发明内容：
[0004]The present invention generally relates to systems and methods involving three-dimensionally printed articles for use in footwear. The present subject matter of the present invention involves, in some cases, interrelated products, alternative solutions to a particular problem, and/or a plurality of different uses of one or more systems and/or articles.
[0005]In one set of embodiments, three-dimensionally printed (3D-printed) articles for use in footwear are provided. The 3D-printed article may have a gradient in a property between a first portion and a second portion. In some embodiments, the property may be selected from the group consisting of stiffness, Shore A hardness, microindentation hardness, nanoindentation hardness, pore size, density, color, surface roughness, reflectivity, strength, elongation at break, tensile elastic modulus, modulus at 100% strain, opacity, and dimensional change upon heat activation. In some embodiments, the 3D-printed article may be a single integrated material.
[0006]In some embodiments, the 3D-printed articles for use in footwear may be selected to have a particular material composition, such that they can be recycled together with other parts of a shoe. In some embodiments, a textile for a footwear upper, and a 3D-printed article at least partially disposed on top of the textile, may comprise substantially the same raw material (e.g. thermoplastic polyurethane (TPU)). In some embodiments, the 3D-printed article, the upper textile, and at least a portion of the bottom of the shoe (e.g., midsole, insole, outsole) may comprise the same raw material. In some cases, these materials may all be thermoplastics.
[0007]In another set of embodiments, a 3D-printed article for use in footwear may be printed as a separate article and then subsequently be inserted, glued, or assembled into and/or onto another part of the article of footwear. In some embodiments, the 3D-printed article may have at least a portion that is an open-celled or closed-celled lattice structure. In some embodiments, the article may comprise substantially the same material as in other parts of the shoe (e.g., TPU).
[0008]In some embodiments, a method may comprise 3D-printing an article having a gradient in a property between a first portion and a second portion. The property may be a mechanical property. The article may be a single integrated material.
[0009]In some embodiments, a method may comprise 3D-printing an article having a gradient in a property between a first portion and a second portion. The property may be an optical property. The article may be a single integrated material.
[0010]In some embodiments, a method may comprise 3D-printing an article having a gradient in a property between a first portion and a second portion. The property may be a structural property. The article may be a single integrated material.
[0011]In some embodiments, a 3D-printed article for use in footwear may comprise a plurality of sensors. In some embodiments, the sensors may be pressure sensors.
[0012]In another set of embodiments, methods are provided. A method may comprise 3D-printing an article having a gradient in a property between a first portion and a second portion. In some embodiments, the property may be selected from the group consisting of stiffness, Shore A hardness, microindentation hardness, nanoindentation hardness, pore size, and density. In some embodiments, the article may be a single integrated material.
[0013]In some embodiments, a method for designing a personalized 3D-printed article for use in footwear may comprise acquiring information from a plurality of pressure sensors distributed within a first 3D-printed article. The method may also comprise printing a second 3D-printed article having a gradient in a property based on the information. In some embodiments, the property may be selected from the group consisting of stiffness, Shore A hardness, microindentation hardness, nanoindentation hardness, pore size, and density.
[0014]In one aspect, articles are provided. In some embodiments, an article may be an article of footwear. In some embodiments, the article of footwear comprises an upper. The upper may comprise a textile or polymer film. The upper may comprise a three-dimensionally printed feature, e.g., comprising a thermoplastic material. In some embodiments, the three-dimensionally printed feature is directly attached to the textile or polymer film. In some embodiments, the majority of the weight of the upper comprises substantially the same thermoplastic material as that of the three-dimensionally printed feature. In some embodiments, the three-dimensionally printed feature comprises a first portion and a second portion, wherein there is at least a 10% difference in microindentation hardness between the first portion and the second portion.
[0015]In some embodiments, the three-dimensionally printed feature has a gradient in one or more material properties. In some embodiments, each of the one or more material properties is selected from the group consisting of: stiffness, tensile elastic modulus, Shore A hardness, Shore D hardness, microindentation hardness, nanoindentation hardness, flexural modulus, and color. In some embodiments, the three-dimensionally printed feature has a gradient in one or more additional material properties. In some embodiments, each of the one or more additional material properties is selected from the group consisting of: stiffness, tensile elastic modulus, Shore A hardness, Shore D hardness, nanoindentation hardness, flexural modulus, and color. In some embodiments, at least one of the one or more material properties differs by at least 10% between a first portion and a second portion of the three-dimensionally printed feature. In some embodiments, the three-dimensionally printed feature has at least one section that is a single integrated material. In some embodiments, the three-dimensionally printed feature has a section that is a single integrated material, and the section has the first portion and the second portion. In some embodiments, the three-dimensionally printed feature comprises a first portion and a second portion. In some embodiments, there is at least a 10% difference in tensile elastic modulus between the first portion and the second portion. In some embodiments, there is at least a 10% difference in Shore A hardness between the first portion and the second portion.
[0016]In some embodiments, the majority of the weight of the entire footwear article comprises substantially the same thermoplastic material as that of the three-dimensionally printed feature. In some embodiments, the majority of the weight of the entire footwear article consists of substantially the same thermoplastic material as that of the three-dimensionally printed feature. In some embodiments, the three-dimensionally printed feature comprises at least a section that is a single integrated material and has a gradient in tensile elastic modulus between the first portion and the second portion. In some embodiments, the three-dimensionally printed feature is attached to the textile or film without the use of an adhesive.
[0017]In some embodiments, at least a portion of the upper has a pigment containing inkjet ink disposed on at least one surface of the upper. In some embodiments, the pigment containing inkjet ink is disposed on an internal surface of a first textile, wherein the internal surface is at least partially visible through at least the first textile that is at least partially transparent. In some embodiments, the pigment containing inkjet ink is disposed on an internal surface of a first textile, wherein the internal surface is at least partially visible through a second textile that is at least partially optically transparent. In some embodiments, the pigment containing inkjet ink is disposed on an internal surface of a first textile, wherein the internal surface is at least partially visible through at least the first textile that is at least partially transparent. In some embodiments, the pigment containing inkjet ink may also be partially visible through a second textile that is also at least partially optically transparent. In some embodiments, the three-dimensionally printed feature is at least partially transparent, and the three-dimensionally printed feature has a pigment containing inkjet ink disposed on the feature.
[0018]In some embodiments, the thermoplastic material which the majority of the weight of the upper comprises is a thermoplastic polyurethane.
[0019]In some embodiments, at least a portion of the three-dimensionally printed feature is an open-celled lattice. In some embodiments, at least a portion of the three-dimensionally printed feature is a closed-celled lattice. In some embodiments, the three-dimensionally printed feature comprises a gradient in tensile elastic modulus. In some embodiments, the first portion has a Shore A hardness below 75 A, and the second portion has a Shore A hardness greater than 85 A; and wherein the three-dimensionally printed feature is a single integrated material.
[0020]In some embodiments, the three-dimensionally printed feature comprises a thermoplastic polyurethane.
[0021]In some embodiments, the majority of the weight of the upper consists of substantially the same thermoplastic material as that of the three-dimensionally printed feature.
[0022]In some embodiments, an article may be an article of apparel. In some embodiments, the article of apparel comprises a textile or polymer film. In some embodiments, the article of apparel comprises a three-dimensionally printed feature comprising a thermoplastic material. In some embodiments, the three-dimensionally printed feature is directly attached to the textile or polymer film. In some embodiments, the majority of the weight of the article of apparel comprises substantially the same thermoplastic material as that of the three-dimensionally printed feature. In some embodiments, the three-dimensionally printed feature comprises a first portion and a second portion, wherein there is at least a 10% difference in microindentation hardness between the first portion and the second portion.
[0023]In some embodiments, the three-dimensionally printed feature has a gradient in one or more material properties. In some embodiments, each of the one or more material properties is selected from the group consisting of: stiffness, tensile elastic modulus, Shore A hardness, Shore D hardness, microindentation hardness, nanoindentation hardness, flexural modulus, and color. In some embodiments, at least one of the one or more material properties differs by at least 10% between a first portion and a second portion of the three-dimensionally printed feature. In some embodiments, the three-dimensionally printed feature has at least one section that is a single integrated material. In some embodiments, the three-dimensionally printed feature has a section that is a single integrated material, and the section has the first portion and the second portion. In some embodiments, the three-dimensionally printed feature comprises a first portion and a second portion. In some embodiments, there is at least a 10% difference in tensile elastic modulus between the first portion and the second portion. In some embodiments, there is at least a 10% difference in Shore A hardness between the first portion and the second portion.
[0024]In some embodiments, the textile or polymer film is not three-dimensionally printed. In some embodiments, the thermoplastic material which the majority of the weight of the article of apparel comprises is a thermoplastic polyurethane.
[0025]In some embodiments, the majority of the weight of the article of apparel consists of substantially the same thermoplastic material as that of the three-dimensionally printed feature.
[0026]In some embodiments, an article of footwear comprises a three-dimensionally printed feature comprising an open-celled lattice. In some embodiments, an article of footwear comprises a three-dimensionally printed feature comprising a closed-celled lattice. In some embodiments, the article of footwear comprises a closed cell foam. In some embodiments, the three-dimensionally printed feature is at least partially embedded inside of the closed cell foam. In some embodiments, at least a portion of the open-celled lattice has an Asker C hardness less than Asker C 55. In some embodiments, at least a portion of the open-celled lattice has an Asker C hardness less than Asker C 50.
[0027]In some embodiments, the closed cell foam is not three-dimensionally printed.
[0028]In some embodiments, the three-dimensionally printed feature comprises a first portion and a second portion, wherein there is at least a 10% difference in compression force deflection between the first portion and the second portion.
[0029]In some embodiments, the three-dimensionally printed feature is an insert into the closed cell foam and the closed cell foam is a portion of the article of footwear selected from the group consisting of: midsole, outsole, insole, sockliner, and footbed.
[0030]In some embodiments, the three-dimensionally printed feature comprises a thermoplastic material, and the thermoplastic material has substantially the same composition as the material which the majority of the weight of the remainder of the shoe comprises. In some embodiments, the three-dimensionally printed feature comprises a thermoplastic material, and the thermoplastic material has substantially the same composition as the material of which the majority of the weight of the remainder of the shoe consists. In some embodiments, the three-dimensionally printed feature comprises a thermoplastic polyurethane, a polyurea, or a combination of the two, and wherein the three-dimensionally printed feature composition comprises at least 15% by weight of raw materials that are derived from organisms of the plant kingdom.
[0031]Other advantages and novel features of the present invention will become apparent from the following detailed description of various non-limiting embodiments of the invention when considered in conjunction with the accompanying figures.
具体实施方式：
[0059]Inventive three-dimensionally printed (3D-printed) articles for use in footwear or other applications, and associated methods, are generally described herein. In some embodiments, the 3D-printed article may comprise one or more features that are challenging or impossible to obtain in articles manufactured by other techniques. As an example, the 3D-printed article may be a single integrated material which comprises a gradient in one or more properties (e.g., pore size, density, stiffness, stiffness of solid components of the article, Shore A hardness, microindentation hardness, nanoindentation hardness, degree of cross-linking, chemical composition, color, abrasion resistance, thermal conductivity, electrical conductivity, stiffness anisotropy, elastic modulus, flexural modulus, filler content, opacity, conductivity, breathability) between two or more portions of the material. This may be achieved using a 3D printing process by printing the 3D-printed article using an ink that can be dynamically changed as the article is printed (by, e.g., changing the ratios of different components that make up the ink or polymer that is deposited, changing the temperature of the ink, and the like). In some embodiments, the 3D-printed article may have one or more features that are preferred by users of the 3D-printed article or footwear of which the 3D-printed article is one component. For example, the 3D-printed article may be a single integrated material and/or may lack seams, adhesives, and other features that are typically used to join two or more materials together. In some embodiments, the 3D-printed article may have an open-celled lattice architecture that may have a different feel or performance attributes, and the article would be unreasonably difficult or impossible to fabricate through molding processes. In some embodiments, the 3D-printed article may have a closed-celled lattice architecture that may have a different feel or performance attributes, and the article would be unreasonably difficult or impossible to fabricate through molding processes. These and other 3D-printed articles may be more comfortable for users, and/or may be less subject to degradation or damage during normal usage of the article.
[0060]It should be understood that references herein to 3D-printed articles may encompass articles that include more than one layer (e.g., articles that comprise multiple layers printed on top of each other) and/or may encompass articles that include a single layer (e.g., articles in which a single layer of material has been printed). 3D-printed articles may encompass articles printed from 3D-printers and/or articles that extend macroscopically in three dimensions (e.g., with a minimal extent in each dimension of 50 microns, 100 microns, 200 microns, 500 microns, or 1 mm). Similarly, 3D-printing may encompass printing articles that include more than one layer and/or printing articles that include a single layer. 3D-printing may encompass printing articles on 3D-printers, printing articles extend macroscopically in three dimensions (e.g., with a minimal extent in each dimension of 50 microns, 100 microns, 200 microns, 500 microns, or 1 mm).
[0061]It should also be understood that articles other than 3D-printed articles and printing methods other than 3D-printing are also contemplated. For example, some embodiments relate to articles that have one or more of the features of the 3D-printed articles described herein (e.g., a gradient in one or more properties) but are not 3D-printed articles. Some articles may include both one or more 3D-printed components and one or more non-3D-printed components. Similarly, some embodiments relate to methods that have one or more features of the methods described herein (e.g., may comprise employing a multi-axis deposition system) but which do not include a 3D-printing step. Some methods may include both one or more 3D-printing steps and one or more non-3D-printing steps.
[0062]Certain methods (e.g., methods including exclusively 3D-printing steps, methods including exclusively non-3D printing steps, methods including both 3D-printing steps and non-3D-printing steps) comprise depositing one or more film(s) onto a 3D-surface. Some or all of the films, if more than one are deposited, may be thin film(s).
[0063]Certain methods (e.g., methods including exclusively 3D-printing steps, methods including exclusively non-3D printing steps, methods including both 3D-printing steps and non-3D-printing steps) comprise depositing a material that does not form a film on a substrate. For instance, a material may be deposited onto a substrate into which it infiltrates. As an example, a material may be deposited onto a porous substrate (e.g., a porous textile) and then infiltrate into at least a portion of the pores of the porous substrate. After it has been deposited onto the porous substrate, it may fill a portion of the pores of the porous substrate. The material may enhance the mechanical properties of the substrate. In some embodiments, a material deposited onto a substrate into which it infiltrates, such as a porous substrate, does not extend an appreciable distance (or at all) beyond the surface of the porous substrate.
[0064]In one set of embodiments, one or more methods for manufacturing 3D-printed articles as described herein may be advantageous in comparison to other methods for making articles for use in footwear. For example, a footwear manufacturer employing a method as described herein may be able to use fewer processes to create the article than would be employed in other comparable processes (e.g., the manufacturer may use a three-dimensional printer (3D printer) in a single process to make a component that would otherwise be made by a combination of several processes such as injection molding, lamination, and the like). This may allow for more rapid and/or more facile manufacturing. As another example, one or more of the methods described herein may not necessarily require the use equipment that is expensive to manufacture and whose cost is typically recovered only after repeated use (e.g., molds). Some of the methods described herein may instead employ a 3D printer to create articles whose design can be modified as desired with little or no added cost. In some embodiments, it may be economical for methods as described herein to create small batches of 3D-printed articles (e.g., batches of less than 100, less than 50, or less than 10). It is thus possible for manufacturers may employ some of the methods described herein to respond to changing market conditions, to create articles for use in footwear that are designed for individual users or groups of users, etc. In some embodiments, it may be advantageous to use one or more of the methods described herein to fabricate a 3D-printed article at the point of sale and/or to avoid long distance shipping. In some embodiments, it may be advantageous to use one or more of the methods described herein to fabricate a 3D-printed article with enhanced performance that could not, or at least could not reasonably, be fabricated through molding methods.
[0065]A non-limiting example of a 3D-printed article for use in footwear is shown in FIG. 1A. In this figure, 3D-printed article 100 comprises first portion 110 and second portion 120. As used herein, a portion of an article may refer to any collection of points within the article (i.e., points that are within the portion of space bounded by the external surfaces of the article). Portions of the article are typically, but not always, volumes of space within the article (in some embodiments, a portion may be a surface within an article, a line within an article, or a point within an article). Portions of the article may be continuous (i.e., each point within the portion may be connected by a pathway that does not pass through any points external to the portion) or may be discontinuous (i.e., the portion may comprise at least one point that cannot be connected to at least one other point within the article by a pathway that does not pass through any points external to the portion). Portions of an article may be substantially homogeneous with respect to one or more properties (e.g., one or more properties of the portion may vary with a standard deviation of less than or equal to 1%, 2%, 5%, or 10% throughout the portion), and/or may be heterogeneous with respect to one or more properties (e.g., one or more properties of the portion may vary with a standard deviation of greater than or equal to 1%, 2%, 5%, or 10% throughout the portion).
[0066]Portions of an article may have any suitable size. In some embodiments, a portion may have a largest dimension and/or may comprise one or more features with a size of greater than or equal to 100 microns, greater than or equal to 200 microns, greater than or equal to 500 microns, greater than or equal to 1 mm, greater than or equal to 2 mm, greater than or equal to 5 mm, greater than or equal to 10 mm, greater than or equal to 20 mm, greater than or equal to 50 mm, greater than or equal to 1 cm, or greater than or equal to 2 cm. In some embodiments, a portion may have a largest dimension and/or may comprise one or more features with a size of less than or equal to 5 cm, less than or equal to 2 cm, less than or equal to 1 cm, less than or equal to 5 mm, less than or equal to 2 mm, less than or equal to 1 mm, less than or equal to 500 microns, or less than or equal to 200 microns. Combinations of the above-referenced ranges are also possible (e.g., greater than or equal to 100 microns and less than or equal to 5 cm). Other ranges are also possible.
[0067]In some embodiments, a 3D-printed article may comprise two or more portions, where one or more properties (e.g., average pore size, density, stiffness, stiffness of solid components of the article, Shore A hardness, microindentation hardness, nanoindentation hardness, degree of cross-linking, chemical composition, color, abrasion resistance, thermal conductivity, electrical conductivity, stiffness anisotropy, elastic modulus, flexural modulus, filler content, opacity, conductivity, breathability) of a first portion may differ from one or more properties of a second portion. The one or more properties may be structural properties (e.g., average pore size, density, surface roughness, filler content), chemical properties (e.g., average degree of cross-linking, chemical composition), mechanical properties (e.g., average stiffness, stiffness of solid components, Shore A hardness, microindentation hardness, nanoindentation hardness, abrasion resistance, stiffness anisotropy, elastic modulus, flexural modulus, strength, elongation at break, tensile elastic modulus, modulus at 100% strain), optical properties (e.g., color, opacity, reflectivity), and/or other properties (e.g., average thermal conductivity, electrical conductivity, conductivity, breathability, dimensional change upon heat activation). In some embodiments, the difference in properties between the first portion and the second portion may comprise a gradient of the one or more properties (e.g., the property or properties may vary relatively smoothly from a first value in the first portion to a second value in the second portion). In other embodiments, there may be a sharp change in one or more of the properties at a boundary of one or more of the first portion and the second portion.
[0068]It should be understood that while FIG. 1A shows the second portion positioned above the first portion, other arrangements of the first portion with respect to the second portion are also contemplated. For example, the first portion may be positioned beside the second portion, the first portion may surround the second portion, the first portion and the second portion may interpenetrate (e.g., a first portion may comprise a foam that interpenetrates with a second portion that comprises an elastomer), etc. It should also be noted that while FIG. 1A shows the second portion directly adjacent the first portion, this configuration should not be understood to be limiting. In some embodiments, the first portion may be separated from the second portion by one or more intervening portions positioned between the first portion and the second portion. As used herein, a portion that is positioned “between” two portions may be directly between the two portions such that no intervening portion is present, or an intervening portion may be present.
[0069]Similarly, while FIG. 1A only depicts two portions, it should also be understood that an article may comprise three portions, four portions, or more portions. In some embodiments, portions within a 3D-printed article as described herein may also further comprise sub-portions. Each portion and/or sub-portion may differ from each other (sub-)portion in at least one way (e.g., any two (sub-)portions may comprise at least one property that is different), or one or more (sub-)portions may be substantially similar to other (sub-)portion(s) of the 3D-printed article.
[0070]In some embodiments, two or more portions may be disposed relative to each other such that they may be connected by a pathway along which the 3D-printed article lacks an interface along which one or more properties (e.g., average pore size, density, stiffness, stiffness of solid components of the article, Shore A hardness, microindentation hardness, nanoindentation hardness, degree of cross-linking, chemical composition, color, abrasion resistance, thermal conductivity, electrical conductivity, stiffness anisotropy, elastic modulus, flexural modulus, filler content, opacity, conductivity, breathability) undergo step changes. In other words, the property or properties may vary smoothly along the pathway. The pathway may be a straight path pathway (e.g., it may be a line segment), or it may include one or more curves or corners (e.g., it may be a meander, as described more fully below). In some embodiments, the pathway may be a pathway along which material was deposited during formation of the 3D-printed article, such as a pathway travelled by a print head (or by a substrate with respect to the print head) during 3D-printing.
[0071]When two or more portions are connected by a pathway, the pathway may have any suitable length. In some embodiments, the pathway has a length of greater than or equal to 0.5 mm, greater than or equal to 1 mm, greater than or equal to 2 mm, greater than or equal to 5 mm, greater than or equal to 10 mm, greater than or equal to 20 mm, greater than or equal to 50 mm, greater than or equal to 100 mm, greater than or equal to 200 mm, greater than or equal to 500 mm, greater than or equal to 1 m, greater than or equal to 2 m, or greater than or equal to 5 m. In some embodiments, the pathway has a length of less than or equal to 10 m, less than or equal to 5 m, less than or equal to 2 m, less than or equal to 1 m, less than or equal to 500 mm, less than or equal to 200 mm, less than or equal to 100 mm, less than or equal to 50 mm, less than or equal to 20 mm, less than or equal to 10 mm, less than or equal to 5 mm, less than or equal to 2 mm, or less than or equal to 1 mm. Combinations of the above-referenced ranges are also possible (e.g., greater than or equal to 0.5 mm and less than or equal to 10 m, or greater than or equal to 0.5 mm and less than or equal to 50 mm). In some embodiments, the length of the pathway may have a certain relationship to the 3D-printed article (e.g., if the 3D-printed article is an article of footwear, the length of the pathway may be the length of the article of footwear). Other ranges are also possible.
[0072]When a first portion and a second portion are connected by a pathway, a property (e.g., average pore size, density, stiffness, stiffness of solid components of the article, Shore A hardness, microindentation hardness, nanoindentation hardness, degree of cross-linking, chemical composition, color, abrasion resistance, thermal conductivity, electrical conductivity, stiffness anisotropy, elastic modulus, flexural modulus, filler content, opacity, conductivity, breathability) may change along the pathway at a rate that is advantageous. The average rate of change of the property may be greater than or equal to 0.05% of the average of the property in the first portion per mm, greater than or equal to 0.1% of the average of the property in the first portion per mm, greater than or equal to 0.2% of the average of the property in the first portion per mm, greater than or equal to 0.5% of the average of the property in the first portion per mm, greater than or equal to 1% of the average of the property in the first portion per mm, greater than or equal to 2% of the average of the property in the first portion per mm, greater than or equal to 20% of the average of the property in the first portion per mm, or greater than or equal to 100% of the average of the property in the first portion per mm. The average rate of change of the property may be less than or equal to 100% of the average of the property in the first portion per mm, less than or equal to 20% of the average of the property in the first portion per mm, less than or equal to 5% of the average of the property in the first portion per mm, less than or equal to 2% of the average of the property in the first portion per mm, less than or equal to 1% of the average of the property in the first portion per mm, less than or equal to 0.5% of the average of the property in the first portion per mm, less than or equal to 0.2% of the average of the property in the first portion per mm, or less than or equal to 0.1% of the average of the property in the first portion per mm. Combinations of the above-referenced ranges are also possible (e.g., greater than or equal to 0.05% and less than or equal to 5%, greater than or equal to 0.05% and less than or equal to 100%). Other ranges are also possible. It should be understood that the average rates of changed described above may apply to pathways that straight (e.g., pathways that are line segments), or to pathways that are curved.
[0073]In some embodiments, a first portion and a second portion as described herein may be components of a 3D-printed article that is a single integrated material. As used herein, two or more portions that together form a single integrated material are not separated by a separable interface. In some embodiments, a single integrated material may not separate into discrete parts during the course of normal use, and/or may be separated into discrete parts whose morphologies would not be predictable prior to normal use and/or along interfaces that would not be predictable prior to normal use. For instance, a single integrated material may lack seams and/or lack an adhesive that bonds two or more portions together. In some cases, the 3D-printed article as a whole may lack an interface at which one or more properties (e.g., average pore size, density, stiffness, stiffness of solid components of the article, Shore A hardness, microindentation hardness, nanoindentation hardness, degree of cross-linking, chemical composition, color, abrasion resistance, thermal conductivity, electrical conductivity, stiffness anisotropy, elastic modulus, flexural modulus, filler content, opacity, conductivity, breathability) undergo step changes as described above. In some cases, the property or properties may vary smoothly throughout the 3D-printed article.
[0074]In some embodiments, one or more portions may together form an 3D-printed article with one or more of the following features: macrovoids embedded within the article (e.g., a midsole) without an intersecting interface from overmolding, lamination, or ultrasonic welding; one or more open-celled lattices; one or more closed-celled lattices; variations in density across geometries that would be challenging to form by molding; interpenetrating foams and elastomers that may, in some embodiments, not be separated by an interface due to molding or lamination; and/or one or more interfaces between different materials with extreme undercuts (e.g., materials with a negative draft angle, materials which cannot be injection molded using a single mold because they would be unable to slide out of the mold).
[0075]In some embodiments, an article of footwear comprises a three-dimensionally printed feature (e.g., each of the open-celled lattice structures 3002 and 3004 of FIG. 30) comprising an open-celled lattice. In some embodiments, an article of footwear comprises a three-dimensionally printed feature comprising a closed-celled lattice. In some embodiments, the article of footwear comprises a closed cell foam (e.g., some embodiments of midsole 3006 of FIG. 30). In some embodiments, the three-dimensionally printed feature is at least partially embedded inside of the closed cell foam (e.g., the lower portions of open-celled lattice structures 3002 and 3004 are embedded in midsole 3006 of FIG. 30). In some embodiments, at least a portion of the open-celled lattice has an Asker C hardness less than Asker C 55. In some embodiments, at least a portion of the open-celled lattice has an Asker C hardness less than Asker C 50.
[0076]In some embodiments, at least a portion of the open-celled lattice has a lower hardness than other open-celled lattices in articles of footwear or apparel. In some embodiments, at least a portion of the open-celled lattice has an Asker C hardness less than or equal to Asker C 55, less than or equal to Asker C 50, less than or equal to Asker C 45, or less than or equal to Asker C 40. In some embodiments, at least a portion of the open-celled lattice has a Shore OO hardness of greater than or equal to OO 55, greater than or equal to OO 60, greater than or equal to OO 65, or greater than or equal to OO 70. Combinations of the above-referenced ranges are also possible (e.g., an Asker C hardness less than or equal to Asker C 55 and a Shore OO hardness of greater than or equal to OO 55, an Asker C hardness less than or equal to Asker C 50 and a Shore OO hardness of greater than or equal to OO 60). Other ranges are also possible. In some embodiments, at least a portion of the open-celled lattice has a Shore OO hardness of greater than OO 55 and an Asker C hardness less than Asker C 55.
[0077]In some embodiments, the three-dimensionally printed feature comprising a open-celled lattice comprises or consists of a polymeric material. For example, in some embodiment, the three-dimensionally printed feature comprising a open-celled lattice comprises or consists of a polymeric material selected from the group consisting of: thermoplastic polyurethane (TPU), a polyurethane thermosetting elastomer, a silicone, and a combination thereof.
[0078]In some embodiments, the open-celled lattice has an appropriate infill density, at least in part so as to contribute to the low hardness of at least a portion of the open-celled lattice. In some embodiments, the open-celled lattice has an infill density of greater than or equal to 10%, greater than or equal to 20%, greater than or equal to 30%, greater than or equal to 40%, or greater than or equal to 80%. In some embodiments, the open-celled lattice has an infill density of less than or equal to 80%, less than or equal to 75%, less than or equal to 65%, less than or equal to 55%, less than or equal to 45%, less than or equal to 35%, or less than or equal to 25%. Combinations of the above-referenced ranges are also possible (e.g., an infill density of greater than or equal to 10% and less than or equal to 80%, an infill density of greater than or equal to 20% and less than or equal to 80%). Other ranges are also possible.
[0079]In some embodiments, the open-celled lattice has appropriate infill rotations per layer, which may also be referred to as infill angles per layer, at least in part so as to contribute to the low hardness of at least a portion of the open-celled lattice. In some embodiments, the open-celled lattice has infill rotations per layer of greater than or equal to 10 degrees, greater than or equal to 20 degrees, greater than or equal to 30 degrees, greater than or equal to 40 degrees, or greater than or equal to 60 degrees. In some embodiments, the open-celled lattice has infill rotations per layer of less than or equal to 90 degrees, less than or equal to 80 degrees, less than or equal to 70 degrees, or less than or equal to 60 degrees. Combinations of the above-referenced ranges are also possible (e.g., infill rotations per layer of greater than or equal to 10 degrees and less than or equal to 90 degrees, infill rotations per layer of greater than or equal to 20 degrees and less than or equal to 80 degrees). Other ranges are also possible. For example, in some embodiments, a layer of the open-celled lattice has an infill rotation of from 0 degrees to 360 degrees, inclusive. In some embodiments, any layer of the open-celled lattice can be printed at any angle. As used herein, an angle, theta, that is from 0 degrees to 180 degrees, inclusive, also refers to an angle, delta, that is the sum of theta and 180 degrees. For example, 0 degrees also refers to 180 degrees, and 150 degrees also refers to 330 degrees. In some embodiments, the infill rotations per layer may follow a repeating pattern (e.g., 90 degrees, 30 degrees, 330 degrees, repeat). In some embodiments, the infill rotations per layer may not follow a repeating pattern.
[0080]In some embodiments, the open-celled lattice has an infill density in the range from 10% to 75%, inclusive, and/or has infill rotations per layer in the range from 10 degrees to 90 degrees, inclusive.
[0081]In some embodiments, at least a portion of the closed-celled lattice has a lower hardness than other closed-celled lattices in articles of footwear or apparel. In some embodiments, at least a portion of the closed-celled lattice has an Asker C hardness less than or equal to Asker C 55, less than or equal to Asker C 50, less than or equal to Asker C 45, or less than or equal to Asker C 40. In some embodiments, at least a portion of the closed-celled lattice has a Shore OO hardness of greater than or equal to OO 55, greater than or equal to OO 60, greater than or equal to OO 65, or greater than or equal to OO 70. Combinations of the above-referenced ranges are also possible (e.g., an Asker C hardness less than or equal to Asker C 55 and a Shore OO hardness of greater than or equal to OO 55, an Asker C hardness less than or equal to Asker C 50 and a Shore OO hardness of greater than or equal to OO 60). Other ranges are also possible. In some embodiments, at least a portion of the closed-celled lattice has a Shore OO hardness of greater than OO 55 and an Asker C hardness less than Asker C 55.
[0082]In some embodiments, the three-dimensionally printed feature comprising a closed-celled lattice comprises or consists of a polymeric material. For example, in some embodiment, the three-dimensionally printed feature comprising a closed-celled lattice comprises or consists of a polymeric material selected from the group consisting of: thermoplastic polyurethane (TPU), a polyurethane thermosetting elastomer, a silicone, and a combination thereof.
[0083]In some embodiments, the closed-celled lattice has an appropriate infill density, at least in part so as to contribute to the low hardness of at least a portion of the closed-celled lattice. In some embodiments, the closed-celled lattice has an infill density of greater than or equal to 10%, greater than or equal to 20%, greater than or equal to 30%, greater than or equal to 40%, or greater than or equal to 80%. In some embodiments, the closed-celled lattice has an infill density of less than or equal to 80%, less than or equal to 75%, less than or equal to 65%, less than or equal to 55%, less than or equal to 45%, less than or equal to 35%, or less than or equal to 25%. Combinations of the above-referenced ranges are also possible (e.g., an infill density of greater than or equal to 10% and less than or equal to 80%, an infill density of greater than or equal to 20% and less than or equal to 80%). Other ranges are also possible.
[0084]In some embodiments, the closed-celled lattice has appropriate infill rotations per layer, which may also be referred to as infill angles per layer, at least in part so as to contribute to the low hardness of at least a portion of the closed-celled lattice. In some embodiments, the closed-celled lattice has infill rotations per layer of greater than or equal to 10 degrees, greater than or equal to 20 degrees, greater than or equal to 30 degrees, greater than or equal to 40 degrees, or greater than or equal to 60 degrees. In some embodiments, the closed-celled lattice has infill rotations per layer of less than or equal to 90 degrees, less than or equal to 80 degrees, less than or equal to 70 degrees, or less than or equal to 60 degrees. Combinations of the above-referenced ranges are also possible (e.g., infill rotations per layer of greater than or equal to 10 degrees and less than or equal to 90 degrees, infill rotations per layer of greater than or equal to 20 degrees and less than or equal to 80 degrees). Other ranges are also possible. For example, in some embodiments, a layer of the closed-celled lattice has an infill rotation of from 0 degrees to 360 degrees, inclusive. In some embodiments, any layer of the closed-celled lattice can be printed at any angle. As used herein, an angle, theta, that is from 0 degrees to 180 degrees, inclusive, also refers to an angle, delta, that is the sum of theta and 180 degrees. For example, 0 degrees also refers to 180 degrees, and 150 degrees also refers to 330 degrees. In some embodiments, the infill rotations per layer may follow a repeating pattern (e.g., 90 degrees, 30 degrees, 330 degrees, repeat). In some embodiments, the infill rotations per layer may not follow a repeating pattern.
[0085]In some embodiments, the closed-celled lattice has an infill density in the range from 10% to 75%, inclusive, and/or has infill rotations per layer in the range from 10 degrees to 90 degrees, inclusive.
[0086]In some embodiments, the closed cell foam (e.g., some embodiments of midsole 3006 of FIG. 30) is not three-dimensionally printed.
[0087]In some embodiments, the three-dimensionally printed feature comprises a first portion and a second portion, wherein there is at least a 10% difference in compression force deflection between the first portion and the second portion.
[0088]In some embodiments, the three-dimensionally printed feature is an insert into the closed cell foam and the closed cell foam is a portion of the article of footwear selected from the group consisting of: midsole, outsole, insole, sockliner, and footbed.
[0089]In some embodiments, the three-dimensionally printed feature comprises a thermoplastic material, and the thermoplastic material has substantially the same composition as the material which the majority of the weight of the remainder of the shoe comprises. In some embodiments, the three-dimensionally printed feature comprises a thermoplastic material, and the thermoplastic material has substantially the same composition as the material of which the majority of the weight of the remainder of the shoe consists. In some embodiments, the three-dimensionally printed feature comprises a thermoplastic polyurethane, a polyurea, or a combination of the two, and wherein the three-dimensionally printed feature composition comprises at least 15% by weight of raw materials that are derived from organisms of the plant kingdom.
[0090]As will be known to those of ordinary skill in the art, a foam is a structure having both solid and vapor portion(s). A closed cell foam comprises individual vapor-containing cavities, including at least a first vapor-containing cavity and a second vapor-containing cavity, that are not connected to one another. An open-celled foam comprises vapor-containing cavities, including at least a first vapor-containing cavity and a second vapor-containing cavity, that are connected to one another.
[0091]In some embodiments, a structure may be a “lattice”, e.g. an “open-celled lattice” or a “closed-celled lattice,” each of which may refer to a regular repeated three-dimensional arrangement of cavities in a solid matrix, at a larger scale but analogous to the arrangement of atoms, ions or molecules in a crystalline solid. An open-celled lattice comprises cavities, in a regular repeated three-dimensional arrangement, that are connected to one another. An open-celled lattice also comprises solid regions, in a regular repeated three-dimensional arrange