Footwear and apparatus and method for making same

Abstract

A shoe insole ( 28 ) comprises a base layer ( 34 ) and an optional top layer ( 36 ). The base layer ( 34 ) comprises functional zones ( 40 ) configured according to a user's physiological data, needs, and intended use. The insoles ( 28 ) may either partially or wholly be made using additive manufacturing techniques.

What is claimed is: 
     
         1 . An insole for footwear, the insole comprising:
 at least one layer of insole material, the at least one layer of insole material being configured to comprise plural functional zones, each functional zone comprising a material structure comprised of unit cells, the material structure of at least one functional zone differing from the material structure of at least one other functional zone.   
     
     
         2 . The insole of  claim 1 , wherein each functional zone is configured individually. 
     
     
         3 . The insole of  claim 1 , wherein the material structure varies in unit cell shape. 
     
     
         4 . The insole of  claim 3 , wherein the material structure of at least one functional zone is configured to comprise a beam and lattice construct. 
     
     
         5 . The insole of  claim 4 , wherein the material structure varies in lattice beam thickness. 
     
     
         6 . The insole of  claim 3 , wherein the unit cell structure is selected from the group consisting of mass and connector structures and TPMS structures. 
     
     
         7 . The insole of  claim 1 , wherein the plural functional zones are based on a user's physiological data. 
     
     
         8 . The insole of  claim 1 , wherein the properties of each functional zone are predetermined with respect to at least compression response. 
     
     
         9 . The insole of  claim 1 , wherein the at least one layer of insole material is configured to comprise a zone interface between at least two of the plural functional zones, and wherein the zone interface is configured to functionally connect with the material structure of adjacent plural functional zones. 
     
     
         10 . The insole of  claim 1 , wherein the material structure for the functional zone is configured in dependence upon a characteristic of a wearer of the footwear. 
     
     
         11 . The insole of  claim 10 , wherein the material structure for the functional zone is configured in dependence upon a desired compression response for the wearer in the functional zone. 
     
     
         12 . The insole of  claim 11 , wherein the desired compression response for the wearer is predetermined based on the desire of a user of the insole. 
     
     
         13 . The insole of  claim 1 , wherein at least part of the insole is manufactured using additive manufacturing. 
     
     
         14 . The insole of  claim 1 , wherein at least two of the plural functional zones are monolithically formed with one another. 
     
     
         15 . Footwear comprising:
 an exterior sole configured to interface with a contact surface;   an upper attached to the exterior sole and configured to at least partially define a cavity for foot insertion;   an insole according to  claim 1 , the insole insertable into or formed within the cavity.   
     
     
         16 . A method of making an insole for footwear, the method comprising:
 receiving a characteristic of usage of the footwear; and   fabricating an insole of the footwear by individually configuring material structure of plural functional zones of at least one layer of insole material in accordance with the characteristic of usage.   
     
     
         17 . The method of  claim 16 , wherein the characteristic of usage comprises a desired compression response for a wearer of the footwear. 
     
     
         18 . The method of  claim 16 , further comprising fabricating at least a portion of the insole of the footwear by additive manufacturing techniques. 
     
     
         19 . Apparatus for manufacturing footwear, the apparatus comprising:
 memory circuitry comprising a stored association of insole material structures with plural footwear usage parameters;   an input interface configured to receive usage information concerning an intended usage of the footwear; and   processor circuitry configured:
 to use the stored association and the usage information to generate an insole configuration for an insole for the footwear, the insole configuration comprising plural functional zones of at least one layer of insole material, each functional zone comprising a material structure which is configured individually for the functional zone; and 
 to generate insole configuration output to a footwear fabricator configured to make the insole according to the insole configuration. 
   
     
     
         20 . The apparatus of  claim 19 , wherein the processor circuitry is configured to control the footwear fabricator.