SOLE ASSEMBLY FOR ARTICLE OF FOOTWEAR

Abstract

A sole assembly including an outsole and a midsole that balances proprioception, flexibility, protection and running efficiency. The midsole can define a flexibility void in the arch region of the assembly. The outsole can include ground contacting wearing tread extending through the arch region adjacent the flexibility void, with the outsole minimized adjacent the flexibility void to enhance flexibility, along with the flexibility void, in the arch region. The sole assembly can include a 4 mm to 8 mm or other heel to toe drop to accommodate a variety of running and other activities. The sole assembly can be outfitted with shock pods of denser, more rigid material than the midsole to dissipate forces from the wearer to the midsole over a larger area. The midsole can include a non-supportive upwardly extending portion in the arch to provide a wearer with the false perception that the arch is supported to reduce fatigue.

Description

BACKGROUND OF THE INVENTION

The present invention relates to footwear, and more particularly to a sole assembly for an article of footwear.

The technical performance of shoes, boots, sandals and other articles of footwear is dependent in large part on the sole assembly. This is particularly true in the field of running shoes, where footwear manufacturers cater to the needs of runners, but usually at either one of two extremes. For example, there are a number of sole assemblies that are designed to provide a protective barrier between the wearer's foot and the ground. This can be desired when the shoes are designed for running or traversing rugged trails, or alternatively hard surfaced sidewalks and roads. These sole assemblies often also are quite supportive of the wearer's foot. With the added protection and support, such sole assemblies usually are lacking in ground feel and flexibility. Sometimes, they can actually impair running efficiency.

At the other extreme, there are a number of shoes that offer a barefoot-like running feel, with significant flexibility due to a minimalist construction. The sole assemblies of these footwear typically offer very little protection, support and cushioning. Many times, the only thing between a running surface and the wearer's foot is a thin rubber sole layer. Indeed, even the tread on these types of shoes can be lacking in an effort to save weight. This can come at the cost of reduced traction.

Further, with many barefoot running shoes, the effort to save weight comes at the expense of reduced ground contact through the arch. Frequently, barefoot running shoes are configured so that the ground contacting tread only contacts the ground in the heel and forefoot with the tread in the midfoot not contacting the ground. In some cases, this can leave some metatarsals, particularly the supportive outer/medial metatarsal unsupported, which can lead to balance and/or stability issues, particularly when running off road or on earthen trails. This can also cause the wearer's arch or midfoot to fatigue more easily.

Although there are many existing sole technologies for different types of activities, most are designed for only one of opposing extremes due to mutually competing characteristics like flexibility and protection or support.

SUMMARY OF THE INVENTION

A sole assembly is provided that balances proprioception, flexibility, protection and running efficiency via a thoughtful construction including a midsole and an outsole.

In one embodiment, the sole assembly can include an outsole and a midsole. The sole assembly generally can be divided into a forefoot, an arch or midfoot, and a heel. The midfoot can include a flexibility void that adds mobility and flexibility to the arch region of the sole assembly.

In another embodiment, the sole assembly can be structured so that the outsole in the midfoot is minimized, and the midsole wraps upward adjacent a medial portion of a wearer's arch to provide structure without adding significant weight.

In still another embodiment, the midsole can be constructed to provide an upwardly extending portion in the midfoot to fill an underfoot void under the wearer's arch, generally following the natural contours of the wearer's foot. The upwardly extending portion, and the midsole itself through the midfoot, can be constructed from a soft, low density material. With this construction, the midsole in the arch may not offer actual substantial physical support to the wearer's arch, but instead can provide a level of sensory contact to the underside of the wearer's arch so that the arch muscles and nerves falsely perceive actual support. In turn, perceiving this support, the arch can relax somewhat in a natural gait cycle, thereby reducing arch fatigue over extended periods of activity.

In yet another embodiment, the sole assembly in the midfoot is constructed so that the outsole includes an arch stabilizer through the midfoot. This arch stabilizer can include a ground contacting portion, which can extend between the heel and the forefoot, to offer ground contact through the midfoot.

In even another embodiment, the sole assembly arch stabilizer can be located adjacent the flexibility void, with the flexibility void extending across part of the width of the sole assembly, and the arch stabilizer extending across the remainder of the width of the sole assembly through the midfoot of the sole assembly.

In a further embodiment, the sole assembly can be configured with a particular heel to toe drop to provide enhanced cushioning for trail running or other activities where the wearer's gait may include increased heel strike. The heel to toe drop can be sufficient to provide additional cushioning for shock absorption and energy return. The heel to toe drop can range optionally from about 0.0 mm to about 10.0 mm, further optionally about 4.0 mm to about 8.0 mm, even further optionally about 5.0 mm to about 7.0 mm and yet further optionally about 6.0 mm.

In still a further embodiment, the sole assembly can include shock pods positioned in the heel and/or forefoot, under the ball of the foot. The midsole can be constructed from a first material of a first density, and the shock pods can be constructed from a second material of a second density. The second density can be greater than the first density. The shock pods can dissipate forces from the heel and/or forefoot over a larger area of the midsole, and optionally can provide more firm ground feedback to the wearer. In some cases, the shock pods offer a more stable support platform in the forefoot and/or heel as well.

In even a further embodiment, the sole assembly of can be incorporated into a footwear construction and can be combined with other sole components, such as an insole and/or footbed. The sole assembly and associated outsole parts can be cemented or otherwise secured to the undersurface of upper having a closed bottom.

The present invention provides a sole assembly having a balance of enhanced protective structure, mobility and proprioception. Further, the flexibility imparted through the arch, as well as the overall stability of the sole assembly, can enhance running efficiency and comfort to the wearer. In addition, the sole assembly can provide improved impact protection on rugged or hard surfaces.

These and other objects, advantages, and features of the invention will be more fully understood and appreciated by reference to the description of the current embodiment and the drawings.

Before the embodiments of the invention are explained in detail, it is to be understood that the invention is not limited to the details of operation or to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. The invention may be implemented in various other embodiments and of being practiced or being carried out in alternative ways not expressly disclosed herein. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of “including” and “comprising” and variations thereof is meant to encompass the items listed thereafter and equivalents thereof as well as additional items and equivalents thereof. Further, enumeration may be used in the description of various embodiments. Unless otherwise expressly stated, the use of enumeration should not be construed as limiting the invention to any specific order or number of components. Nor should the use of enumeration be construed as excluding from the scope of the invention any additional steps or components that might be combined with or into the enumerated steps or components.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of footwear including a sole assembly in accordance with a current embodiment;

FIG. 2 is a side view of medial side of the sole assembly;

FIG. 3 is a side view of a lateral side of the sole assembly;

FIG. 4 is a bottom view of the sole assembly;

FIG. 5 is an exploded perspective view of the footwear including the sole assembly;

FIG. 6 is a section view of the sole assembly taken along line 6-6 of FIG. 4;

FIG. 7 is a section view of the sole assembly taken along line 7-7 of FIG. 4;

FIG. 8 is a section view of the sole assembly taken along line 8-8 of FIG. 4;

FIG. 9 is a section view of the sole assembly taken along line 9-9 of FIG. 4;

FIG. 10 is a section view of the sole assembly taken along line 10-10 of FIG. 4;

FIG. 11 is a section view of the sole assembly taken along line 11-11 of FIG. 4; and

FIG. 12 is a section view of the sole assembly taken along line 12-12 of FIG. 4.

DETAILED DESCRIPTION OF THE CURRENT EMBODIMENTS

An article of footwear in accordance with a current embodiment is shown in FIGS. 1-12 and generally designated 10. The footwear includes a sole assembly 20 having a midsole 30 and outsole 40. The footwear 10 generally includes an upper assembly 12 that is optionally of a Strobel construction in which a foot-receiving upper 14 is closed on its bottom or lowermost portion by a Strobel board, an insole board, sock or liner 15 or other similar component. Although not shown, the footwear 10 can include a footbed and/or other upper components with the footbed fitted into the upper 10.

As illustrated in FIGS. 2, 4 and 6, the sole assembly generally includes a flexibility void 50 that is largely defined through the arch region 82 as described below. The sole assembly 20 can include an arch stabilizer 60 which can include a ground contacting portion 62 optionally in the form of wearing tread 46, optionally having one or more lugs that is adapted to engage the ground 6 when a wearer stands thereon. The sole assembly 20 also can include a heel-to-toe drop differential of optionally about 4.0 mm to about 8.0 mm, further optionally, about 6.0 mm as shown in FIG. 6. That heel-to-toe drop can be the difference between the thickness measurements T1 and T2 in the respective forefoot and heel. The midsole 30 can define one or more recesses 51 and 52 in the forefoot region and the heel region. In these recesses, shock pods 51A and 52A can be disposed. The shock pods can be constructed from a material that is denser and firmer and/or more rigid than the material from which the midsole is constructed. This can transmit forces generated by the user's forefoot and/or heel impacting those shock pods to be dissipated over a larger surface area on the upper surface 31 of the midsole and the midsole 30 in general. The shock pods also can provide a firmer feel to the areas where the user's foot and heel contact the sole assembly 20.

Although the current embodiments are illustrated in the context of an athletic or running shoe, they may be incorporated into any type or style of footwear, including performance shoes, hiking shoes, trail shoes and boots, hiking boots, all-terrain shoes, barefoot running shoes, sneakers, conventional tennis shoes, walking shoes, multisport footwear, casual shoes, dress shoes or any other type of footwear or footwear components. It also should be noted that directional terms, such as “vertical,” “horizontal,” “top,” “bottom,” “upper,” “lower,” “inner,” “inwardly,” “outer” and “outwardly,” are used to assist in describing the invention based on the orientation of the embodiments shown in the illustrations. Further, the terms “medial,” “lateral” and “longitudinal” are used in the manner commonly used in connection with footwear. For example, when used in referring to a side of the shoe, the term “medial” refers to the inward side (that is, the side facing the other shoe) and “lateral” refers to the outward side. When used in referring to a direction, the term “longitudinal direction” refers to a direction generally extending along the length of the shoe between toe and heel, and the term “lateral direction” refers to a direction generally extending across the width of the shoe between the medial and lateral sides of the shoe. The use of directional terms should not be interpreted to limit the invention to any specific orientation.

Further, as used herein, the term “arch region” (or arch or midfoot) refers generally to the portion of the footwear or sole assembly corresponding to the arch or midfoot of the wearer's foot; the term “forefoot region” (or forefoot) refers generally to the portion of the footwear forward of the arch region corresponding to the forefoot (for example, including the ball and the toes) of a wearer's foot; and the term “heel region” (or heel) refers generally to that portion of the footwear rearward of the arch region corresponding to the heel of the wearer's foot. The forefoot 81, arch or midfoot 82 and heel 83 are generally identified in FIG. 2, however, it is to be understood that delineation of these regions may vary depending upon the configuration of the sole assembly and footwear.

For purposes of disclosure, the embodiments herein are described in connection with footwear 10 in the form of a running or athletic shoe 10 having an upper assembly 12, which as mentioned above, can include a Strobel construction. Of course, the sole assembly 20 herein can be combined with any other type or style of upper construction capable of being suitably joined with the sole assembly 20. The joining of the sole assembly and the upper can be accomplished using adhesives, cement, injection molding, pour molding or any other technique used to join an upper and sole. As illustrated, the insole board or liner 15 can rest or be placed immediately adjacent the midsole upper surface 31 and shock pods 51A and 52A, if optionally included in the construction.

The sole assembly 20 can be of a two-piece construction as mentioned above, generally including the midsole 30 and outsole 40. The midsole 30 can be constructed from a material having a first density that is generally less dense than the density of the outsole 40. The first density can optionally be about 1 pound per cubic foot to about 20 pounds per cubic foot, and further optionally about 2 pounds per cubic foot to about 12 pounds per cubic foot, even further optionally about 11.86 pounds per cubic foot, yet further optionally about 12.49 pounds per cubic foot, or other densities depending on the application. Generally the first density of the midsole is such that it compresses relatively easily to provide cushion to the wearer's foot. The midsole first material also can have a first durometer, optionally about 35 Asker C to about 55 Asker C, further optionally about 42 Asker C to about 48 Asker C, and even further optionally about 45 Asker C or about 43 Asker C. The midsole can be constructed from ethyl vinyl acetate (EVA), polyurethane, latex, foam, a gel or other materials.

The midsole 30 can include an upper surface 31 and an opposing lower surface 32. Generally, the upper surface 31 can be joined directly to the closure 15 of the upper assembly 12. The upper surface 31 can be contoured to closely follow the natural contours of the bottom of a wearer's foot. For example, in the heel region 83, the midsole 30 can include a heel cup 55 that generally extends around and receives a wearer's heel therein when the footwear is worn by a wearer. The heel cup 55 can include an upwardly extending flange 56 that is a substantially continuous wall bounding and surrounding the rearward portion of the wearer's heel. This upwardly extending flange or wall 56 also can extend upwardly along the lowermost portion 16 of the upper assembly 12 when the upper is joined with the sole assembly 20. The wall 56 can extend upwardly optionally about 1.0 mm to about 10.0 mm, further optionally about 2.0 mm to about 6.0 mm, or other distances as desired. The wall 56 can offer some reinforcing support to the upper in the heel region, and generally prevent lateral or medial rolling of the heel.

The outsole 40 can be disposed below the midsole 30 and the upper 12. The outsole 40 can be constructed from one or more materials, and the current embodiment can be constructed from a mixture of foam and rubber. Alternatively, it can be constructed from a thermoplastic polyurethane elastomer (TPU), nylon or other polymer blend that includes nylon and/or TPU. Of course, the outsole can be constructed from any relatively wear resistant polymer, elastomer and/or natural or synthetic rubber or other materials capable of providing the desired functional characteristics. The outsole also can be constructed to include thermoplastic elastomers and/or thermalset elastomers. Other materials such as fiber-reinforced polymers can be used. These can include epoxy, polyethylene, polyester, thermosetting plastic reinforced with carbon, glass and/or aramid fibers.

The outsole 40 can include multiple lugs or cleats 47. The lugs 47 can be in the form of cylindrical bodies with texture or surface features at the portion of them which engage the ground. The outsole 40 can also include a flex contour 48 as shown in FIGS. 4 and 6. This flex contour 48 can generally disposed forward of the forefoot, between the ball of the foot and the toes, to enable the toes to flex independently and more easily relative to the ball of the foot. Generally, the flex contour 48 can be a region where the thickness of the outsole is reduced relative to the thickness of the outsole in the ball of the foot and/or the toes.

The outsole 40 also can include a toe flexing contour 49A. This toe flexing contour 49A can divide the outsole into toe pods 49B and 49C (FIG. 4). The toe pods generally can correspond to the big toe and the four smaller toes of a wearer's foot to allow these toes to flex independently of one another providing a more natural feel to the wearer. The toe contour 49A can be a reduced thickness portion of the outsole, similar to the flex contour 48. Indeed, the toe contour 49A and flex contour 48 can be of a same or similar thickness, that is less than the remaining portion of the outsole. These two contours can also intersect one another in the forefoot 81 region of the footwear 10.

As further shown in FIG. 5, the upper surface 31 of the midsole 30 can define a first recess 51 in the forefoot 81 and a second recess 52 in the heel 83. These recesses can be separate or independent as illustrated, or optionally they can be a single continuous recess extending from the heel to the forefoot, optionally passing through the arch. Sometimes, however, this can add rigidity to the sole assembly 20 which can counter flexibility.

As illustrated, the recess 51 can be an oval shape, although other shapes such as rectangular, triangular, trapezoidal, polygonal or other shapes may be selected. The position of the recess 51 is such that when the shock pod 51A is placed in it, the shock pod is disposed directly under the metatarsal heads, generally at the metatarsal/phalanges joint or under the ball of the wearer's foot. The recess 51 and associated shock pod 51A can extend laterally outward toward the lateral side L and medial side M of the sole assembly 20, which are disposed on opposite sides of the longitudinal axis LA (FIG. 4) of the sole assembly 20.

Optionally, the recess 51can be structured so that the upper surfaces of the shock pod 51A lays flush with the upper surface 31 of the midsole 30. Of course, if desired, these surfaces may be slightly offset. The shock pod 51A can be of a shape corresponding to the recess and disposed in the recess 51. If desired, the shock pod 51A can be adhered, glued or otherwise fastened within the recess. Alternatively, it can simply lay loose within the recess, trapped between the midsole and the closure 15 of the upper assembly 12.

The midsole 30 can define a separate independent second recess 52 in the heel 83 as mentioned above. This recess can be similar to the recess 51 in the forefoot 81 but generally positioned under the heel. The recess 52 can be defined within the perimeter of the wall 56 of the heel cup 55. The recess 52 also can extend generally more longitudinally along the longitudinal axis LA (FIG. 4) and can be of a shorter width than length along that longitudinal axis LA. The recess 52 is shown as a generally oval shape, but can be of other shapes depending on the application. The shock pod 52A can be of a like or similar construction, and can fit within the recess 52 in a manner similar to that described with regard to the first recess 51 and shock pod 51A.

The shock pods 51A and 52A can be constructed from a second material having a density that is different from the first density of the first material from which the midsole 30 is constructed. For example, the second density of the shock pods can be greater than the first density of the midsole. The second density can be greater than the first density by at least about 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 100%, 150%, 200% or more depending on the application. The second density can range from optionally from about 1.5 pounds per cubic foot to about 25 pounds per cubic foot, further optionally about 3 pounds per cubic foot to about 15 pounds per cubic foot, even further optionally about 16.23 pounds per cubic foot or other densities depending on the application. In general, the greater density enables the shock pods 51A and 52A to be more rigid and structurally firm than the midsole 30. This enables the shock pods to provide generally stable platforms in the forefoot and/or heel for the user to place the ball of their foot and/or heel upon. In turn, this can provide a firmer feel of the sole assembly against the bottom of the user's foot. It also can provide more protection and more firm feedback to the wearer, particularly when the wearer lands on the ball of their foot or forefoot in their gait cycle. The shock pod second material also can have a durometer that is different from the durometer of the midsole first material. For example, the shock pod second material durometer can be greater than the first material durometer. Optionally, the second material can have a durometer of 40 Asker C to about 60 Asker C, further optionally about 45 Asker C or about 46 Asker C, or greater than the same. Of course, if desired, the shock pods and midsole can be of the same or equal densities and/or durometers.

With the optional firmer, denser material of the shock pods, the shock pods can dissipate the force of impact generated by the user's forefoot and/or heel across a larger surface of the upper surface 31 of the midsole 30, or generally throughout the midsole in the forefoot and heel regions.

With reference to FIG. 6, the midsole 30 can be constructed to include a defined heel-to-toe drop that is adequate for a wearer to engage in activities such as trail running or otherwise traversing surfaces where the user may heel strike during their gait. The upper surface 31 of the midsole 30 can include a particular heel-to-toe drop HT. This heel-to-toe drop can be optionally about 0.0 mm to about 12.0 mm, further optionally about 4.0 mm to about 8.0 mm, yet further optionally about 5.0 mm to about 7.0 mm, even further optionally about 6.0 mm. The heel-to-toe drop HT can be measured as the vertical distance, for example along the direction of gravity when the footwear 10 is on level horizontal ground, between the upper surface of the midsole in the heel region and the upper surface of the midsole in the forefoot region. Generally, the particular regions at which the elevations are taken are at the locations corresponding to those that receive and support a user's calcaneus bone and the user's metatarsal-phalanges joints. As another example, the heel-to-toe drop HT can be the measure of a difference between the heel bottom and the forefoot bottom of a foot wearing footwear 10.

To provide a particular heel-to-toe drop HT geometry, the outsole 40 can have a generally constant thickness. The midsole 30 can have a varied thickness along the length of the sole assembly 20 and in particular the heel-to-toe drop HT. Alternatively, the outsole 40 can have a varied thickness along the length of the sole assembly 20, and the midsole 20 can have either a constant or varied thickness to provide the particular heel-to-toe drop HT.

The change in the footwear geometry and in particular the heel-to-toe drop HT of the footwear can enable a wearer to change his or her stride, and land farther forward on the footwear 10, generally in the midfoot and/or forefoot. Landing on the midfoot 82 and/or forefoot 81 of the sole assembly 20 can set the wearer's ankles, calves, knees, quadriceps and/or hamstrings in a position that can better receive and absorb impact forces associated with striking of the ground.

In the respective regions of the forefoot region 81 and the heel region 83, the overall thickness T1 can be less than the thickness T2. Optionally the thickness T1 in the forefoot can be about 10.0 mm to about 25.0 mm, and the thickness T2 in the heel can be about 15.0 mm to about 35.0 mm. Optionally, these thicknesses can be varied depending on the type of shoe and the terrain upon which the footwear is used.

As further shown in FIG. 6, the midsole 30 can be constructed to include an upwardly extending portion 36. In particular, the upper surface 31 can include the subtle upwardly extending portion in the arch region 82 of the footwear 10. This upwardly extending portion 36 can be shaped to fill an underfoot void. This underfoot void can be defined in the arch of a wearer's foot, between the heel and the forefoot. The upwardly extending portion in the arch region can be configured so that the upper surface 31 of the midsole in the arch region is elevated above the upper surface 31 of the midsole in the forefoot region 81, and also above the upper surface of the midsole in the heel region 83. As an example, the upwardly extending portion 36 can be elevated above the upper surface of the midsole in the heel region and in the forefoot region optionally about 1.0 mm to about 10.0 mm, further optionally about 1.0 mm to about 5.0 mm, and even further optionally about 1.0 mm to about 2.0 mm. In turn, this can result in an undulation of the upper surface when transitioning from the heel to the forefoot immediately under the wearer's foot, with the undulation maxed out, generally in the arch region. Near this upwardly extending portion 36, the thickness T3 of the sole assembly 20 from the upper surface 31 to the ground contacting surface can be optionally about 10.0 mm to about 40.0 mm, further optionally about 15.0 mm to about 20.0 mm, and even further optionally about 17.0 mm.

Optionally, the midsole in the arch 82, and generally the upwardly extending portion, can be constructed so it does not offer substantial physical support to the arch of the wearer's foot. Instead, it can readily compress under small forces, such as optionally about 0 to about 30 pounds of force, further optionally about 5 to about 20 pounds, and even further optionally about 5 to about 10 pounds of force applied by the user's foot in the arch region 82. While not offering actual substantial physical support, that is, no greater than about 0 to about 30 pounds of support, further optionally about 5 to about 20 pounds, and even further optionally about 5 to about 10 pounds, to the arch of the wearer's foot, the contact of this upwardly extending portion 36 with the bottom of the wearer's foot and arch results in the associated arch muscles and/or nerves of the wearer's foot falsely perceiving that there is structural support in this region. In turn, with this falsely perceived support, the arch does not tend to tense up and try to further support itself. This can lead to reduced fatigue over extended periods of running or other activity.

Generally, the thickness and contour of the midsole and outsole can vary from the heel region through the arch region to the forefoot region. This is illustrated in the cross section views of FIGS. 7-12. The structure of the midsole and outsole throughout these regions, and in particular the arch region 82, can contribute to mobility of the shoe. The flexibility of the arch region 82 also can be attributed to the minimal or lack of outsole in that region.

Referring to FIGS. 2, 4 and 10, the footwear 10, and in particular the sole assembly can include a flexibility void 50. This flexibility void 50, and generally the structure of the sole assembly 20 in the arch region 82, can contribute to the overall flexibility of the midfoot of the footwear 10. The flexibility void 50 can be bounded primarily by the midsole 30 and in particular the midsole web 38. The midsole web 38 and corresponding flexibility void 50 can extend inwardly from the medial side M of the sole assembly 20 toward the longitudinal axis LA. The web 38 can follow the contours of a wearer's arch upward, along the medial side of the foot in the arch region 82 to give the wearer a false perception of support there, when the wearer's arch contacts the web 38 or a liner 15 associated therewith.

In the arch region 82, the midsole web 38 can transition generally inward, toward the upwardly extending portion 36 of the midsole. The upwardly extending portion 36 can further transition to an outer wall or lateral sidewall 39 (FIG. 10) in the arch region, which itself can extend upwardly along an outer portion of the upper 12. Generally, the upper surface 31 of the midsole 30 can be continuous in the transition from the midsole web 38 to the upper outwardly extending portion 36 to the wall 39 in the arch region.

The flexibility void 50 can be bounded by multiple perimeters. For example, the flexibility void 50 can extend inwardly from the medial side M of the sole assembly toward the longitudinal axis LA. When viewed from the side view shown in FIG. 2, the flexibility void 50 can define or include a side perimeter 52 defined generally along the medial side M of the sole assembly 20. This side perimeter can be of a curved or arcuate shape. It can extend generally upward from the outsole 40 toward an apex 52A, generally in the middle of the arch region 82 and then extend downward back toward the outsole 40 in the forefoot region 81. Although shown as a curved or arcuate shape, this perimeter 52 can alternatively be constructed of multiple segments angled with regard to one another. Optionally, the flexibility void 50 can extend inwardly from the medial side M of the sole assembly 20 without extending to, or inward from the lateral side L of the sole assembly.

As also shown in FIG. 2, the flexibility void can define a vertical height VH that extends generally from the apex 52A to the ground 6 when the sole assembly is located on the ground. This vertical height can generally be optionally 10.0 mm to 50.0 mm, further optionally 20.0 mm to 40.0 mm, and even further optionally 15.0 mm to about 30.0 mm, depending on the particular application and desired flexibility of the footwear. The midsole web 38 can extend upwardly above the apex 52A a desired distance, and further optionally upwardly along a portion of the upper in this location.

As shown in FIGS. 4 and 10, the flexibility void 50 can also be bounded by a lower perimeter defined along the lower surface 32 of the midsole 30. As shown there, the lower perimeter 54 can be of a generally curved or arcuate shape, of course, other shapes can be selected as desired. Along the lower perimeter 54, the flexibility void 50 can extend in the arch region 82, generally from within or adjacent the heel region 83 and within or adjacent the forefoot region 81. The lower perimeter 52 can extend inwardly from the medial M side of the sole assembly toward the longitudinal axis LA.

The sole assembly can define a sole width W that generally extends from the medial side M to the lateral side L of the sole assembly 20. As shown in FIG. 4, this width W can extend generally perpendicular to the longitudinal axis LA at any location along the longitudinal axis LA. The sole width W can be the width of the sole assembly and any of its components from the outermost lateral side L to the medial side M taken at any point or location along the longitudinal axis LA.

As shown in FIG. 4, the lower perimeter 54 of the flexibility void 50 extends inwardly generally toward the longitudinal axis LA. That perimeter 54 can intersect the longitudinal axis LA. Optionally, it can be located substantially entirely only on the medial side M of the longitudinal axis, extending toward and then away from it. Further optionally, the lower perimeter 54 can extend inwardly and across longitudinal axis onto the lateral side L of the longitudinal axis. The precise distance can depend on the overall flexibility void width VW of the void. As better shown in FIG. 10, that void width can generally be about half of the sole width W. Optionally, however, it can be less than half of the sole width W, or greater than half of the sole width W in certain applications. Generally, by increasing the void width VW the flexibility in the sole can be enhanced. Further, altering the amount of outsole 40 in the arch also can affect the overall flexibility of the sole assembly 20 through the arch region 82 and generally the mobility of the arch.

The dimensions of the void 50 can have particular relationships relative to one another. For example, the void height VH can be less than the void length VL. In some constructions, the void length can be about 100%, 150%, 200%, or 250% greater than the void height. Optionally, the void width VW can be about the same or equal to the void height. Of course, the void width VW can be greater or less than the void height VH depending on the particular application. In some constructions, the void height and void width are both less than the void length.

Optionally, when viewed from a cross-sectional view transverse to the axis LA, for example as shown in FIG. 10, the flexibility void 50 can be in a partial arch form extending generally from the outsole 40 upwardly to the outer most portion of the midsole web 38 on the medial side M.

Portions of the outsole 40 can extend upwardly into the flexibility void 50. For example, a plurality of projections 45A, 45B and 45C extending from the outsole 40, can extend upwardly into the void 50. These projections can terminate short of the side perimeter 52 of the void 50. These projections 45A, 45B and 45C can be separated from one another by distance D2 so that the midsole web 38 is exposed from a medial side M view of the sole assembly 20 between each of the respective projections within the distance D2.

Generally, the projections can be of a jagged form or shape. Optionally, they can be of a particular geometric shape. For example, they can be triangular as shown, or alternatively can be polygonal, trapezoidal, hemicircular, rounded, angled or of other shapes depending on the particular application and the desired flexibility in the arch region 82. Further optionally, the projections can be constructed so that they do not inhibit the overall flexibility provided by the void. In some cases, they can be constructed so that the projections actually flex relative to or toward one another within the void. Even further optionally, the projections 45A, 45B and 45C can include one or more of the cleats or lugs 47 extending thereon.

As shown in FIGS. 1, 4 and 10, immediately adjacent the flexibility void 50, the outsole 40 can include an arch stabilizer 60. The arch stabilizer can include a ground contacting portion 62, which can be part of the wearing surface of the outsole that in some cases can correspond with the wearing tread 46. The arch stabilizer 60 can simply be a portion of the outsole 40 disposed in the arch region, where that arch stabilizer 60 includes at least a portion 62 that contacts the ground 6 when the wearer wears the footwear on the ground. In this construction, the wearing tread 46 can form at least a portion of the ground contacting portion 62 of the arch stabilizer 60. The arch stabilizer 60 can be constructed so that it is disposed under the midsole 30. The midsole 30 through the arch region 82 can be constructed as shown in FIG. 10 so that the arch stabilizer is positioned generally under the fourth and fifth metatarsals, and optionally the third metatarsal in the arch region 82.

The arch stabilizer 60 can be positioned adjacent the lower perimeter 54 of the flexibility void 50 and can bound a portion of that perimeter. In this case, immediately adjacent the void 50 is a ground contacting portion 62 through the arch region 82 of the sole assembly 20. Generally, the arch stabilizer 60 can extend through at least a portion of the arch or midfoot 82, optionally from the forefoot region 81 all the way to the heel region 83, so that the outsole 40 contacts the ground, or at least includes wearing tread 46 that contacts the ground, continuously through the forefoot region 81, the arch region 82 and the heel region 83 along at least portions of the outsole when a user stands firmly on the ground.

In the midfoot or arch region 82, the arch stabilizer 60 and in particular the ground contacting portion 62 can transition to a plurality of projections 45A, 45B and 45C, which extend upwardly along an exposed underside 32 of the midsole 30. These projections can be integrally formed as a single piece construction of the outsole 40.

The flexibility void 50 and arch stabilizer 60 can cooperatively extend across the sole width W. For example, the void 50 can extend across a first portion of the sole width W and the arch stabilizer 60 can extend across the remaining portion of the sole width W. Collectively, the void width VW and the width of the arch stabilizer 60 can equal the sole width W. If desired, the ground contacting portion 62 of the arch stabilizer 60 can be about 10%, 15%, 25%, 30%, 35%, 40%, 50%, 60% or more or less of the sole width W, depending on the desired flexibility of the footwear through the midfoot and/or arch. The void width VW can be a corresponding about 90%, 85%, 75%, 70%, 65%, 60%, 50%, or 40%, or more or less of the sole width W.

Directional terms, such as “vertical,” “horizontal,” “top,” “bottom,” “upper,” “lower,” “inner,” “inwardly,” “outer” and “outwardly,” are used to assist in describing the invention based on the orientation of the embodiments shown in the illustrations. The use of directional terms should not be interpreted to limit the invention to any specific orientations.

The above description is that of current embodiments of the invention. Various alterations and changes can be made without departing from the spirit and broader aspects of the invention as defined in the appended claims, which are to be interpreted in accordance with the principles of patent law including the doctrine of equivalents. This disclosure is presented for illustrative purposes and should not be interpreted as an exhaustive description of all embodiments of the invention or to limit the scope of the claims to the specific elements illustrated or described in connection with these embodiments. For example, and without limitation, any individual elements of the described invention may be replaced by alternative elements that provide substantially similar functionality or otherwise provide adequate operation. This includes, for example, presently known alternative elements, such as those that might be currently known to one skilled in the art, and alternative elements that may be developed in the future, such as those that one skilled in the art might, upon development, recognize as an alternative. Further, the disclosed embodiments include a plurality of features that are described in concert and that might cooperatively provide a collection of benefits. The present invention is not limited to only those embodiments that include all of these features or that provide all of the stated benefits, except to the extent otherwise expressly set forth in the issued claims. Any reference to claim elements in the singular, for example, using the articles “a,” “an,” “the” or “said,” is not to be construed as limiting the element to the singular. Any reference to claim elements as “at least one of X, Y and Z” is meant to include any one of X, Y or Z individually, and any combination of X, Y and Z, for example, X, Y, Z; X, Y; X, Z ; and Y, Z.

Claims

1. An article of footwear comprising: an upper;a sole assembly joined with the upper, the sole assembly including a heel region, an arch region and a forefoot region, the sole assembly defining a sole width, the sole assembly comprising: a midsole defining a flexibility void in the arch region, the flexibility void extending inwardly from a medial side of the sole assembly toward a longitudinal axis, the flexibility void being visible to a viewer of the footwear from the medial side of the sole assembly, the flexibility void including a side perimeter defined along the medial side of the sole assembly, and a lower perimeter defined along a lower surface of the midsole, andan outsole disposed under the midsole, the outsole including an arch stabilizer including a ground contacting portion in the arch region, the ground contacting portion providing ground contact of the outsole with the ground in the arch region, the ground contacting portion disposed adjacent the lower perimeter of the flexibility void,wherein the flexibility void and arch stabilizer both extend across respective parts of the sole width from the medial side to a lateral side of the sole assembly,whereby the flexibility void provides flexibility to the arch region of the sole assembly so that the forefoot portion and heel portion can move dynamically relative to one another.

2. The article of footwear of claim 1, wherein the midsole includes an upper surface,wherein the upper surface of the midsole in the heel region is elevated about 4.0 mm to about 8.0 mm above the upper surface of the midsole in the forefoot region.

3. The article of footwear of claim 2 wherein the upper surface of the midsole in the arch region elevated above the upper surface of the midsole in the forefoot region and above the upper surface of the midsole in the heel region.

4. The article of footwear of claim 3, wherein the upper surface of the midsole includes an upwardly extending portion in the arch region,wherein the upwardly extending portion is shaped to fill an underfoot void under the arch of the wearer's foot,whereby the midsole in the arch does not offer physical support to the arch of the wearer's foot, but instead only contacts the arch of the wearer's foot so that at least one of the associated arch muscles and nerves of the wearer's foot falsely perceive actual support.

5. The article of footwear of claim 4, wherein the upper surface of the midsole defines an upwardly opening first recess in the forefoot region, located generally under a ball of a wearer's foot, and a separate upwardly opening second recess in the heel, located generally under a heel of a wearer's foot,wherein first and second shock pods are disposed in the respective first and second recesses.

6. The article of footwear of claim 5, wherein the midsole is constructed from a first material having at least one of a first density and a first durometer,wherein the first and second shock pods are constructed from a second material having at least one of a second density and a second durometers that is greater than the respective at least one of a first density and first durometer,whereby an impact transferred from the forefoot to the first shock pad is dissipated through the first shock pod throughout the midsole in the forefoot region.

7. The article of footwear of claim 1, wherein the flexibility void includes a void height, a void width and a void length,wherein the void height is less than the void length,wherein the void width is less than half the sole width.

8. The article of footwear of claim 1, wherein the flexibility void includes a void height, a void width and a void length,wherein the void height is less than the void length,wherein the void width is greater than half the sole width.

9. An article of footwear comprising: an upper sized and shaped to receive a foot of a wearer, the upper including a Strobel construction;a sole assembly joined with the upper, the sole assembly including a heel region, an arch region and a forefoot region, the sole assembly including a longitudinal axis extending from the heel region to the forefoot region, the sole assembly having a sole width extending across the sole assembly from a lateral side to a medial side, the sole assembly comprising: a midsole constructed from a first material having a first density and a first durometer, the midsole having a lower surface and an opposing upper surface, the midsole defining a flexibility void in the arch region, the flexibility void extending inwardly from the medial side of the sole assembly toward the longitudinal axis, the flexibility void having a void height, a void length and a void width, the void length being greater than the void height, the flexibility void including a generally arcuate perimeter along a lowermost extremity of the flexibility void, andan outsole disposed under the midsole lower surface, the outsole including an arch stabilizer including a ground contacting portion, the ground contacting portion extending between the heel region and the forefoot region, the ground contacting portion providing ground contact of the outsole with the ground through the arch region, the ground contacting portion located adjacent the arcuate perimeter of the flexibility void,wherein the flexibility void extends across a first part of the sole width on the medial side of the longitudinal axis, and the arch stabilizer extends across a remainder of the sole width on the lateral side of the longitudinal axis through the arch region of the sole assembly,wherein the flexibility void is visible to a viewer of the footwear from the medial side of the sole assembly,wherein the upper surface of the midsole in the heel region is elevated about 4.0 mm to about 8.0 mm above the upper surface of the midsole in the forefoot region.

10. The article of footwear of claim 9, wherein the upper surface of the midsole defines a first recess in at least one of the heel region and the forefoot region,wherein the first recess is occupied by a first shock pod,wherein the first shock pod is constructed from a second material having at least one of a second density and a second durometer,wherein the at least one of a second density and a second durometer is greater than the respective first density and first durometer,whereby the first shock pod dissipates an impact of at least one of the wearer's forefoot and heel through the first shock pod and to the midsole to reduce shock to the wearer.

11. The article of footwear of claim 10, wherein the first shock pod is positioned in the first recess and the first recess is disposed in the forefoot region,wherein a second recess is defined in the upper surface of the midsole in the heel region,wherein a separate and different second shock pod is disposed in the second recess.

12. The article of footwear of claim 11 wherein the outsole includes a wearing tread that contacts the ground when a wearer wears the footwear on the ground, wherein the wearing tread forms at least part of the ground contacting portion of the arch stabilizer.

13. The article of footwear of claim 12 wherein the ground contacting portion of the arch stabilizer transitions to a plurality of projections that extend upwardly along an exposed underside of the midsole, generally into the flexibility void.

14. The article of footwear of claim 13 wherein each of the plurality of projections are spaced from one another a preselected distance.

15. The article of footwear claim 9 comprising wearing tread that contacts the ground when a wearer wears the footwear on the ground, wherein the wearing thread terminates adjacent the flexibility void without extending into the flexibility void.

16. The article of footwear of claim 9, wherein the upper surface of the midsole includes an upwardly extending portion in the arch region, the upwardly extending portion shaped to fill an underfoot void under the arch of the wearer's foot,whereby the midsole in the arch does not offer substantial physical support to the arch of the wearer's foot, but instead only contacts the arch of the wearer's foot so that at least one of the associated arch muscles and nerves of the wearer's foot falsely perceive actual support.

17. The article of footwear of claim 16 wherein the outsole is absent from the flexibility void to enhance the flexibility of the sole assembly through the arch region.

18. The article of footwear of claim 9 wherein the flexibility void width is less than half of the sole width.

19. The article of footwear of claim 9 wherein the flexibility void width is greater than half of the sole width.

20. The article of footwear of claim 9 wherein the generally arcuate perimeter of the flexibility void includes a plurality of jagged projections extending upwardly from the outsole.

21. The article of footwear of claim 9 wherein the upper surface of the midsole in the arch region is elevated above the upper surface of the midsole in the forefoot region and above the upper surface of the midsole in the heel region.

22. An article of footwear comprising: an upper having a Strobel construction with a closed bottom;a sole assembly joined with the upper and adjacent the closed bottom of the upper, the sole assembly including a heel region, an arch region and a forefoot region, the sole assembly comprising: a midsole defining an arch shaped flexibility void in the arch region, the flexibility void including a lower perimeter, andan outsole including a wearing tread that contacts the ground when a wearer wears the footwear on the ground, the wearing tread extending through the arch region adjacent the flexibility void lower perimeter,whereby the flexibility void provides flexibility to the arch region of the sole assembly so that the forefoot portion and heel portion can move dynamically relative to one another.