidewall and a second sidewall that converge in the midsole.

19. The article of footwear of claim 18, wherein each sidewall comprises an outsole portion and a midsole portion that are coplanar with each other and at an angle with the ground-facing surface.

20. An article of footwear, comprising:

an upper; and

a sole structure having a perimeter defined by a medial side, a lateral side, a toe end and a heel end, the perimeter forming a forefoot region and a heel region, the sole structure attached to the upper, the sole structure having a ground-facing surface, the sole structure comprising: a medial sipe having a first apex of a first curve in a medial direction within at least a part of the forefoot region, the medial sipe extending through the ground-facing surface and into the sole structure, wherein the medial sipe is contained within the perimeter; a lateral sipe having a second apex of a second curve in a lateral direction within at least a portion of the forefoot region, the lateral sipe extending through the ground-facing surface and into the sole structure, wherein the lateral sipe is contained within the perimeter; and a plurality of transverse sipes intersecting the medial sipe and the lateral sipe, wherein the plurality of transverse sipes extend through the perimeter.