The present disclosure relates generally to sole structures for articles of footwear, and more particularly, to sole structures incorporating a stacked structure and a bladder.
This section provides background information related to the present disclosure which is not necessarily prior art.
Articles of footwear conventionally include an upper and a sole structure. The upper may be formed from any suitable material(s) to receive, secure, and support a 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. A bottom portion of the upper, proximate to a bottom surface of the foot, attaches to the sole structure.
Sole structures generally include a layered arrangement extending between a ground surface and the upper. One layer of the sole structure includes an outsole that provides abrasion-resistance and traction with the ground surface. The outsole may be formed from rubber or other materials that impart durability and wear-resistance, as well as enhance traction with the ground surface. Another layer of the sole structure includes a midsole disposed between the outsole and the upper. The midsole provides cushioning for the foot and may be partially formed from a polymer foam material that compresses resiliently under an applied load to cushion the foot by attenuating ground-reaction forces. The midsole may additionally or alternatively incorporate a fluid-filled bladder to increase durability of the sole structure, as well as to provide cushioning to the foot by compressing resiliently under an applied load to attenuate ground-reaction forces. Sole structures may also include a comfort-enhancing insole or a sockliner located within a void proximate to the bottom portion of the upper and a strobel attached to the upper and disposed between the midsole and the insole or sockliner.
Midsoles employing fluid-filled bladders typically include a bladder formed from two barrier layers of polymer material that are sealed or bonded together. The fluid-filled bladders are pressurized with a fluid such as air, and may incorporate tensile members within the bladder to retain the shape of the bladder when compressed resiliently under applied loads, such as during athletic movements. Generally, bladders are designed with an emphasis on balancing support for the foot and cushioning characteristics that relate to responsiveness as the bladder resiliently compresses under an applied load.
Examples of the present disclosure relate to, among other things, articles of footwear having a sole structure. In one example, the articles of footwear may be worn for an extended period of time. Each of the examples disclosed herein may include one or more of the features described in connection with any of the other disclosed examples.
The drawings described herein are for illustrative purposes only of selected configurations and are not intended to limit the scope of the present disclosure.
Corresponding reference numerals indicate corresponding parts throughout the drawings.
Example configurations will now be described more fully with reference to the accompanying drawings. Example configurations are provided so that this disclosure will be thorough, and will fully convey the scope of the disclosure to those of ordinary skill in the art. Specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of configurations of the present disclosure. It will be apparent to those of ordinary skill in the art that specific details need not be employed, that example configurations may be embodied in many different forms, and that the specific details and the example configurations should not be construed to limit the scope of the disclosure.
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 articles “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore 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 are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. Additional or alternative steps may be employed.
When an element or layer is referred to as being “on,” “engaged to,” “connected to,” “attached to,” or “coupled to” another element or layer, it may be directly on, engaged, connected, attached, or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” “directly attached to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.
The terms first, second, third, etc. 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 be only 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 a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example configurations.
Referring to
With reference to
In some examples, one or more fasteners 206 extend along the upper 100 to adjust a fit of the interior void 201 around the foot and to accommodate entry and removal of the foot therefrom. The upper 100 may include apertures 207 such as eyelets and/or other engagement features such as fabric or mesh loops that receive the fasteners 206. The fasteners 206 may include laces, straps, cords, hook-and-loop, or any other suitable type of fastener. The upper 100 may include a tongue portion 208 that extends between the interior void 201 and the fasteners 206.
With reference to
Referring to
The first and second barrier layers 321 and 322 may, for example, be formed by respective mold portions each defining various surfaces for forming depressions and pinched surfaces corresponding to locations where the seam 323 and/or the web area are formed when the second barrier layer 322 and the first barrier layer 321 are joined and bonded together. In some implementations, adhesive bonding joins the first barrier layer 321 and the second barrier layer 322 to form the bladder 124. In other examples, the first barrier layer 321 and the second barrier layer 322 are joined to form the seam 323 and the web area by thermal bonding. In some examples, one or both of the barrier layers 321 and 322 are heated to a temperature that facilitates shaping and melding. In some examples, the layers 321 and 322 are heated prior to being located between their respective molds. In other examples, the mold may be heated to raise the temperature of the layers 321 and 322. In some examples, a molding process used to form the bladder 124 incorporates vacuum ports within mold portions to remove air such that the first and second layers 321 and 322 are drawn into contact with respective mold portions. In other examples, fluids such as air may be injected into areas between the upper and lower layers 321 and 322 such that pressure increases cause the layers 321 and 322 to engage with surfaces of their respective mold portions. It is contemplated that the bladder 124 may be inflated from 8 PSI to 15 PSI, although other suitable values are contemplated. In an exemplary embodiment, bladder 124 may be inflated to 10 PSI.
Bladder 124 may further include a first outer heel segment 301 and a second outer heel segment 302. First segment 301 may extend along an arc corresponding to a medial side of the article of footwear 10. Second segment 302 may extend along an arc corresponding to a lateral side of the article of footwear 10. Segments 301 and 302 may extend from the heel region 16 to a portion of the mid-foot region 14. Furthermore, in at least some embodiments, segments 301 and 302 may be approximately mirror images of one another about a central longitudinal axis A124 of bladder 124. Segments 301 and 302 are disposed on opposite sides of central longitudinal axis A124, and are each concave when viewed from central longitudinal axis A124.
Referring to
Referring to
In an alternative embodiment, shown in
Referring to
In an alternative embodiment, not shown, the heel region may include only one fluid channel 314 that connects support 303 to the single continuous segment 324. In another embodiment, there may be more than two fluid filled channels 314.
Forefoot portion 305 may include at least two prong-like channels (or prongs) 305A and 305B. Each channel 305A and 305B may extend from support 303 and base 304, in a direction away from the heel (i.e., toward the forefoot). Channel 305A may be disposed on the medial side of a respective bladder, while channel 305B may disposed on the lateral side of the respective bladder 124. Channel 305B may be slightly longer than channel 305A to account for the geometry of the forefoot. Forefoot portion 305 may be fluidly connected to the support 303. Channels 305A and 305B each may extend radially outward moving away from support 303 in the anterior direction. In other words, first channel 305A may extend along an angled path along the medial side of the article of footwear 10. Second channel 305B may extend along an angled path along the lateral side of the article of footwear 10. Channels 305A and 305B each may also include relatively straight portions that extend substantially parallel to central longitudinal axis A124. The straight portions of channels 305A and 305B are those portions of the respective channels closest to the anterior end of the bladder 124. The straight portion of channel 305B may extend further towards the anterior end of the bladder 124 than that of the straight portion of the channel 305A. Channels 305A and 305B may extend generally in opposite directions from one another from where they converge at the anterior end of support 303. In some embodiments, channels 305A and 305B may generally be mirror images of one another, when channels 305A and 305B have the same dimensions. Channels 305A and 305B may be further fluidly connected at multiple points via cross channel lines 315, 316, and 317. in some embodiments, these lines are substantially parallel to one another, and substantially perpendicular to the central longitudinal axis of the bladder 124. However, in other embodiments, it is contemplated that lines 315, 316, and/or 317 may be offset or non-parallel to one another. Additionally, cross channel lines 315-317 may be interconnected by one or more web area sections 309-311. In particular, web area section 309 may be disposed between cross channel line 315 and base 304. Web area section 310 may be disposed between cross channel line 315 and cross channel line 316. Web area section 311 may be disposed between cross channel line 316 and cross channel line 317. Web area section 312 may be disposed on a top side of cross channel line 317. In other words, web area section 312 may be disposed on an opposite side of cross channel line 305E from web area section 311.
Segments 301 and 302, the central support 303, fluid channels 314, the prong channels 305A and 305B, and the cross channel lines 315-317 may form an interconnected and enclosed volume, which contains an inflation fluid. However, it is also contemplated that one or more or all of the aforementioned portions of bladder 124 may be fluidly isolated from the other portions.
In an exemplary embodiment, the bladder 124 may further include an inflation zone 313 disposed on the web area section 312. Inflation zone 313 may represent the anterior-most end of the bladder 124 in the forefoot region 12. Inflation zone 313 may be configured to receive a pressurized fluid (i.e., gas, liquid) to provide cushioning and stability for the foot during use of the footwear 10. In some implementations, compressibility of a first portion of the bladder 124 under an applied load may provide a responsive-type cushioning, while a second portion of the bladder 124 may be configured to provide a soft-type cushioning under an applied load. Accordingly, the bladder 124 may provide gradient cushioning to the article of footwear 10 that changes as the applied load changes (i.e., the greater the load, the more the bladder 124 is compressed and, thus, the more responsive the footwear 10 performs).
Referring to
In an alternative embodiment, bladder 124 may include a polymer foam and/or particulate matter in one or more, or all, regions of the bladder 124 corresponding to the enclosed inner volume of the bladder 124. Specifically, the polymer foam and/or particulate matter may be present in segments 301 and 302, central support 303, base 304, forefoot portion 305, channels 305A and 305B, fluid channels 314, and/or channel connection lines 314-317 in place of, or in addition to, the pressurized fluid to provide cushioning for the foot. In these implementations, the cushioning materials may provide one or more of the segments 301 and 302, central support 303, base 304, forefoot portion 305, channels 305A and 305B, fluid channels 314, and/or channel connection lines 314-317 with cushioning properties different from the segments 301 and 302, central support 303, base 304, forefoot portion 305, channels 305A and 305B, fluid channels 314, and/or channel connection lines 314-317 filled with the pressurized fluid. For example, the cushioning materials may be more or less responsive or provide greater impact absorption than the pressurized fluid.
Referring to
Heel cushioning element 122 may have disposed on its top side a plateau 405, extending upward and away from a top surface 406. The bottom of plateau 405 may be completely surrounded by top surface 406 of the heel cushioning element 122. Top surface 406, thus, may form a flange configured to engage with the bottom surface of plate 121 when footwear 10 is fully-assembled. The height at which plateau 405 extends from top surface 406 may vary. Generally, plateau 405 may extend further (higher) from top surface 406 at its anterior-most regions, and may extend less (lower) from top surface 406 at its posterior-most regions.
Heel cushioning element 122 may have disposed on its bottom side one or more recesses 408A, 408B, and 408C (shown in
In an alternative embodiment, shown in
With continued reference to
Referring to
The mold 130 may be continuously exposed along the outer periphery of the sole structure from the heel region 16 to the forefoot region 12.
Referring to
Referring to
Plate 121 also may include at least two limbs 501 and 502 that protrude from an anterior surface 510 of plate 121 in the anterior direction. Limbs 501, 502, and anterior surface 510 may generally define a U-shaped or horseshoe-shaped boundary around a recess 509. Limbs 501 and 502 may extend from the mid-foot region 14 along the path defining the outer bounds of plate 121. Referring to
Plate 121 may further include a top surface 512, a bottom surface 513, and a sidewall 508. The plate 121 may have a thickness in the heel and mid-foot regions that is greater than a thickness in the forefoot region.
When article of footwear 10 is fully assembled, the recess 509 may extend from the mid-foot region of footwear 10 toward the forefoot region, and may terminate or end at the toe portion 12T.
The sidewall 508 may surround a substantial entirety of the plate 121. The sidewall 508 may extend vertically upward from the top surface 512 of the plate 121. Posterior end 503 may have a substantially bulbous shape corresponding to the sidewall 508. The outer bounds of plate 121 may be defined by a path of the sidewall 508. The path may further be defined by the bulbous posterior end and taper radially outward around the opening 507 and taper radially inward moving in the anterior direction from the opening 507. The path may gradually taper radially outward towards the limbs 501 and 502 and flatten out as it approaches the posterior end 503 of the plate 121 (e.g., the posterior-most portions of limbs 501 and 502 may be substantially flat).
In an alternative embodiment, shown in
Referring to
Upper cushioning element 120 may include an upper sidewall 604, an interior top surface (or interior surface) 610, a cavity 611, and a bottom surface 614. The medial side 22 and the lateral side 24 of the article of footwear 10 may laterally bound upper sidewall 604. The sidewall 604 may extend vertically upward from the interior surface 610. The top surface of sidewall 604 may be defined by an undulating path that slopes between a plurality of peaks and valleys from a posterior base 605 located in the heel region 16 to an anterior base 606 located in the forefoot region 12. The undulating path may have a more gradual slope from one of the peaks 602 to the anterior base 606. The sidewall 604 may be disconnected at the anterior base 606 and may have an area devoid of sidewall 604 at the anterior base 606 in order to accommodate the anterior portion of mold 130 when footwear 10 is assembled (see, e.g.,
Located between the posterior base 605 and the anterior base 606 may be an extension 607. Extension 607 may contact a first contact point 608 near the posterior base 606 and may contact a second contact point 609 near the anterior base 606. Extension 607 may be of the same material as upper cushioning element 120. In another embodiment, extension 607 may be a different material than that of cushioning element 120.
Upper sidewall 604 may bound the interior surface 610 of the upper cushioning element 120. Interior surface 610 may contain the cavity 611 that may be substantially ovular in shape. The shape of cavity 611 may correspond with the shape of opening 507, as cavity 611 also may be configured and dimensioned to receive a portion of plateau 405 when footwear 10 is assembled.
Referring to
In an alternative embodiment, shown in
Referring to
In other words, the bladder 124 may serve as the base of the stacked sole structure. The heel cushioning element 122 may be directly disposed on the top surface of bladder 124. The forefoot cushioning element 123 may be directly coupled to an anterior facing surface of the bladder 124. The plate 121 may be directly disposed on the top surface of bladder 124 in the forefoot region and may be disposed directly on the surface of heel cushioning element 122 in the heel region. Upper cushioning element 120 may be directly disposed on the top surface of the plate 121 in the forefoot and may be directly disposed on the top surface of heel cushioning element 122 in the heel, in some alternative embodiments. This ordered combination forms the stacked sole structure. However, it should be noted that other combinations also are contemplated. For example, in one embodiment, one or more of the aforementioned structures may be omitted from the stack. For example, forefoot cushioning element 123 may be omitted. In such an embodiment, the bladder and/or the plate may be extended in the anterior direction from what is shown in
Referring to
Referring to
Further, when viewing the sole structure along the exterior path of line B, the stacked sole structure may form an opening 801 in the mid-foot region. The opening 801 may be an area devoid of material formed between the plate 121 and the bladder 124. The opening 801 may leave exposed the upper barrier layer of bladder 124 and an exposed bottom surface 513 of plate 121. In other words, the assembled stacked sole may form a gap in the mid-foot between the plate 121 and the bladder 124 such that a viewer would see through this mid-foot portion of the stacked sole structure with an unobstructed view. In other words, when viewed from a vantage point that is exterior of the sole structure, the upper barrier layer of bladder 124 and the bottom surface 513 of plate 121 are open to the environment. The opening 801 may be substantially ovular in shape although other suitable shapes are contemplated, e.g., circular, rounded rectangular, irregular and the like. The opening 801 and the exposed surfaces of bladder 124 and exposed bottom surface 513 are exposed to or otherwise in fluid communication with the external environment/atmosphere exterior of the article of footwear 10.
While
Referring to
Referring to
Referring to
Referring to
One or both of the barrier layers 321 and 322 may independently be transparent, translucent, and/or opaque. As used herein, the term “transparent” for a barrier layer and/or a bladder means that light passes through the barrier layer in substantially straight lines and a viewer can see through the barrier layer. In comparison, for an opaque barrier layer, light does not pass through the barrier layer and one cannot see clearly through the barrier layer at all. A translucent barrier layer falls between a transparent barrier layer and an opaque barrier layer, in that light passes through a translucent layer but some of the light is scattered so that a viewer cannot see clearly through the layer.
The barrier layers of bladder 124 may each be produced from an elastomeric material that includes one or more thermoplastic polymers and/or one or more cross-linkable polymers. In an aspect, the elastomeric material can 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 oligomers) that contains a urethane group (—N(C═O)O—). These polyurethanes can contain additional groups such as ester, ether, urea, allophanate, biuret, carbodiimide, oxazolidinyl, isocynaurate, uretdione, carbonate, and the like, in addition to urethane groups. In an aspect, one or more of the polyurethanes can be produced by polymerizing one or more isocyanates with one or more polyols to produce copolymer chains having (—N(C═O)O—) linkages.
Examples of suitable isocyanates for producing the 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 with 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-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 particular aspects, the polyurethane polymer chains are produced from diisocynates including HMDI, TDI, MDI, H12 aliphatics, and combinations thereof. In an aspect, the thermoplastic TPU can include polyester-based TPU, polyether-based TPU, polycaprolactone[1]based TPU, polycarbonate-based TPU, polysiloxane-based TPU, or combinations thereof.
In another aspect, the polymeric layer can be formed of one or more of the following: 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, polyacrylic imides, and other polymeric materials known to have relatively low gas transmission rates. Blends of these materials, as well as with the TPU copolymers described herein and optionally including combinations of polyimides and crystalline polymers, are also suitable.
The plate 121 may be formed of one or more pliable materials having a durometer that may be less than the durometer of the upper cushioning element 120 and/or equal to the durometer of the cushioning elements 122 and 123. For example, upper cushioning element 120 may be formed of CMP-004 (54-54 Asker C), plate 121 may be formed of Estane 385A, heel cushioning element 122 may be formed of Cushion LU/FO 035 (52-56 Asker C), and forefoot cushioning element 123 may be formed of IP 004 (57-61 Asker C), although other suitable materials also are contemplated.
One or more of the cushioning elements 120, 122, and 123 may be formed of a resilient polymeric material, such as foam or rubber, to impart properties of cushioning, responsiveness, and energy distribution to the foot of the wearer. In the illustrated example, the upper cushioning element 120 may be formed of a first foam material, the heel cushioning element 122 may be formed of a second foam material, and the forefoot cushioning element 123 may formed of a third foam material. The heel cushioning element 122 and the forefoot cushioning element 123 may be formed of the same foam material. For example, the upper cushioning element 120 may be formed of a first foamed material having a first durometer, the heel cushioning element 122 may be formed of a second foamed material having a second durometer that may be less than the first durometer. The forefoot cushioning element 123 may be formed of a third material having a third durometer that may be less than the first durometer and the second durometer. The heel cushioning element 122 and the forefoot cushioning element 123 may include a foamed material that may have the same durometer. The cushioning elements 120, 122, and 123 may be affixed within the sole structure using a fusing process, using an adhesive, or by suspending the elements in a different resilient polymeric material. As discussed above, the cushioning elements 120, 122, and 123 may be formed with cooperating geometries (e.g., steps, protrusions) for restricting relative motion between the cushioning elements 120, 122, and 123 and the sole structure.
Example resilient polymeric materials for the cushioning elements 120, 122, and 123 may include those based on foaming or molding one or more polymers, such as one or more elastomers (e.g., thermoplastic elastomers (TPE)). The one or more polymers may include aliphatic polymers, aromatic polymers, or mixtures of both; and may include homopolymers, copolymers (including terpolymers), or mixtures of both.
In some aspects, the one or more polymers may include olefinic homopolymers, olefinic copolymers, or blends thereof. Examples of olefinic polymers include polyethylene, polypropylene, and combinations thereof. In other aspects, 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 aspects, 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; including derivatives thereof, copolymers thereof, and any combinations thereof.
In yet further aspects, the one or more polymers may include one or more ionomeric polymers. In these aspects, the ionomeric polymers may include polymers with carboxylic acid functional groups, sulfonic acid functional groups, salts thereof (e.g., sodium, magnesium, potassium, etc.), and/or anhydrides thereof. For instance, the ionomeric polymer(s) may include one or more fatty acid-modified ionomeric polymers, polystyrene sulfonate, ethylene-methacrylic acid copolymers, and combinations thereof.
In further aspects, the one or more polymers may include one or more styrenic 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 aspects, the one or more polymers may include 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 include one or more natural and/or synthetic rubbers, such as butadiene and isoprene.
When the resilient polymeric material is a foamed polymeric material, the foamed material may be foamed using a physical blowing agent which phase transitions to a gas based on a change in temperature and/or pressure, or a chemical blowing agent which forms a gas when heated above its activation temperature. For example, the chemical blowing agent may be an azo compound such as adodicarbonamide, sodium bicarbonate, and/or an isocyanate.
In some embodiments, the foamed polymeric material may be a crosslinked foamed material. In these embodiments, a peroxide-based crosslinking agent such as dicumyl peroxide may be used. Furthermore, the foamed polymeric material may include one or more fillers such as pigments, modified or natural clays, modified or unmodified synthetic clays, talc glass fiber, powdered glass, modified or natural silica, calcium carbonate, mica, paper, wood chips, and the like.
The resilient polymeric material may be formed using a molding process. In one example, when the resilient polymeric material is a molded elastomer, the uncured elastomer (e.g., rubber) may be mixed in a Banbury mixer with an optional filler and a curing package such as a sulfur-based or peroxide-based curing package, calendared, formed into shape, placed in a mold, and vulcanized.
In another example, when the resilient polymeric material is a foamed material, the material may be foamed during a molding process, such as an injection molding process. A thermoplastic polymeric material may be melted in the barrel of an injection molding system and combined with a physical or chemical blowing agent and optionally a crosslinking agent, and then injected into a mold under conditions which activate the blowing agent, forming a molded foam.
Optionally, when the resilient polymeric material is a foamed material, the foamed material may be a compression molded foam. Compression molding may be used to alter the physical properties (e.g., density, stiffness and/or durometer) of a foam, or to alter the physical appearance of the foam (e.g., to fuse two or more pieces of foam, to shape the foam, etc.), or both.
The compression molding process desirably starts by forming one or more foam preforms, such as by injection molding and foaming a polymeric material, by forming foamed particles or beads, by cutting foamed sheet stock, and the like. The compression molded foam may then be made by placing the one or more preforms formed of foamed polymeric material(s) in a compression mold, and applying sufficient pressure to the one or more preforms to compress the one or more preforms in a closed mold. Once the mold is closed, sufficient heat and/or pressure is applied to the one or more preforms in the closed mold for a sufficient duration of time to alter the preform(s) by forming a skin on the outer surface of the compression molded foam, fuse individual foam particles to each other, permanently increase the density of the foam(s), or any combination thereof. Following the heating and/or application of pressure, the mold is opened and the molded foam article is removed from the mold.
As set forth above, the sole structure 101 of the present disclosure may advantageously provide layered cushioning in combination with a flexible support plate while simultaneously providing a new aesthetic. Particularly, the sole structure may provide layered cushioning by including a stack structure in the heel and forefoot regions. This configuration may provide improved impact attenuation associated with a heel strike during walking. The sole structure 101 may provide heel layered cushioning by providing an upper cushioning element 120 in layered arrangement with the plate 121, heel cushioning element 122, and bladder 124 in the heel region. The sole structure 101 may provide forefoot layered cushioning by providing an upper cushioning element 120 in layered arrangement with the plate 121 and bladder 124 in the forefoot region. Thus, the sole structure 101, having heel and forefoot layered cushioning, may provide underfoot cushioning. Providing a full-length plate 121 between the upper cushioning element 120 and the bladder 124 may further increase stability within the sole structure 101. Altogether, these features may cooperate to provide a desirable configuration for articles of footwear associated with long periods of standing and walking. Additionally, the desirable configuration for articles of footwear may be associated with a woman's foot structure.
The following Clauses provide an exemplary configuration for an article of footwear and sole structure described above.
The following Clauses provide an exemplary configuration for an article of footwear and sole structure as described above.
Clause 1. A sole structure for an article of footwear, the sole structure comprising a forefoot region disposed adjacent an anterior end; a heel region disposed adjacent a posterior end; a bottom cushion extending from the heel region to the forefoot region; a heel cushion coupled to a top surface of the bottom cushion in the heel region; a support plate coupled to a) a top surface of the heel cushion in the heel region, and b) a top surface of the bottom cushion in the forefoot region; and a top cushion coupled to a top surface of the support plate.
Clause 2. The sole structure of clause 1, wherein the bottom cushion is a fluid-filled bladder.
Clause 3. The sole structure of clause 2, wherein the fluid-filled bladder includes a first segment in the heel region, the first segment containing a fluid-filled hollow interior, the first segment being concave when viewed from a central longitudinal axis of the bladder; and a second segment in the heel region disposed on an opposite side of the central longitudinal axis than the first segment, the second segment containing a fluid-filled hollow interior, the second segment being concave when viewed from the central longitudinal axis of the bladder.
Clause 4. The sole structure of clause 3, wherein the fluid-filled bladder further includes a central support disposed laterally between the first segment and the second segment in the heel region, the central support containing a fluid-filled hollow interior, wherein the central support extends to a midfoot region of sole structure, to a position anterior of anterior-most portions of the first segment and the second segment.
Clause 5. The sole structure of clause 4, wherein the fluid-filled bladder further includes a first prong extending from an anterior end of the central support, wherein the first prong has 1) a first section that extends radially outward in an anterior direction, and 2) a second section extending anterior to an anterior end of the first section, wherein the second section is substantially parallel to the central longitudinal axis.
Clause 6. The sole structure of clause 5, wherein the fluid-filled bladder further includes a second prong extending from an anterior end of the central support, wherein the first prong has 1) a first section that extends radially outward in the anterior direction, and 2) a second section extending anterior to an anterior end of the first section, wherein the second section is substantially parallel to the central longitudinal axis, wherein the first prong and the second prong extend in opposite directions relative to the central longitudinal axis.
Clause 7. The sole structure of clause 4, wherein outer surfaces of the central support are laterally-outermost portions of the bladder in the midfoot region.
Clause 8. The sole structure of clause 2, wherein the fluid-filled bladder includes an exposed upper surface when the sole structure is in a fully-assembled configuration.
Clause 9. The sole structure of clause 8, wherein the exposed upper surface is not directly connected to any other material.
Clause 10. The sole structure of clause 8, wherein the exposed upper surface is disposed in a midfoot region of the sole structure.
Clause 11. The sole structure of clause 8, wherein the exposed upper surface is visible from a vantage point that is exterior of the sole structure.
Clause 12. The sole structure of clause 8, wherein the exposed upper surface is open to the environment exterior of the article of footwear.
Clause 13. The sole structure of clause 1, wherein along a first path of an exterior of the sole structure, the heel region is arranged from a bottom to a top of the article, to include the bottom cushion; the heel cushion; the support plate; and the top cushion.
Clause 14. The sole structure of clause 13, wherein along a second path of the exterior of the sole structure, a midfoot region is arranged from the bottom to the top of the article, to include the bottom cushion, wherein the bottom cushion includes an exposed upper surface in the midfoot region when the sole structure is fully assembled; a gap that is open to the external environment, the gap being defined at a bottom end by the exposed upper surface of the bottom cushion; the support plate; and the top cushion.
Clause 15. The sole structure of clause 14, wherein along a third path of the exterior of the sole structure, the forefoot region is arranged from the bottom to the top of the article, to include a forefoot cushion; the support plate; and the top cushion.
Clause 16. The sole structure of clause 15, wherein along the second path, the heel cushion and the forefoot cushion are absent.
Clause 17. The sole structure of clause 15, wherein along the third path, the bottom cushion is absent.
Clause 18. The sole structure of clause 15, wherein along a fourth path of the exterior of the sole structure that is posterior to the third path, the forefoot region is arranged from the bottom to the top of the article, to include the bottom cushion; the support plate; and the top cushion.
Clause 19. The sole structure of clause 18, wherein along the fourth path, the heel cushion and the forefoot cushion are absent.
Clause 20. The sole structure of clause 15, wherein along a fifth path of the exterior of the sole structure that is anterior to the third path, the forefoot region is arranged from the bottom to the top of the article, to include the forefoot cushion; and the top cushion.
Clause 21. The sole structure of clause 20, wherein along the fifth path, the bottom cushion, the heel cushion, and the plate are absent.
Clause 22. A sole structure for an article of footwear, the sole structure comprising a forefoot region disposed adjacent an anterior end; a heel region disposed adjacent a posterior end; a mid-foot region disposed intermediate the forefoot region and the heel region, wherein along a first path of the exterior of the sole structure, the heel region is arranged from a bottom to a top of the article, to include a bottom cushion; a heel cushion; a support plate; and a top cushion.
Clause 23. The sole structure of clause 22, wherein along a second path of the exterior of the sole structure, the mid-foot region is arranged from the bottom to the top of the article, to include the bottom cushion, wherein the bottom cushion includes an exposed upper surface in the mid-foot region when the sole structure is fully assembled; a gap that is open to the external environment, the gap being defined at a bottom end by the exposed upper surface of the bottom cushion; the support plate; and the top cushion.
Clause 24. The sole structure of clause 23, wherein along a third path of the exterior of the sole structure, the forefoot region is arranged from the bottom to the top of the article, to include a forefoot cushion; the support plate; and the top cushion.
Clause 25. The sole structure of clause 24, wherein along a fourth path of the exterior of the sole structure that is posterior to the third path, the forefoot region is arranged from the bottom to the top of the article, to include the bottom cushion; the support plate; and the top cushion.
Clause 26. The sole structure of clause 25, wherein along a fifth path of the exterior of the sole structure that is anterior to the third path, the forefoot region is arranged from the bottom to the top of the article, to include the bottom cushion; and the top cushion.
Clause 27. The sole structure of clause 24, wherein along the second path, the heel cushion and the forefoot cushion are absent.
Clause 28. The sole structure of clause 24, wherein along the third path, the bottom cushion is absent.
Clause 29. The sole structure of clause 25, wherein along the fourth path, the heel cushion and the forefoot cushion are absent.
Clause 30. The sole structure of clause 26, wherein along the fifth path, the bottom cushion, the heel cushion, and the plate are absent.
Clause 31. A sole structure for an article of footwear, the sole structure comprising a forefoot region disposed adjacent an anterior end; a heel region disposed adjacent a posterior end; a mid-foot region disposed intermediate the forefoot region and the heel region, wherein when viewed externally from the article, the mid-foot region is arranged from a bottom to a top of the article, to include a bottom cushion; a gap that is open to the external environment; a support plate; and a top cushion.
Clause 32. The sole structure of clause 31, wherein the bottom cushion includes a fluid-filled bladder.
Clause 33. A sole structure for an article of footwear, the sole structure comprising a fluid-filled bladder extending from a heel region to a forefoot region of the sole structure, wherein the fluid-filled bladder includes an exposed upper surface when the sole structure is in a fully-assembled configuration.
Clause 34. The sole structure of clause 33, wherein the exposed upper surface is not directly connected to any other material.
Clause 35. The sole structure of clause 33, wherein the exposed upper surface is disposed in a midfoot region of the sole structure.
Clause 36. The sole structure of clause 33, wherein the exposed upper surface is visible from a vantage point that is exterior of the sole structure.
Clause 37. A bladder for a sole structure of an article of footwear, the bladder comprising a first segment in a heel region, the first segment containing a fluid-filled hollow interior, the first segment being concave when viewed from a central longitudinal axis of the bladder; a second segment in the heel region disposed on an opposite side of the central longitudinal axis than the first segment, the second segment containing a fluid-filled hollow interior, the segment being concave when viewed from the central longitudinal axis of the bladder; a central support disposed laterally between the first segment and the second segment in the heel region, the central support containing a fluid-filled hollow interior, wherein the central support extends to a midfoot region of bladder, to a position anterior of anterior-most portions of the first segment and the second segment.
Clause 38. The bladder of clause 37, further including a first prong extending from an anterior end of the central support, wherein the first prong has 1) a first section that extends radially outward in the anterior direction, and 2) a second section extending anterior to an anterior end of the first section, wherein the second section is substantially parallel to the central longitudinal axis
Clause 39. The bladder of clause 38, further including a second prong extending from an anterior end of the central support, wherein the first prong has 1) a first section that extends radially outward in the anterior direction, and 2) a second section extending anterior to an anterior end of the first section, wherein the second section is substantially parallel to the central longitudinal axis
Clause 40. The bladder of clause 37, wherein outer surfaces of the central support are laterally-outermost portions of the bladder in the midfoot region.
Clause 41. The bladder of clause 37, wherein a lateral width of a narrowest portion of the bladder is from about 10% to about 50% of a lateral width of a widest section of the heel region of the sole structure.
Clause 42. The bladder of clause 39, wherein the first segment, the second segment, the central support, the first prong, and the second prong collectively form an interconnected enclosed hollow area containing a fluid.
Clause 43. An article of footwear comprising an upper; and a sole structure, as in one of clauses 1-21, attached to the upper.
Clause 44. An article of footwear comprising an upper; and a sole structure, as in one of clauses 22-30, attached to the upper.
Clause 45. An article of footwear comprising an upper; and a sole structure, as in clause 31 or 32, attached to the upper.
Clause 46. An article of footwear comprising an upper; and a sole structure, as in one of clauses 33-36, attached to the upper.
Clause 47. An article of footwear comprising an upper; and a sole structure attached to the upper, the sole structure including a bottom cushion, a heel cushion, a support plate, and a top cushion.
Clause 48. The article of footwear of clause 46, wherein the bottom cushion extends from a heel region to a forefoot region.
Clause 49. The article of footwear of clause 46, wherein the heel cushion is coupled to a top surface of the bottom cushion in a heel region.
Clause 50. The article of footwear of clause 46, wherein the support plate is coupled to 1) a top surface of the heel cushion in a heel region, and 2) a top surface of the bottom cushion in a forefoot region.
Clause 51. The article of footwear of clause 46, wherein the top cushion is coupled to a top surface of the support plate.
Clause 52. An article of footwear comprising an upper; a sole structure attached to the upper, wherein the sole structure includes a bottom cushion, a heel cushion, a support plate, a top cushion, and a gap; and a heel counter extending around a posterior end of the upper from one or more contact portions to an apex.
Clause 53. An article of footwear comprising an upper; and a sole structure attached to the upper, wherein the sole structure is arranged in a heel region from a bottom to a top of the article of footwear to include: a bottom cushion, a heel cushion, a support plate, and a top cushion.
Clause 54. An article of footwear comprising an upper; and a sole structure attached to the upper, wherein the sole structure is arranged in a mid-foot region from a bottom to a top of the article of footwear to include: a bottom cushion, a gap open to the external environment, a support plate, and a top cushion.
Clause 55. An article of footwear comprising an upper; and a sole structure attached to the upper, wherein the sole structure includes a fluid-filled bladder extending from a heel region to a forefoot region of the sole structure, wherein the fluid-filled bladder includes an exposed upper surface when the sole structure is in a fully-assembled configuration.
Clause 56. An article of footwear comprising an upper; and a sole structure attached to the upper, the sole structure including a bottom cushion, a heel cushion, a support plate, a top cushion, wherein one or more of the bottom cushion, the heel cushion, the support plate, and the top cushion are each formed of one or more different materials.
The foregoing description has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular configuration are generally not limited to that particular configuration, but, where applicable, are interchangeable and can be used in a selected configuration, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.
This application claims priority to U.S. Provisional Application No. 63/290,236, filed Dec. 16, 2021, the entirety of which is incorporated herein by reference.
Number | Date | Country | |
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63290236 | Dec 2021 | US |