KR102852265B1 - Sole structure for footwear products - Google Patents

Abstract

A sole structure for a footwear article comprises: an upper cushion extending from a first end to a second end; a lower cushion including a tray extending toward a second end of the upper cushion and having a first segment attached to the upper cushion adjacent the first end; and at least one bladder disposed between the tray of the lower cushion and the upper cushion.

Description

Sole structure for footwear products

Related Application Cross References:

This PCT International Application claims the benefit of U.S. Patent Application Serial No. 17/666,337, filed February 7, 2022, which claims priority under 35 U.S.C. §119(e) to U.S. Provisional Patent Application Serial No. 63/146,953, filed February 8, 2021, the disclosure of which is hereby incorporated by reference in its entirety.

The present disclosure relates generally to articles of footwear, and more specifically to sole structures for articles of footwear.

This section provides background information relevant to the disclosure of this application, but is not necessarily prior art.

Footwear typically includes an upper structure and a sole structure. The upper may be formed of any suitable material(s) to accommodate, secure, and support the foot on the sole structure. The upper may cooperate with laces, straps, or other fasteners to adjust the fit of the upper around the foot. The bottom portion of the upper, closest to the bottom of the foot, is attached to the sole structure.

Sole structures typically include a layered arrangement extending between the ground surface and the upper. For example, the sole structure includes a midsole and an outsole. The midsole is typically positioned between the outsole and the upper and provides cushioning for the foot. The midsole may include a pressurized fluid-filled chamber that resiliently compresses under an applied load to cushion the impact of the foot by attenuating ground-reaction forces. The outsole may be formed of rubber or other materials that provide abrasion resistance and traction with the ground, and that impart durability and wear resistance, as well as enhance traction with the ground.

The drawings described herein are for illustrative purposes only of selected configurations and not all possible implementations, and are not intended to limit the scope of the present disclosure.
FIG. 1 is a side view illustrating the lateral side of a footwear article including an example of a sole structure according to the present disclosure.
Figure 2 is a side view showing the medial side of the footwear article of Figure 1.
Fig. 3 is an exploded perspective view showing the outer side of the sole structure of Fig. 1 as seen from above.
Fig. 4 is an exploded perspective view showing the inside of the sole structure of Fig. 1 as viewed from below.
Fig. 5 is a bottom plan view illustrating the sole structure of Fig. 1.
FIG. 6 is a cross-sectional view of the sole structure of FIG. 1 taken along line 6-6 in FIG. 5.
Fig. 7 is a cross-sectional view of the sole structure of Fig. 1 taken along line 7-7 in Fig. 5.
Fig. 8 is a cross-sectional view of the sole structure of Fig. 1 taken along line 8-8 in Fig. 5.
FIG. 9 is a cross-sectional view of the sole structure of FIG. 1 taken along line 9-9 in FIG. 5.
FIG. 10 is a top plan view illustrating a cushioning element of the sole structure of FIG. 1.
Corresponding drawing symbols indicate corresponding parts throughout the drawings.

The exemplary configurations will now be more fully described with reference to the accompanying drawings. These exemplary configurations are provided to ensure that the disclosure is thorough and fully conveys the scope of the disclosure to those skilled in the art. To provide a thorough understanding of the disclosed configurations, specific details, such as examples of specific components, devices, and methods, are described. It will be apparent to those skilled in the art that the specific details are not necessarily required, that the exemplary configurations can be implemented in many different forms, and that the specific details and exemplary configurations should not be construed as limiting the scope of the disclosed configurations.

The terminology used herein is for the purpose of describing particular exemplary configurations only and is not intended to be limiting. As used herein, the singular nouns may also include the plural forms unless the context clearly dictates otherwise. The terms "comprises," "comprising," "containing," "having," and "having" are inclusive and thus specify the presence of features, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein should not be construed as requiring performance in the particular order discussed or illustrated, unless specifically identified as such. Additional or alternative steps may be used.

When an element or layer is "on," "connected to," "attached to," or "joined to" another element or layer, it may be directly on, connected to, connected to, attached to, or joined to that other element or layer, or there may be intervening elements or layers present. In contrast, when an element is referred to as being "directly on," "directly connected to," "directly attached to," or "directly joined to" another element or layer, there may not be intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a similar manner (e.g., "between" versus "directly between," "adjacent" versus "directly adjacent," etc.). As used herein, the terms "and/or" or "and/or" include any and all combinations of one or more of the associated listed items.

Terms such as first, second, and third may be used herein to describe various elements, components, regions, layers, and/or sections. These elements, components, regions, layers, and/or sections should not be limited by these terms. These terms may only be used to distinguish one element, component, region, layer, or section from another region, layer, or section. Terms such as "first," "second," and other numerical terms do not imply order or sequence unless clearly indicated by context. Thus, a first element, component, region, layer, or section discussed below could also be referred to as a second element, component, region, layer, or section without departing from the teachings of the exemplary configurations.

In one configuration, a sole structure for a footwear article is provided, comprising: an upper cushion extending from a first end to a second end; a lower cushion including a tray extending toward a second end of the upper cushion, the tray having a first segment attached to the upper cushion adjacent the first end; and at least one bladder disposed between the tray of the lower cushion and the upper cushion.

Embodiments of this disclosure may include one or more of the following optional features: A plate may be positioned between at least one bladder and an upper cushion. A first side of at least one bladder may be attached to a tray, and an opposing second side of at least one bladder may be attached to the plate.

In one configuration, the lower cushion may include a support portion attached to the upper cushion. In such a configuration, the tray may be cantilevered from the support portion.

At least one bladder may include a first bladder disposed on a medial side of the sole structure and a second bladder disposed on a lateral side of the sole structure. The tray may include a first socket for receiving the first bladder and a second socket for receiving the second bladder. Additionally, or alternatively, at least one of the upper cushion and the lower cushion may include a peripheral side having a plurality of dimples. The dimples may be arranged in a plurality of rows and columns.

The outer sole may be positioned on the opposite side of the lower cushion from at least one bladder. Additionally, or alternatively, the tray of the lower cushion may include a foam material.

In another configuration, a sole structure for an article of footwear is provided, and includes a cushion arrangement, the cushion arrangement comprising: (i) an upper cushion having a top surface and a bottom surface formed on an opposite side of the top surface; (ii) a lower cushion having a bottom surface and an top surface formed on an opposite side of the bottom surface, the top surface opposing the bottom surface of the upper cushion; and (iii) a socket formed between the bottom surface of the upper cushion and the top surface of the lower cushion. At least one bladder is disposed within the socket between the top cushion and the bottom cushion.

Embodiments of this disclosure may include one or more of the following optional features: A plate may be positioned between at least one bladder and an upper cushion. A first side of at least one bladder may be attached to the lower cushion, and an opposite second side of at least one bladder may be attached to the plate.

In one configuration, the lower cushion may include a support portion attached to the upper cushion; and a tray cantilevered from the support portion. The tray may define a lower portion of the socket.

At least one bladder may include a first bladder disposed on a medial side of the sole structure and a second bladder disposed on a lateral side of the sole structure. An upper surface of the lower cushion may include a first socket for receiving the first bladder and a second socket for receiving the second bladder. Additionally, or alternatively, at least one of the upper cushion and the lower cushion may include a peripheral surface having a plurality of dimples. The dimples of the plurality of dimples may be arranged in a plurality of rows and columns.

The outer sole may be positioned adjacent to the lower surface of the lower cushion. Additionally, or alternatively, at least one of the upper cushion and the lower cushion may include a foam material.

Details of one or more embodiments of the present disclosure are set forth in the accompanying drawings and the description below. Other aspects, features, and advantages will be apparent from the specification, drawings, and claims.

Referring to FIG. 1, a footwear article (10) includes a sole structure (100) and an upper (200) attached to the sole structure (100). The footwear (10) may further include an anterior end (12) associated with a forward-most point of the footwear (10) and a posterior end (14) corresponding to a rear-most point of the footwear (10). As illustrated in FIG. 5, a longitudinal axis (A ₁₀ ) of the footwear (10) extends parallel to the ground surface from the anterior end (12) to the posterior end (14) along the length of the footwear (10), and generally divides the footwear (10) into a medial side (16) and a lateral side (18). Accordingly, the medial side (16) and the lateral side (18) correspond to opposite sides of the footwear (10), respectively, and extend from the front end (12) to the rear end (14). As used herein, the longitudinal direction refers to a direction extending from the front end (12) to the rear end (14), whereas the lateral direction refers to a direction extending transversely to the longitudinal direction from the medial side (16) to the lateral side (18).

An article of footwear (10) may be divided into one or more regions. The regions may include a forefoot region (20), a midfoot region (22), and a heel region (24). The forefoot region (20) may be further subdivided into a toe portion (20 _T ) corresponding to a phalange and a ball portion (20 _B ) associated with a metatarsal bone of the foot. The midfoot region (22) may correspond to an arch of the foot, and the heel region (24) may correspond to a back portion of the foot including the calcaneus bone.

A sole structure (100) includes a midsole (102) configured to provide cushioning and support; and an outsole (104) defining a ground-engaging surface (i.e., a surface that contacts the ground during the stance phase of a gait cycle) of the sole structure (100). Unlike conventional sole structures that include a single-piece midsole and outsole, the sole structure (100) of the present disclosure is configured as a composite structure comprising multiple components joined together. For example, the midsole (102) includes a resilient cushioning element or cushioning arrangement (106); one or more bladders (108); and a plate (110). Additionally, the outsole (104) may include a plurality of outsole fragments attached to the midsole (102) to provide zonal traction and abrasion resistance.

Referring to FIGS. 1 and 2, a cushioning element (106) of a midsole (102) extends from a first end (112) at a front end (12) of a footwear (10) to a second end (114) at a rear end (14) of the footwear. Here, the second end (114) may define a protrusion (116) extending beyond the upper (200) at the rear end (14). In addition, the cushioning element (106) has a top side (118) that faces the upper (200) and defines a profile of a footbed of the sole structure (100); a bottom side (120) that is formed from the top side (118) on an opposite side of the cushioning element (106) and defines a profile of a ground-contacting surface of the sole structure (100); and further includes an outer peripheral side surface (122) extending from the upper surface (118) to the lower surface (120) and defining an outer peripheral profile of the sole structure (100).

Optionally, the outer peripheral side (122) of the cushioning element (106) may include a plurality of dimples (124) arranged between the upper surface (118) and the lower surface (120) along the heel region (24). In the illustrated example, the dimples (124) are arranged as an array comprising a plurality of rows and columns of dimples (124). The dimples (124), when included, improve the aerodynamics of the sole structure by turbulentizing airflow along the outer peripheral side (122) to minimize drag as the article of footwear (10) moves through the swing phase of the gait cycle.

As described in more detail below, the cushioning element (106) includes a receptacle (126) formed on the inside of the cushioning element (106) between the upper surface (118) and the lower surface (120) in the forefoot region (20). The receptacle (126) is configured to receive and support one or more bladders (108) on the inside of the cushioning element (106). In other words, the cushioning element (106) extends above the bladders (108) (i.e., between the bladders (108) and the upper (200)) and below the bladders (108) (i.e., between the bladders (108) and the outsole (104).

Although the cushioning element (106) may be formed as a monolithic structure comprising a homogeneous elastomeric material, the cushioning element (106) of the present example may be defined in terms of multiple parts or subcomponents. For example, the cushioning element (106) includes an upper cushioning member or cushion (130) positioned adjacent to the upper (200); and a lower cushioning member or cushion (132) positioned adjacent to the outsole (104). The upper cushioning member (130) extends continuously from a first end (112) of the cushioning element (106) to a second end (114) of the cushioning element (106). Conversely, the lower cushioning member (132) may be segmented into segments and include an anterior segment (134) disposed at a first end (112) of the cushioning element (106) and a posterior segment (136) disposed at a second end (114) of the cushioning element (106). As discussed in more detail below, the anterior segment (134) may be spaced from the posterior segment by a gap (138) extending from the medial side (16) to the lateral side (18) in the midfoot region (22).

Now, referring to FIGS. 3 to 9, the upper cushioning member (130) extends continuously from the first end (112) of the cushioning element (106) to the second end (114) of the cushioning element (106). The upper cushioning member (130) includes a top surface (118) of the cushioning element (106) and a lower side (140) formed on an opposite side of the upper cushioning member (130) from the top surface (118). An upper portion of the outer peripheral side (122) connects the top surface (118) to the lower side (140). As illustrated in FIG. 3, the top surface (118) of the upper cushioning member (130) defines an insole (142) of the sole structure (100). As illustrated in FIG. 4, the lower surface of the upper buffer member (130) includes an upper pocket portion (144) configured to receive an upper portion of the plate (110) when the sole structure (100) is assembled.

The upper cushioning member (130) defines an upper portion (116a) of a posterior projection (116). As illustrated, the upper portion (116a) is formed where the upper surface (118) and the outer peripheral side (122) extend beyond the insole (142) from the second end (114). Here, a gap between a portion of the outer peripheral side (122) on the medial side (16) and a portion of the outer peripheral side (122) on the lateral side (18) defines a width of the projection (116) that tapers from the insole (142) to the second end (114). In a similar manner, the upper surface (118) and the lower surface (140) of the upper cushion member (130) converge to each other to provide a protrusion (116) having a thickness that gradually tapers in the direction from the insole (142) to the second end (114).

Still referring to FIGS. 3-9, the lower cushioning member (132) and its segments (134, 136) may be described as including a lower surface (120) of the cushioning element (106). Additionally, the segments (134, 136) may cooperate to define an upper surface (150) of the lower cushioning member (132) formed on an opposite surface of the lower cushioning member (132) than the lower surface (120). Lower portions of the peripheral side (122) interconnect the lower surface (120) and the upper surface (150) along each of the segments (134, 136). When the sole structure (100) is assembled, the upper surface (150) of the lower cushioning member (132) is attached to the lower surface (140) of the upper cushioning member (130) to form the cushioning element (106).

The upper surface (150) of the lower cushioning member (132) includes a lower pocket portion (152) configured to receive an upper portion of the plate (110) when the sole structure (100) is assembled. Since the lower cushioning member (132) may be formed as a fragmentary structure including a front segment (134) and a rear segment (136) that are spaced apart from each other by a gap (138), a first portion of the lower pocket portion (152) may be formed within the upper surface (150) of the front segment (134), and a second portion of the lower pocket portion (152) may be formed within the upper surface of the rear segment (136).

A front segment (134) of a lower cushioning member (132) is positioned adjacent to a first end (112) of a cushioning element (106). The front segment (134) extends from the first end (112) through the forefoot region (20) to a terminal end (154) adjacent to and opposite the midfoot region (22). The front segment (134) includes a support portion (156) extending from the first end (112) through the toe portion (20 _T ); and a tray (158) extending from the support portion (156) through the ball portion (20 _B) to the terminal end (154). Typically, the thickness of the support portion (156) extends from the upper surface (150) to the lower surface (120) such that the support portion (156) provides cushioning and support through the toe portion (20 _T ). Conversely, the tray (158) is formed by a portion of the anterior segment (134) having a reduced thickness relative to the support portion (156). The tray (158) extends from the posterior wall of the support portion (156) to the free-hanging distal end (154) of the anterior segment (134). Therefore, the tray (158) can be described as being cantilever-supported from the posterior wall of the support portion (156).

The tray (158) includes one or more recessed sockets (160) formed within the upper surface (150) of the cushioning element (106). Each of the one or more sockets (160) is configured to receive a corresponding one of the one or more bladders (108) within the interior of the front segment (134). Thus, the sockets (160) cooperate with the plate (110) and/or the upper cushioning member (130) to define a receiving portion (126) of the cushioning element (106), as previously discussed. In the illustrated example, the tray (158) includes a pair of sockets (160) recessed from the upper surface (150) such that when the sole structure (100) is assembled, the bladders (108) are seated flush with the upper surface (150) of the lower cushioning member (132). Here, a first socket of the sockets (160) is positioned adjacent to the inner side (16) of the sole structure (100) at the ball portion (20 _B ), and a second socket of the sockets (160) is positioned adjacent to the outer side (18) of the sole structure (100) at the ball portion (20 _B ). As illustrated, when the sole structure (100) is assembled, the sockets (160) are exposed along the outer and inner peripheral side surfaces (122) at the distal end (154) so that the bladders (108) are visible without shrinking along the distal end (154) and the faces (16, 18).

Optionally, the sockets (160) may extend at least partially inwardly of the rear side wall of the support portion (156), defining a peninsular region (162) within the rear side wall of the support portion (156) extending at least partially between the inner socket (160) and the outer socket (160). The peninsular region (162) may include an opening (164) extending through the thickness of the front segment (134) from the upper surface (150) to the lower surface (120). Additionally, the distal end (154) may include a tapered notch (166) extending between the sockets (160) and facing the peninsular region (162) across the tray (158). Here, when a torsional load is applied to the tray (158) (i.e., during a turning or cutting operation), the notch (166) and the hollow peninsula region (162) cooperate to cause the sockets (160) of the tray (158) to move relative to each other.

Continuing with reference to FIGS. 3-9, a rear segment (136) of a lower cushioning member (130) extends from a second end (114) of a cushioning element (106) through a heel region (24) to a distal end (168) opposite the anterior segment (134) within the midfoot region (22). A portion of an upper surface (150) of the lower cushioning member (132) formed by the rear segment (136) defines a portion of a lower pocket (152) within the midfoot region (22) and the heel region (24). A lower surface (120) of the rear segment (136) forms a convex surface having a continuous curvature from the second end (114) to the distal end (168). Thus, the rear segment (136) is configured to provide rolling and continuous contact during the heel-strike phase of the gait cycle. Here, the rear segment (136) forms a lower portion (116b) of the protrusion (116) at the second end (114) of the buffer element (106). As illustrated in FIGS. 1 and 2, the curved lower surface (120) of the lower buffer member (132) converges with the inclined upper surface (118) of the upper buffer member (130) to provide the protrusion (116) with a thickness (T ₁₁₆ ) that gradually tapers from the insole (142) to the second end (114).

The rear segment (136) includes an elongated channel (170) formed within the lower surface (120) and extending from a distal end (168) of the rear segment (136) inwardly into the heel region (24). The channel (170) has a tapered or triangular cross-section extending from the lower surface (120) to an apex between the lower surface (120) and the upper surface (150). The channel (170) is formed through the distal end (168) of the rear segment (136) such that the channel (170) defines a notch (172) extending from the upper surface (150) to the lower surface through the distal end (168). The channels (170) and notches (172) cooperate to form medial and lateral lobes (174) that extend along the length of the posterior segment (136) and can be articulated.

As described above, the components (132, 134, 136) of the cushioning element (106) are formed of an elastomeric material, such as foam or rubber, to impart cushioning, sensitivity, and energy distribution properties to the wearer's foot. In the illustrated example, the upper cushioning member (130) comprises a first foam material, the front segment (134) of the lower cushioning member (132) comprises a second foam material, and the rear segment (136) of the lower cushioning member (132) comprises a third foam material. For example, the upper cushioning member (130) and the front segment (134) may include a first foam material to provide greater cushioning to impart distribution, while the rear segment (136) may include a foam material having greater stiffness to provide increased stability to the heel region (24) of the sole structure (100).

The elastomeric materials of the example of the cushioning element (106) may include materials based on foaming or molding one or more elastomeric polymers (e.g., thermoplastic elastomers (TPEs)). The one or more polymers may include aliphatic polymers, aromatic polymers, or mixtures of the two; and may include homopolymers, copolymers (including terpolymers), or mixtures of the two.

In some embodiments, the one or more polymers may include olefin homopolymers, olefin copolymers, or blends thereof. Examples of olefin polymers include polyethylene, polypropylene, and combinations thereof. In other embodiments, the one or more polymers may include one or more ethylene copolymers, such as ethylene-vinyl acetate (EVA) copolymers, EVOH copolymers, ethylene-ethyl acrylate copolymers, ethylene-unsaturated mono-fatty acid copolymers, and combinations thereof.

In further embodiments, the one or more polymers may include one or more polyacrylates, such as polyacrylic acid, esters of polyacrylic acid, polyacrylonitrile, polyacrylic acetate, polymethyl acrylate, polyethyl acrylate, polybutyl acrylate, polymethyl methacrylate, and polyvinyl acetate; derivatives thereof, copolymers thereof, and any combination thereof.

In yet further embodiments, the one or more polymers may comprise one or more ionomeric polymers. In such embodiments, the ionomeric polymers may comprise polymers containing carboxylic acid functional groups, sulfonic acid functional groups, salts thereof (e.g., sodium, magnesium, potassium, etc.), and/or anhydrides thereof. For example, the ionomeric polymer(s) may comprise one or more fatty acid-modified ionomeric polymers, polystyrene sulfonate, ethylene-methacrylic acid copolymers, and combinations thereof.

In further embodiments, the one or more polymers may include one or more styrene block copolymers, such as acrylonitrile butadiene styrene block copolymers, styrene acrylonitrile block copolymers, styrene ethylene butylene styrene block copolymers, styrene ethylene butadiene styrene block copolymers, styrene ethylene propylene styrene block copolymers, styrene butadiene styrene block copolymers, and combinations thereof.

In further embodiments, the one or more polymers may comprise one or more polyamide copolymers (e.g., polyamide-polyether copolymers) and/or one or more polyurethanes (e.g., cross-linked polyurethanes and/or thermoplastic polyurethanes). Alternatively, the one or more polymers may comprise one or more natural and/or synthetic rubbers, such as butadiene and isoprene.

When the elastomeric material is a foamed polymer material, the foamed material may be foamed using a physical blowing agent, which transitions from its own phase to a gas based on changes in temperature and/or pressure, or a chemical blowing agent, which forms a gas when heated above its own activation temperature. For example, the chemical blowing agent may be an azo compound, such as azodicarbonamide, sodium bicarbonate, and/or an isocyanate.

In some embodiments, the foamed polymer material may be a crosslinked foam material. In such embodiments, a peroxide-based crosslinking agent, such as dicumyl peroxide, may be used. Additionally, the foamed polymer material may contain one or more fillers, such as pigments, modified or natural clays, modified or unmodified synthetic clays, talc glass fibers, powdered glass, modified or natural silica, calcium carbonate, mica, paper, wood chips, and the like.

The elastomeric material may be formed using a forming process. In one example, when the elastomeric material is a formed elastomer, the uncured elastomer (e.g., rubber) may be mixed in a Banbury mixer with optional fillers and a curing package, such as a sulfur- or peroxide-based curing package, calendared, formed into a shape, and placed in a mold to vulcanize.

In another example, when the elastomeric material is a foamed material, the material may be foamed during a molding process, such as an injection molding process. The thermoplastic polymer material may be melted within the barrel of an injection molding system, combined with a physical or chemical blowing agent and an optional crosslinking agent, and then injected into the mold under conditions that activate the blowing agent, forming the molded foam.

Optionally, when the elastomeric material is a foamed material, the foamed material may be a compression molded foam. Compression molding may be used to change the physical properties of the foam (e.g., density, stiffness, and/or durometer), to change the physical appearance of the foam (e.g., by fusing two or more pieces of foam to form the foam), or both.

The compression molding process preferably begins by forming one or more foam preforms, for example, by injection molding a polymeric material to foam, forming foamed particles or beads, cutting foamed sheet stock, etc. The compression molded foam can then be made by placing one or more preforms formed of the foamed polymeric material(s) within a compression mold and applying sufficient pressure to compress the one or more preforms within the closed mold. Once the mold is closed, sufficient heat and/or pressure is applied to the one or more preforms within the closed mold for a sufficient period of time to form a skin on the outer surface of the compression molded foam, thereby modifying the preform(s), fusing the individual foam particles to one another, and permanently increasing the density of the foam(s), or any combination thereof. After heating and/or applying pressure, the mold is opened and the molded foam article is removed from the mold.

Continuing with reference to FIGS. 3 and 4, the plate (110) extends from a first end (176) within the toe portion (20 _T ) to a second end (178) within the heel region (24). The plate (110) includes a top surface (180) and a bottom surface (182) formed on an opposite surface from the top surface (180). A distance from the top surface (180) to the bottom surface (182) defines a thickness of the plate (110). An outer periphery extends between the top surface (180) and the bottom surface (182) and defines an outer periphery profile of the plate (110) that corresponds to the peripheral profiles of the upper and lower pocket portions (144, 152). The plate (110) may be embedded between the upper buffer member (130) and/or the lower buffer member (132) such that the upper surface (180) of the plate (110) is received within the upper pocket portion (144) and the lower surface (182) of the plate (110) is received within the lower pocket portion (152). Here, the first end (176) of the plate (110) is received within the portion of the lower pocket portion (152) defined by the front segment (134), and the second end (178) of the plate (110) is received within the portion of the lower pocket portion (152) defined by the rear segment (136). Accordingly, the lower surface (182) of the plate (110) is received within the opening (164) in the front segment (134); and is exposed (i.e., visible) toward the ground surface through a gap (138) formed between the front segment (134) and the rear segment (136).

The plate (110) comprises a material that provides relatively high strength and stiffness, such as a polymeric material and/or a composite material. In some examples, the plate (110) is a composite material manufactured using a fiber sheet or textile, such as a pre-impregnated (i.e., "prepreg") fiber sheet or textile. Alternatively, or in addition, the plate (110) may be manufactured by strands formed from multiple filaments of one or more types of fibers (e.g., fiber tows) by attaching fiber tows to a substrate or to each other to manufacture a plate having fiber strands arranged at largely predetermined angles or in predetermined positions. When using fiber strands, the types of fibers included within the strands may include synthetic polymer fibers that can be melted and re-solidified with other fibers present within the strand; and optionally other components such as stitching threads or a substrate or both. Alternatively, or in addition thereto, the fibers of the strands and optionally other components such as stitching threads or a substrate or both may be solidified by applying a resin after attaching the strands of fibers to the substrate and/or to each other.

In some embodiments, the plate (110) has a substantially uniform thickness. In some examples, the thickness of the plate (110) ranges from about 0.6 millimeters (mm) to about 3.0 mm. In one example, the thickness of the plate (110) is substantially equal to 1.0 mm. In other implementations, the thickness of the plate (110) is non-uniform such that the plate (110) can have a greater thickness in one area (20, 22, 24) of the sole structure (200) than in the other areas (20, 22, 24).

With particular reference to FIGS. 1-4 and 8, one or more bladders (108) are illustrated as including a medial bladder (108) and a lateral bladder (108) that are received within the receiving portion (126) of the cushioning element (106) between the upper cushioning member (130) and the lower cushioning member (132). More specifically, the bladders (108) are each received within one of the sockets (160). Thus, the medial bladder (108) is positioned within a first socket (160) that is closest to the medial surface (16) of the sole structure (100), while the lateral bladder (108) is positioned within a second socket (160) that is closest to the lateral surface (16) of the sole structure (100).

Each of the bladders (108) may include a pair of barrier layers (184a, 184b) formed along a peripheral seam and joined together to define a chamber (186) inside the bladder (108). Here, the upper barrier layer (184a) defines a top surface of the bladder (108), and the lower barrier layer (184b) defines a bottom surface of the bladder (108). When the sole assembly (100) is assembled, the lower barrier layer (184b) is received inside one of the sockets (160) of the tray (158) such that the bladder (108) is supported on the foam material of the front segment (134). The upper surface of the upper barrier layer (184a) is positioned at the same height as the upper surface (150) of the buffer element (106) and is attached to the lower surface (182) of the plate (110) from the inside of the gap (138).

As used herein, the term "barrier layer" (e.g., barrier layers 184a, 184b) encompasses both single-layer and multi-layer films. In some embodiments, one or both of the barrier layers (184a, 184b) are each manufactured (e.g., thermoformed or blown) as a single-layer film (a single layer). In other embodiments, one or both of the barrier layers (184a, 184b) are each manufactured (e.g., thermoformed or blown) as a multi-layer film (a plurality of sublayers). In each aspect, each layer or sublayer can have a film thickness ranging from about 0.2 micrometers to about 1 millimeter. In further embodiments, the film thickness for each layer or sublayer can range from about 0.5 micrometers to about 500 micrometers. In further embodiments, the film thickness for each layer or sublayer can range from about 1 micrometer to about 100 micrometers.

One or both of the barrier layers (184a, 184b) can independently be transparent, translucent, and/or opaque. As used herein, the term "transparent" with respect to a barrier layer and/or a fluid-filled chamber means that light passes through the barrier layer in a substantially straight line such that a viewer can see through the barrier layer. In contrast, for an opaque barrier layer, light does not pass through the barrier layer and no one can ever clearly see through the barrier layer. A translucent barrier layer falls between a transparent barrier layer and an opaque barrier layer, wherein light passes through a translucent barrier layer, but some of the light is scattered so that a viewer cannot clearly see through the layer.

The barrier layers (184a, 184b) may each be made of an elastomeric material containing one or more thermoplastic polymers and/or one or more crosslinkable polymers. In one aspect, the elastomeric material may include one or more thermoplastic elastomeric materials, such as one or more thermoplastic polyurethane (TPU) copolymers, one or more ethylene-vinyl alcohol (EVOH) copolymers, and the like.

As used herein, "polyurethane" refers to a copolymer (including an oligomer) containing urethane groups (-N(C=O)O-). Such polyurethanes may contain, in addition to urethane groups, additional groups such as esters, ethers, ureas, allophanates, biurets, carbodiimides, oxazolidinyls, isocyanurates, uretdiones, carbonates, and the like. In one aspect, one or more of the polyurethanes may be produced by polymerizing one or more polyols and one or more isocyanates to produce copolymer chains having (-N(C=O)O-) linkages.

Examples of suitable isocyanates for forming polyurethane copolymer chains include diisocyanates such as aromatic diisocyanates, aliphatic diisocyanates, and combinations thereof. Examples of suitable aromatic diisocyanates include toluene diisocyanate (TDI), TDI adducts containing trimethyloylpropane (TMP), methylene diphenyl diisocyanate (MDI), xylene diisocyanate (XDI), tetramethylxylylene diisocyanate (TMXDI), hydrogenated xylene diisocyanate (HXDI), naphthalene 1,5-diisocyanate (NDI), 1,5-tetrahydronaphthalene diisocyanate, para-phenylene diisocyanate (PPDI), 3,3'-dimethyldiphenyl-1-4,4'-diisocyanate (DDDI), 4,4'-dibenzyl diisocyanate (DBDI), 4-chloro-1,3-phenylene diisocyanate, and combinations thereof. In some embodiments, the copolymer chains are substantially free of aromatic groups.

In certain embodiments, the polyurethane polymer chains are formed from diisocyanates including HMDI, TDI, MDI, H12 aliphatic compounds, and combinations thereof. In one embodiment, the thermoplastic TPU can include a polyester-based TPU, a polyether-based TPU, a polycaprolactone-based TPU, a polycarbonate-based TPU, a polysiloxane-based TPU, or combinations thereof.

In another embodiment, the polymer layer may be formed of one or more of the following materials: EVOH copolymers, poly(vinyl chloride), polyvinylidene polymers and copolymers (e.g., polyvinylidene chloride), polyamides (e.g., amorphous polyamides), amide-based copolymers, acrylonitrile polymers (e.g., acrylonitrile-methyl acrylate copolymers), polyethylene terephthalate, polyether imides, polyacryl imides, and other polymeric materials known to have relatively low gas permeability. Blends of the above materials are also suitable, as well as blends of the above materials with the TPU copolymers described herein, optionally including combinations of polyimides and crystalline polymers.

The barrier layers (184a, 184b) may include two or more sublayers (multilayer films), such as those disclosed in U.S. Patent Nos. 5,713,141 to Mitchell et al. and 5,952,065 to Mitschell et al., the disclosures of which are incorporated herein by reference in their entireties. In embodiments where the barrier layers (184a, 184b) include two or more sublayers, examples of suitable multilayer films include microlayer films, such as those disclosed in U.S. Patent No. 6,582,786 to Bonk et al., the disclosures of which are incorporated herein by reference in their entireties. In further embodiments, the barrier layers (184a, 184b) each independently comprise alternating sublayers of one or more TPU copolymer materials and one or more EVOH copolymer materials, wherein the total number of sublayers of each of the barrier layers (184a, 184b) comprises at least 4 sublayers, at least 10 sublayers, at least 20 sublayers, at least 40 sublayers, and/or at least 60 sublayers.

The fluid filled chamber (186) can be manufactured from the barrier layers (184a, 184b) using any suitable technique, such as thermoforming (e.g., vacuum thermoforming), blow molding, extrusion, injection molding, vacuum forming, rotational molding, transfer molding, pressure forming, heat sealing, casting, low pressure casting, spin casting, reaction injection molding, radio frequency (RF) welding, and the like. In one aspect, the barrier layers (184a, 184b) can be manufactured by co-extrusion followed by vacuum thermoforming to manufacture an inflatable chamber (186) that can optionally include one or more valves (e.g., one-way valves) that allow the chamber (186) to be filled with a fluid (e.g., a gas).

The chamber (186) may be provided in a fluid-filled state (e.g., as provided within the footwear (10)) or unfilled. The chamber (186) may be filled to contain any suitable fluid, such as a gas or a liquid. In one embodiment, the gas may comprise air, nitrogen (N ₂ ), or any other suitable gas. In other embodiments, alternatively, the chamber (186) may comprise other media, such as pellets, beads, pulverized recycled material, and the like (e.g., foamed beads and/or rubber beads). By providing the fluid to the chamber (186), the chamber (186) is thereby pressurized. Alternatively, the fluid provided to the chamber (186) may be at atmospheric pressure, such that the chamber (186) is not pressurized, but rather simply contains a fluid volume at atmospheric pressure.

The fluid-filled chamber (186) preferably has a low gas permeability to preserve its own maintained gas pressure. In some embodiments, the fluid-filled chamber (186) has a gas permeability to nitrogen gas that is about ten times lower than the nitrogen gas permeability for a butyl rubber layer of substantially the same dimensions. In one aspect, the fluid-filled chamber (186) has a nitrogen gas permeability of no more than 15 cubic centimeters per square meter atmosphere day (cm ³ /m ² ·atm·day) for an average film thickness of 500 micrometers (based on the thickness of the barrier layers (184a, 184b)). In further aspects, the permeability is no more than 10 cm ³ /m ² ·atm·day, or no more than 5 cm ³ /m ² ·atm·day, or no more than 1 cm ³ /m ² ·atm·day.

Each chamber (186) of the bladders (108) can contain a tensile element (188) (FIG. 8) therein. Each tensile element (188) can include a series of tensile strands (190) extending between an upper tensile sheet (192) and a lower tensile sheet (192). The upper tensile sheet (192) can be attached to a first barrier layer (184a) of the barrier layers, while the lower tensile sheet (192) can be attached to a second barrier layer (184b) of the barrier layers. In this manner, when the chamber (186) contains pressurized fluid, the tensile strands (190) of the tensile element (188) are placed in a tensile state. Because the upper tensile sheet (192) is attached to the upper barrier layer (184a) and the lower tensile sheet (192) is attached to the lower barrier layer (184b), the tensile strands (190) maintain the intended shape of the bladders (108) when pressurized fluid is injected into the chambers (186).

The outsole (104) is formed of an elastomeric material and is attached to a lower surface (120) of the lower cushioning member (132). In the illustrated example, the outsole (104) includes a forefoot segment (194) attached to a lower surface (120) of the shear segment (134); and a pair of heel segments (196) each attached to a lower surface (120) of each of the lobes (174). Optionally, the forefoot segment (194) of the outsole (104) includes an aperture (198) formed therethrough, which corresponds to an opening (164) formed therethrough in the forward segment (134) of the lower cushioning member (132). Thus, the lower surface (182) of the plate (110) is exposed through the outsole opening (198) and the cushioning element opening (164).

The upper (200) forms an enclosure having a plurality of components that cooperate with each other to define an internal void (202) and an ankle opening (204), wherein the internal void and the ankle opening cooperate with each other to receive a foot and secure the foot for support on the sole structure (200). The upper (200) may be formed of one or more materials that are sewn or adhesively bonded together to define the internal void (202). Suitable materials for the upper (200) include, but are not limited to, textiles, foams, leather, and synthetic leather. The upper (200) of the example may be formed of a combination of one or more substantially inelastic or inelastic materials and one or more substantially elastic or stretchable materials disposed in different regions of the upper (200) to facilitate movement of the article of footwear (10) between a tightened state and a loosened state. The one or more elastic materials may include any combination of one or more elastic fabrics, such as, without limitation, spandex, elastane, rubber, or neoprene. The one or more inelastic materials may include any combination of one or more of thermoplastic polyurethane, nylon, leather, vinyl, or another material/fabric that does not impart elastic properties.

The following items provide exemplary configurations for the footwear articles and sole structures described above.

Item 1. A sole structure for a footwear article, wherein the sole structure comprises: an upper cushion extending from a first end to a second end; a lower cushion including a tray extending toward a second end of the upper cushion and having a first segment attached to the upper cushion adjacent the first end; and at least one bladder disposed between the tray of the lower cushion and the upper cushion.

Item 2. A sole structure for a footwear article, wherein the sole structure of Item 1 further includes a plate disposed between the at least one bladder and the upper cushion.

Item 3. A sole structure for a footwear article, wherein in Item 2, a first side of the at least one bladder is attached to the tray, and an opposite second side of the at least one bladder is attached to the plate.

Item 4. A sole structure for a footwear article, wherein in any one of Items 1 to 3, the lower cushion includes a support portion attached to the upper cushion, and the tray is cantilever-supported from the support portion.

Item 5. A sole structure for a footwear article, wherein in any one of Items 1 to 4, the at least one bladder includes a first bladder disposed on an inner surface of the sole structure and a second bladder disposed on an outer surface of the sole structure.

Item 6. A sole structure for a footwear article, wherein the tray comprises a first socket for accommodating the first bladder and a second socket for accommodating the second bladder in Item 5.

Item 7. A sole structure for a footwear article, wherein in any one of Items 1 to 6, at least one of the upper cushion and the lower cushion includes an outer peripheral side surface having a plurality of dimples.

Item 8. A sole structure for a footwear article, wherein the dimples in Item 7 are arranged in a plurality of columns and rows.

Item 9. A sole structure for a footwear article, wherein in any one of Items 1 to 8, the sole structure further includes an outer sole disposed on an opposite surface of the lower cushion from the at least one bladder.

Item 10. A sole structure for a footwear article according to any one of Items 1 to 9, wherein the tray of the lower cushion comprises a foam material.

Item 11. A sole structure for a footwear article, wherein the sole structure includes a cushion arrangement, wherein the cushion arrangement includes (i) an upper cushion having an upper surface and a lower surface formed on an opposite surface of the upper surface; (ii) a lower cushion having a lower surface and an upper surface formed on an opposite surface of the lower surface and facing the lower surface of the upper cushion; and (iii) a socket formed between the lower surface of the upper cushion and the upper surface of the lower cushion. At least one bladder is disposed inside the socket between the upper cushion and the lower cushion.

Item 12. A sole structure for a footwear article, wherein the sole structure of Item 11 further includes a plate disposed between the at least one bladder and the upper cushion.

Item 13. A sole structure for a footwear article, wherein in Item 12, a first side of the at least one bladder is attached to the lower cushion, and an opposite second side of the at least one bladder is attached to the plate.

Item 14. A sole structure for a footwear article, wherein in any one of Items 11 to 13, the lower cushion comprises: a support portion attached to the upper cushion; and a tray that is cantilever-supported from the support portion and defines a lower portion of the socket.

Item 15. A sole structure for a footwear article, wherein in any one of Items 11 to 14, the at least one bladder includes a first bladder disposed on an inner surface of the sole structure and a second bladder disposed on an outer surface of the sole structure.

Item 16. A sole structure for a footwear article, wherein the upper surface of the lower cushion in Item 15 includes a first socket for receiving the first bladder and a second socket for receiving the second bladder.

Item 17. A sole structure for a footwear article, wherein in any one of Items 11 to 16, at least one of the upper cushion and the lower cushion includes an outer peripheral surface having a plurality of dimples.

Item 18. A sole structure for a footwear article, wherein the dimples of the plurality of dimples in Item 17 are arranged in a plurality of rows and columns.

Item 19. A sole structure for a footwear article according to any one of Items 11 to 18, wherein the sole structure further includes an outer sole disposed adjacent to the lower surface of the lower cushion.

Item 20. A sole structure for a footwear article, wherein at least one of the upper cushion and the lower cushion comprises a foam material, in any one of items 11 to 19.

The foregoing description has been provided for illustrative and explanatory purposes. It is not intended to be exhaustive or limiting of the present disclosure. Individual elements or features of a particular configuration are generally not limited to that particular configuration, but may be interchanged where applicable and may be used in a selected configuration even if not specifically shown or described. Furthermore, the same may be varied in many ways. Such variations should not be construed as a departure from the present disclosure, and all such modifications are intended to be included within the scope of the present disclosure.

Claims (20)

In a sole structure for a footwear product, the sole structure is
An upper cushion extending from the first end to the second end;
As a lower cushion,
A first cushion including a tray attached to the upper cushion adjacent to the first end and extending to a distal end toward the second end of the upper cushion, and
A second cushion attached to the upper cushion and spaced apart from the first cushion by a gap, wherein the tray of the first cushion faces the second cushion across the gap.
lower cushion including; and
At least one bladder supported between the tray of the first cushion and the upper cushion and including a front end and a rear end, wherein the terminal end of the tray is aligned with the rear end of the at least one bladder or extends beyond the rear end.
A sole structure for a footwear article, comprising: A sole structure for a footwear article, wherein in the first paragraph, the sole structure further includes a plate disposed between the at least one bladder and the upper cushion. A sole structure for a footwear article, wherein, in the second paragraph, a first side of the at least one bladder is attached to the tray, and an opposite second side of the at least one bladder is attached to the plate. A sole structure for footwear, wherein in the first paragraph, the lower cushion includes a support portion attached to the upper cushion, and the tray is cantilever-supported from the support portion. A sole structure for a footwear article, wherein in the first paragraph, the at least one bladder includes a first bladder disposed on an inner surface of the sole structure and a second bladder disposed on an outer surface of the sole structure. A sole structure for a footwear article, wherein in the fifth paragraph, the tray includes a first socket for accommodating the first bladder and a second socket for accommodating the second bladder. A sole structure for a footwear article, wherein at least one of the upper cushion and the lower cushion in the first paragraph includes an outer peripheral side surface having a plurality of dimples. A sole structure for a footwear article, wherein the dimples are arranged in a plurality of columns and rows in the seventh paragraph. A sole structure for a footwear article, wherein in the first paragraph, the sole structure further includes an outer sole disposed on the opposite surface of the lower cushion from the at least one bladder. A sole structure for footwear, wherein the tray of the lower cushion in the first paragraph comprises a foam material. In a sole structure for a footwear product, the sole structure is
As a cushion arrangement,
i. An upper cushion having an upper surface and a lower surface formed on an opposite surface of the upper surface;
ii. A lower cushion including a first cushion and a second cushion, wherein each of the first cushion and the second cushion has a lower surface and an upper surface formed on an opposite surface of the lower surface and facing the lower surface of the upper cushion;
iii. a socket formed between the lower surface of the upper cushion and the upper surface of the first cushion; and
iv. A gap separating the first cushion and the second cushion
a cushion arrangement comprising; and
At least one bladder comprising a top surface and a bottom surface
A sole structure for a footwear article, comprising: a bottom surface of said at least one bladder being in contact with and supported on an upper surface of said first cushion within said socket. A sole structure for a footwear article, wherein the sole structure further includes a plate disposed between the at least one bladder and the upper cushion. A sole structure for a footwear article, wherein, in claim 12, a first side of the at least one bladder is attached to the lower cushion, and an opposite second side of the at least one bladder is attached to the plate. A sole structure for a footwear article, wherein the lower cushion comprises: a support portion attached to the upper cushion; and a tray that defines a lower portion of the socket while being cantilevered from the support portion. A sole structure for a footwear article, wherein in claim 11, the at least one bladder includes a first bladder disposed on an inner surface of the sole structure and a second bladder disposed on an outer surface of the sole structure. A sole structure for a footwear article, wherein the upper surface of the lower cushion in the 15th paragraph includes a first socket for accommodating the first bladder and a second socket for accommodating the second bladder. A sole structure for a footwear article, wherein at least one of the upper cushion and the lower cushion in the 11th paragraph includes an outer peripheral surface having a plurality of dimples. A sole structure for a footwear article, wherein the dimples of the plurality of dimples in the 17th paragraph are arranged in a plurality of rows and columns. A sole structure for a footwear article, wherein the sole structure further includes an outer sole disposed adjacent to the lower surface of the lower cushion. A sole structure for a footwear article, wherein at least one of the upper cushion and the lower cushion comprises a foam material in the 11th paragraph.