SOLE STRUCTURE FOR ARTICLE OF FOOTWEAR AND RELATED METHOD OF ASSEMBLY

FIELD

The present disclosure relates generally to an article of footwear and, more particularly, to a sole structure for an article of footwear.

BACKGROUND

This section provides background information related to the present disclosure and is not necessarily prior art.

Articles of footwear conventionally include an upper and a sole structure. The upper may comprise 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. For example, a sole structure may include a midsole and an outsole. The midsole is generally disposed between the outsole and the upper and provides cushioning for the foot. The midsole may include a pressurized, fluid-filled chamber that compresses resiliently under an applied load to cushion the foot by attenuating ground-reaction forces. Such fluid-filled chambers are formed separately from the midsole and are typically constructed from a different material than a material forming the midsole. For example, a fluid-filled chamber may comprise barrier layers constructed from thermoplastic polyurethane (TPU) while a midsole may comprise a foamed polymeric material. After formation of the fluid-filled chamber, the fluid-filled chamber is permanently attached to the sole structure by foaming a polymeric material around the fluid-filled chamber to form the midsole or, alternatively, the fluid-filled chamber is adhesively bonded to a foamed midsole to secure a desired location of the fluid-filled chamber relative to the midsole.

While conventional fluid-filled chambers are adequately secured to a material of a midsole during manufacturing of an article of footwear, conventional manufacturing methods require additional assembly operations to attach the fluid-filled chamber to the midsole such as applying a layer of adhesive between the midsole and the fluid-filled chamber. Such additional operations add to the overall cost and complexity associated with manufacturing a sole structure and, thus, the resulting article of footwear.

DRAWINGS

The drawings described herein are for illustrative purposes only of selected configurations and not all possible implementations, and are not intended to limit the scope of the present disclosure.

FIG. 1 is a perspective view of an article of footwear in accordance with the principles of the present disclosure;

FIG. 2 is a top exploded view of the article of footwear of FIG. 1;

FIG. 3 is a bottom exploded view of the article of footwear of FIG. 1;

FIG. 4 is a top view of a bladder for use with the article of footwear of FIG. 1;

FIG. 5 is a side view of the bladder of FIG. 4;

FIG. 6 is a perspective view of the article of footwear of FIG. 1 showing a bladder in a first position during installation of the bladder into an opening of a midsole of the article of footwear of FIG. 1;

FIG. 7 is a perspective view of the article of footwear of FIG. 1 showing the bladder of FIG. 6 in a second position during installation of the bladder into the opening of the midsole of FIG. 6;

FIG. 8 is a perspective view of the article of footwear of FIG. 1 showing the bladder of FIG. 6 rotated from the second position of FIG. 7 into an installed position within the midsole;

FIG. 9 is cross-sectional view of the article of footwear of FIG. 1 taken along Line 9-9 of FIG. 8;

FIG. 10 is a cross-sectional view of the article of footwear of FIG. 1 taken along Line 10-10 of FIG. 8;

FIG. 11 is a perspective view of an article of footwear in accordance with the principles of the present disclosure; and

FIG. 12 is a cross-sectional view of the article of footwear of FIG. 11 taken along Line 12-12 of FIG. 11.

Corresponding reference numerals indicate corresponding parts throughout the drawings.

DETAILED DESCRIPTION

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.

In one configuration, a sole structure for an article of footwear is provided and comprises a midsole including a cavity having a first projection extending from a first surface within the cavity in a first direction and a second projection extending from a second surface within the cavity in a second direction toward the first projection and a cushion including a first recess provided on a first side of the cushion and a second recess provided on an opposite, second side of the cushion, the first recess receiving the first projection and the second recess receiving the second projection.

The sole structure may include one or more of the following optional features. For example, the first projection may be aligned with the second projection. Namely, a distal end of the first projection may oppose and be aligned with a distal end of the second projection. Additionally or alternatively, at least one of the first projection and the second projection may be elongate and may extend between a first end and a second end along a longitudinal axis of the at least one of the first projection and the second projection, at least one of the first end and the second end including a bevel. In this configuration, the first projection may substantially fill the first recess and the second projection may substantially fill the second recess.

The cushion may be a bladder. The bladder may include a first barrier layer joined to a second barrier layer to define a chamber, the chamber having a plurality of segments defined by a web area of the bladder. A portion of the web area may be disposed between a distal end of the first projection and a distal end of the second projection. In one configuration, the bladder may be pressurized.

An article of footwear may incorporate the sole structure.

A method is also provided and includes forming a midsole including a cavity and a first projection extending in a first direction from a first surface of the midsole within the cavity, forming a cushion including a first recess disposed on a first side of the cushion, inserting the cushion into the cavity of the midsole, and rotating the cushion within the cavity until the first projection is received by the first recess.

The method may include one or more of the following optional features. For example, forming the midsole may include forming a second projection extending in a second direction from a second surface of the midsole within the cavity toward the first projection. The second projection may be aligned with the first projection. For example, the second projection may be aligned with the first projection such that a distal end of the second projection opposes a distal end of the first projection.

Forming a midsole having a first projection may include forming the midsole with an elongate projection. Additionally or alternatively, the first recess may be substantially filled with the first projection when the first projection is received by the first recess.

In one configuration, forming a cushion may include forming a bladder. Forming a bladder may include joining a first barrier layer to a second barrier layer to define a chamber having a plurality of segments defined by a web area of the bladder, the web area of the bladder defining the first recess. The bladder may be pressurized.

The midsole and the cushion may be incorporated into an article of footwear.

Referring to FIG. 1, an article of footwear 10 includes a sole structure 100 and an upper 200 attached to the sole structure 100. The footwear 10 may further include an anterior end 12 associated with a forward-most point of the footwear 10, and a posterior end 14 corresponding to a rearward-most point of the footwear 10. As shown in FIG. 1, a longitudinal axis A₁₀of the footwear 10 extends along a length of the footwear 10 from the anterior end 12 to the posterior end 14 parallel to a ground surface, and generally divides the footwear 10 into a medial side 16 and a lateral side 18. Accordingly, the medial side 16 and the lateral side 18 respectively correspond with opposite sides of the footwear 10 and extend from the anterior end 12 to the posterior end 14. As used herein, a longitudinal direction refers to the direction extending from the anterior end 12 to the posterior end 14, while a lateral direction refers to the direction transverse to the longitudinal direction and extending from the medial side 16 to the lateral side 18.

The article of footwear 10 may be divided into one or more regions. The regions may include a forefoot region 20, a mid-foot region 22, and a heel region 24. The forefoot region 20 may be subdivided into a toe portion 20_Tcorresponding with phalanges and a ball portion 20_Bassociated with metatarsal bones of a foot. The mid-foot region 22 may correspond with an arch area of the foot, and the heel region 24 may correspond with rear portions of the foot, including a calcaneus bone.

The article of footwear 10, and more particularly, the sole structure 200, may be further described as including a peripheral region 26 and an interior region 28, as indicated in FIG. 1. The peripheral region 26 is generally described as being a region between the interior region 28 and an outer perimeter of the sole structure 200. Particularly, the peripheral region 26 extends from the forefoot region 20 to the heel region 24 along each of the medial side 16 and the lateral side 18, and wraps around each of the forefoot region 20 and the heel region 24. The interior region 28 is circumscribed by the peripheral region 26, and extends from the forefoot region 20 to the heel region 24 along a central portion of the sole structure 200. Accordingly, each of the forefoot region 20, the mid-foot region 22, and the heel region 24 may be described as including the peripheral region 26 and the interior region 28.

The upper 100 forms an enclosure having plurality of components that cooperate to define an interior void 102 and an ankle opening 104, which cooperate to receive and secure a foot for support on the sole structure 200. For example, the upper 100 includes a pair of quarter panels 106 in the mid-foot region 22 on opposite sides of the interior void 102. A throat 108 extends across the top of the upper 100 and defines an instep region extending between the quarter panels 106 from the ankle opening 104 to the forefoot region 20. In the illustrated example, the throat 108 is enclosed, whereby a material panel extends between the opposing quarter panels 106 in the instep region to cover the interior void 102. Here, the material panel covering the throat 108 may comprise a material having a higher modulus of elasticity than the material forming the quarter panels 106. Alternatively, the material of the throat 108 may be the same or similar material as a material forming the quarter panels 106.

The upper 100 of the article of footwear 10 may be further described as including heel side panels 110 extending through the heel region 24 along the lateral and medial sides 16, 18 of the ankle opening 104. A heel counter 112 wraps around the posterior end 14 of the footwear 10 and connects the heel side panels 110. Uppermost edges of the throat 108, the heel side panels 110, and the heel counter 112 cooperate to form a collar 114, which defines the ankle opening 104 of the interior void 102.

While the upper 100 is described as including quarter panels 106, a throat 108, heel side panels 110, and a heel counter 112, one or more of the foregoing elements 106, 108, 110, 112 may be integrally formed with one another to provide the shape of the upper 100 shown in the figures. For example, the upper 100 could have a unitary construction if a textile is formed (i.e., woven) into the shape of the upper 100 shown in FIG. 2 or if the shape of the upper 100 is formed by using a 3D printing process. In these cases, the various elements 106, 108, 110, 112 identified above would identify different regions of the unitary upper 100. While the upper 100 could have a unitary construction comprising a textile or could be formed by using a 3D printing process, the upper 100 will hereinafter be described as being formed from one or more materials that are joined together to form the upper 100.

The upper 100 may comprise one or more materials that are stitched or adhesively bonded together to define the interior void 102. Suitable materials of the upper 100 may include, but are not limited to, textiles, foam, leather, and synthetic leather. The example upper 100 may comprise a combination of one or more substantially inelastic or non-stretchable materials and one or more substantially elastic or stretchable materials disposed in different regions of the upper 100 to facilitate movement of the article of footwear 10 between the tightened state and the loosened state. The one or more elastic materials may include any combination of one or more elastic fabrics such as, without limitation, spandex, elastane, rubber, or neoprene. The one or more inelastic materials may include any combination of one or more of thermoplastic polyurethanes, nylon, leather, vinyl, or another material/fabric that does not impart properties of elasticity.

With particular reference to FIG. 3, the sole structure 100 is shown as including a midsole 30, a cushion 32, and an outsole 34. The midsole 30 extends along the length of the sole structure 100 from the anterior end 12 of the article of footwear 10 to the posterior end 14 of the article of footwear 10. Further, the midsole 30 extends from the medial side 16 of the article of footwear 10 to the lateral side 18 of the article of footwear 10.

As shown in FIGS. 2 and 3, the midsole 30 includes a main body 36 and a peripheral flange 38 extending from the main body 36 in a direction toward the upper 200. The main body 36 includes a first surface 40 facing the upper 20, a second surface 42 disposed on an opposite side of the main body 36 than the first surface 40 and opposing a ground surface during wear, and a cavity 44 provided at a location of the midsole 30 corresponding to the heel region 24 of the article of footwear 10. As will be described in greater detail below, the cavity 44 receives the cushion 32 therein. While the cavity 44 will be described hereinafter as being located at a region of the midsole 30 corresponding to the heel region 24 of the article of footwear 10, the cavity 44 could be located at any location along the length of the midsole 30 and could extend continuously from the forefoot region 20 of the article of footwear 10 to the heel region 24 of the article of footwear 10. If the cavity 44 extends along a length of the sole structure 100 between one or more of the forefoot region 20, the mid-foot region 22, and the heel region 24, the cushion 32 could be similarly sized to extend along the length of and substantially fill a majority of the cavity 44.

The main body 36 additionally includes a first window 46 at the medial side 16 of the article of footwear 10 and a second window 48 at the lateral side 18 of the article of footwear 10. The first window 46 and the second window 48 are each in fluid communication with the cavity 44 and with one another. Further, the first window 46 may be aligned with the second window 48 across a width of the sole structure 100 (i.e., in a direction extending between the medial side 16 and the lateral side 18).

With particular reference to FIG. 9, the cavity 44 is shown as including a first plurality of projections 50 and a second plurality of projections 52. The first plurality of projections 50 includes projections 50 that extend in a direction from a top surface 54 of the cavity 44 in a direction away from the upper 200. Similarly, the second plurality of projections 52 includes projections 52 that extend in a direction from a bottom surface 56 of the cavity 44 in a direction toward the upper 200. As shown in FIG. 9, each projection 50 of the first plurality of projections 50 is aligned with a respective projection 52 of the second plurality of projections 52 and, further, includes a distal end 58 that is spaced apart from a distal end 60 of the respective projection 52. As shown in FIG. 2, each projection 50, 52 may include a rounded or arcuate end 62 opposing a respective window 46, 48. Finally, each projection 50, 52 is elongate and extends across a majority of the cavity 44 between the first window 46 and the second window 48.

The peripheral flange 36 extends from the first surface 40 of the midsole 30 in a direction toward the upper 200. The peripheral flange 36 extends at least partially over the upper in each of the forefoot region 20, the mid-foot region 22, and the heel region 24. Specifically, the midsole 30 may extend over at least a portion of the quarter panels 106, the heel side panels 110, and the heel counter 112. The peripheral flange 36 includes a substantially curved and undulating profile having a series of peaks 64 and valleys 66 that alternate along the medial side 16 and the lateral side 18 of the article of footwear 10. As shown in FIG. 2, the peripheral flange 36 may extend in a direction toward the upper 200 to the greatest extent in the heel region 24 such that a height of the peripheral flange 36—relative to the first surface 40—gradually increases from the forefoot region 20 to the heel region 24.

The midsole 30 may comprise a foam material. For example, the midsole 30 may comprise a foam, resilient polymeric material. In one configuration, the midsole 30 is formed via a 3D printing process, whereby layers of material are deposited on one another until the structure of the midsole 30 shown in FIGS. 2 and 3 is created. The material used to form the midsole 30 may be deposited from a print head (not shown) to build the various layers on one another to form the structure of the midsole 30. The material may be a thermoplastic polyurethane (TPU) that foams after being dispensed from the print head. In one configuration, the deposited material expands (i.e., foams) between approximately 20%-30% of its original size after being dispensed from the print head to provide the midsole 30 with the ability to cushion forces during wear.

The 3D printing process may comprise any 3D printing process, method, or machine including, but not limited to, fused deposition modeling (a.k.a., fused filament fabrication), laser sintering, binder jet 3D printing (a.k.a., powder bed and inkjet printing), stereolithography, digital light process, liquid 3D printing, and multi jet fusion.

Forming the midsole 30 via a 3D printing process allows the midsole 30 to include the cavity 44 and, further, to allow the cavity 44 to include the projections 50, 52. Further, the midsole 30—including the foregoing features 44, 50, 52 and excluding the cushion 32—may comprise a unitary (i.e., monolithic) structure. If the midsole 30 comprises a unitary structure, the entire sole structure 100 may include a unitary structure such that each element of the sole structure 100—apart from the cushion 32—is part of the same, monolithic structure. Additionally, the upper 200 may comprise a unitary structure that is part of the same monolithic structure of the sole structure 100—apart from the cushion 32.

When 3D printing the midsole 30, plural layers of the material of the midsole 30 may be deposited on one another until the structure shown in the figures is created. Further, the midsole 30 may comprise only a portion that is 3D printed or, alternatively, the entire structure of the midsole 30 may be 3D printed. Whether the midsole 30 is created using a 3D printing process or a different process, the midsole 30 may comprise a lattice structure. Finally, the midsole 30 may be separately 3D printed and attached to the upper 200 or, alternatively, the sole structure 100—including the midsole 30—may be 3D printed along with the upper 200 by depositing plural layers of material on one another until the structure of the sole structure 100 and the upper 200 shown in the figures is created. In one configuration, the deposited plural layers comprise an elastically deformable material.

Regardless of how much of the sole structure 100 and/or the upper 200 is created using a 3D printing process, the portions of the sole structure 100 and/or the upper 200 created via a 3D printing process may be created by depositing plural layers of filaments that are aligned in parallel with one another until the structure of the sole structure 100 and/or the upper 200 shown in the figures is created. The deposited filaments aligned in parallel with one another may be spaced apart from one another with a gap disposed therebetween, whereby the gap is wider than a width of one or more of the plural filaments immediately adjacent the gap or the gap is narrower than a width of one or more of the plural filaments immediately adjacent the gap.

As can be appreciated, forming a cavity—such as the cavity 44—along with projections extending into and from opposite walls defining the cavity—such as projections 50, 52—is difficult using a conventional manufacturing process such as, for example, injection molding. Namely, forming the midsole 30 shown in the figures via an injection molding process would be difficult, as removing the midsole 30 from an injection-molding tool would be difficult following formation given the intricacies of the structure associated with the cavity 44 and the projections 50, 52. It should be noted that a conventional manufacturing process could be used to form the midsole 30, but would likely require the midsole 30 to include two separate pieces that are separately formed and joined together.

As set forth below, if the midsole 30 is formed via a conventional manufacturing process such that the midsole 30 includes two separate pieces that are joined together, the midsole, example resilient polymeric materials for forming the midsole 30 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 azodicarbonamide, 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 comprising a 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.

With particular reference to FIGS. 4 and 5, the cushion 32 is shown as being a bladder including an opposing pair of barrier layers 68a, 68b, which can be joined to each other at discrete locations to define a fluid-filled chamber 70, a web area 72, and a peripheral seam 74. In the shown configuration, the barrier layers 68a, 68b include a first, upper barrier layer 68a and a second, lower barrier layer 68b. Alternatively, the fluid-filled chamber 70 can be produced from any suitable combination of one or more barrier layers. While the fluid-filled chamber 70 is shown as including a chamber 70 containing pressurized fluid, the chamber 70 could additionally comprise a mechanical structure such as, for example, a tensile element (not shown).

As used herein, the term “barrier layer” (e.g., barrier layers 68a, 68b) encompasses both monolayer and multilayer films. In some embodiments, one or both of barrier layers the 68a, 68b are each produced (e.g., thermoformed or blow molded) from a monolayer film (a single layer). In other embodiments, one or both of the barrier layers 68a, 68b are each produced (e.g., thermoformed or blow molded) from a multilayer film (multiple sublayers). In either aspect, each layer or sublayer can have a film thickness ranging from about 0.2 micrometers to about 1 millimeter. In further embodiments, the film thickness for each layer or sublayer can range from about 0.5 micrometers to about 500 micrometers. In yet further embodiments, the film thickness for each layer or sublayer can range from about 1 micrometer to about 100 micrometers.

One or both of the barrier layers 68a, 68b can independently be transparent, translucent, and/or opaque. As used herein, the term “transparent” for a barrier layer and/or a fluid-filled chamber 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 68a, 68b can 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-based TPU, polycarbonate-based TPU, polysiloxane-based TPU, or combinations thereof.

In another aspect, the polymeric layer can comprise 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 barrier layers 68a, 68b may include two or more sublayers (multilayer film) such as shown in Mitchell et al., U.S. Pat. No. 5,713,141 and Mitchell et al., U.S. Pat. No. 5,952,065, the disclosures of which are incorporated by reference in their entirety. In embodiments where the barrier layers 68a, 68b include two or more sublayers, examples of suitable multilayer films include microlayer films, such as those disclosed in Bonk et al., U.S. Pat. No. 6,582,786, which is incorporated by reference in its entirety. In further embodiments, barrier layers 68a, 68b may each independently include alternating sublayers of one or more TPU copolymer materials and one or more EVOH copolymer materials, where the total number of sublayers in each of the barrier layers 68a, 68b includes at least four (4) sublayers, at least ten (10) sublayers, at least twenty (20) sublayers, at least forty (40) sublayers, and/or at least sixty (60) sublayers.

The fluid-filled chamber 70 can be produced from the barrier layers 68a, 68b using any suitable technique, such as thermoforming (e.g. vacuum thermoforming), blow molding, extrusion, injection molding, vacuum molding, rotary molding, transfer molding, pressure forming, heat sealing, casting, low-pressure casting, spin casting, reaction injection molding, radio frequency (RF) welding, and the like. In an aspect, the barrier layers 68a, 68b can be produced by co-extrusion followed by vacuum thermoforming to produce an inflatable chamber 70, which can optionally include one or more valves (e.g., one way valves) that allows the chamber 70 to be filled with the fluid (e.g., gas).

The chamber 70 can be provided in a fluid-filled (e.g., as provided in footwear 10) or in an unfilled state. The chamber 70 can be filled to include any suitable fluid, such as a gas or liquid. In an aspect, the gas can include air, nitrogen (N₂), or any other suitable gas. In other aspects, the chamber 70 can alternatively include other media, such as pellets, beads, ground recycled material, and the like (e.g., foamed beads and/or rubber beads). The fluid provided to the chamber 70 can result in the chamber 70 being pressurized. Alternatively, the fluid provided to the chamber 70 can be at atmospheric pressure such that the chamber 70 is not pressurized but, rather, simply contains a volume of fluid at atmospheric pressure.

The fluid-filled chamber 70 desirably has a low gas transmission rate to preserve its retained gas pressure. In some embodiments, the fluid-filled chamber 70 has a gas transmission rate for nitrogen gas that is at least about ten (10) times lower than a nitrogen gas transmission rate for a butyl rubber layer of substantially the same dimensions. In an aspect, fluid-filled chamber 70 has a nitrogen gas transmission rate of 15 cubic-centimeter/square-meter·atmosphere·day (cm³/m²·atm·day) or less for an average film thickness of 500 micrometers (based on thicknesses of the barrier layers 68a, 68b). In further aspects, the transmission rate is 10 cm³/m²·atm·day or less, 5 cm³/m²·atm·day or less, or 1 cm³/m²·atm·day or less.

Referring to FIGS. 4 and 5, the fluid-filled chamber 70 includes a series of interconnected, fluid-filled segments including a first segment 76 and a second segment 78 extending along a length of the fluid-filled chamber 70 and substantially parallel to one another. The fluid-filled chamber 70 additionally includes a third segment 80, a fourth segment 82, and a fifth segment 84 extending between and fluidly connecting the first segment 76 and the second segment 78. As shown, the third segment, 80, the fourth segment 82, and the fifth segment 84 extend substantially parallel to one another and substantially perpendicular to the first segment 76, the second segment 78, and the longitudinal axis A₁₀of the article of footwear 10.

As shown in FIG. 4, the first segment 76 includes a first distal end 86a that extends past the fifth segment 84 and a second distal end 86b that extends past the third segment 80. Similarly, the second segment 78 includes a first distal end 88a that extends past the fifth segment 84 and a second distal end 88b that extends past the third segment 80. As shown, the first distal end 86a of the first segment 76 opposes the first distal end 88a of the second segment 78 across a width of the fluid-filled chamber 70 and the second distal end 86b of the first segment 76 opposes the second distal end 88b of the second segment 78 across a width of the chamber 70. Based on the foregoing, and as shown in FIG. 4, the fluid-filled chamber 70 is symmetric about a central, longitudinal axis and is symmetric about a central, longitudinal axis passing through the fourth segment 82.

As shown in FIG. 5, the distal ends 86a, 86b, 88a, 88b each includes a tapered surface 90 extending in a direction toward the upper barrier layer 68a. The tapered surfaces 90 oppose a respective tapered surface 92 of the cavity 44 when the fluid-filled chamber 70 is received within the cavity 44, as shown in FIG. 9.

The web area 72 is defined by portions of the upper barrier layer 68a and the lower barrier layer 68b being joined to one another. The web area 72 generally defines the shape of the segments 76, 78, 80, 82, 84 and includes a pair of first recesses 94 and a pair of second recesses 96. The recesses 94, 96 are each elongate and extend between a first rounded end 98a disposed proximate to the first segment 76 and a second rounded end 98b disposed proximate to the second segment 78. As shown in FIG. 9, the recesses 94 are provided at an opposite side of the bladder 32 than the recesses 96. Further, each recess 94 is aligned with a respective recess 96 across a width of the bladder 32.

With particular reference to FIGS. 6-8, assembly of the bladder 32 to the midsole 30 will be described in detail. Initially, the midsole 30 and the bladder 32 are separately formed. At this point, the bladder 32 may be attached to the midsole 30 by inserting the bladder 32 into one of the windows 46, 48 of the midsole 30. The first window 46 and the second window 48 are sized such that a cross-sectional size of each window 46, 48 is smaller than a maximum corresponding cross-sectional size of the bladder 32. Accordingly, and as will be described below, the bladder 32 is either compressed or temporarily deformed during insertion of the bladder 32 into a respective one of the windows 46, 48. While the bladder 32 could be installed into the cavity 44 via the first window 46 or the second window 48, the bladder 32 will be described as being inserted into the cavity 44 at the first window 46. Further, while the bladder 32 is described and shown as being inserted into one of the first window 46 or the second window 48 at the medial side 16 or the lateral side 18 of the sole structure 100, the bladder 32 could be inserted into any aperture formed through a side surface of the midsole 30 that is in communication with the cavity 44. For example, an aperture having a similar size and shape as the windows 44, 46 may be provided at a sidewall of the midsole 30 within the heel region 24 at the posterior end 14 that is in communication with the cavity 44. The bladder 32 could be inserted into the cavity 44 via such an aperture.

The bladder 32 may be positioned adjacent to the first window 46 such that the first distal end 86a, 88a of the first segment 76 and the second segment 78, respectively, engage an outer, perimeter edge of the midsole 30 that defines the first window 46. At this point, a force may be applied to the first segment 76 and the second segment 78 to move the distal ends 86a, 88a in a direction toward one another in an effort to fit the distal ends 86a, 88a into the first window 46. Movement of the distal ends 86a, 88a in a direction toward one another may be caused by the bladder 32 being compressed and/or temporarily deformed to fit into the first window 46. Compression and/or temporary deformation of the bladder 32 may be facilitated by providing an opening to the first window 46 with a bevel or taper to facilitate such compression and/or deformation during insertion of the bladder 32 into the first window 46.

Once the distal ends 86a, 88a are sufficiently inserted into the first window 46, a force may be applied to the bladder 32 to move the bladder 32 relative to and within the cavity 44 in a direction extending between the medial side 16 and the lateral side 18; substantially perpendicular to the longitudinal axis A₁₀of the article of footwear 10, as shown in FIG. 7.

Once the bladder 32 is in the position shown in FIG. 7, a rotational force may be applied to the bladder 32 to rotate the bladder 32 ninety degrees (90°) relative to and within the cavity 44 into the position shown in FIG. 8, whereby the distal ends 86a, 88a are facing in a direction toward the anterior end 12 and the distal ends 86b, 88b are facing in a direction toward the posterior end 14. At this point, the first segment 76 and the second segment 78 are substantially parallel to the longitudinal axis A₁₀of the article of footwear 10. Because the cavity 44 includes a greater cross-sectional size than the first window 46 and the second window 48, when the bladder 32 is moved into the position shown in FIG. 8, the bladder 32 is allowed to return to a relaxed or expanded state from the compressed or deformed state due to the resilient nature of the bladder 32 and/or a pressure of the fluid disposed within the chamber 70. While the cavity 44 is described as including a greater cross-sectional size than the first window 46 and the second window 48, a maximum vertical height of the cavity 44 (i.e., in a direction substantially perpendicular to the second surface 42 of the midsole 30) may be less than or greater than a thickness of the bladder 32. Further, a maximum medio-lateral width of the bladder 32 (i.e., extending in a direction between the first segment 76 and the second segment 78) may be less than a maximum medio-lateral width (i.e., extending in a direction between the medial side 16 and the lateral side 18) of the cavity 44.

When the bladder 32 is in the position shown in FIG. 8, the first projections 50 are received within and substantially fill respective ones of the first recesses 94 and the second projections 52 are received within and substantially fill respective ones of the second recesses 96. In so doing, portions of the web area 72 are located between opposing distal ends 58, 60 of the respective projections 50, 52 within the respective recesses 94, 96. Insertion of the projections 50, 52 into the respective recesses 94, 96 helps to fix a position of the bladder 32 relative to the midsole 30 so that the bladder 32 remains in a desired position relative to the midsole 30 during use.

The bladder 32 is held in place due to engagement between the projections 50, 52 and the recesses 94, 96, as the projections 50, 52 include a complimentary shape to the shape of the recesses 94, 96. Accordingly, when the bladder 32 is rotated into position relative to the midsole 30, the projections 50, 52 substantially fill each recess 94, 96. In addition, one or more of the top surface 54 and the bottom surface 56 of the cavity 44 may include a texture to increase frictional engagement between the bladder 32 and the surfaces 54, 56 of the cavity 44 in an effort to maintain a desired position of the bladder 32 within the cavity 44.

While the cushion 32 is described and shown as being a bladder having a fluid-filled chamber 70, the bladder 32 could be replaced with a foam element having the shape of the bladder 32. The foam element could include an exterior surface having a high gloss-unit value, thereby proving the exterior surface of the foam element with a glossy appearance. In so doing, the exterior surface allows the foam element to look like a bladder. Replacing the bladder 32 with a foam element having the same shape as the bladder 32—with or without an exterior surface having a high gloss-unit value—provides the sole structure 100 with different cushioning properties, as compared to the fluid-filled chamber 70. In addition, the cushion 32 could comprise a mechanical cushioning structure including one or more of a compressible lattice structure or a compressible minimal surface area structure. See, U.S. Pat. No. 11,0713,48 titled Footwear Sole Structure issued Jul. 27, 2020, the contents of which are expressly incorporated by reference in their entirety.

As described, the cushion 32 may be inserted into the midsole 30 via the first window 46 or the second window 48, may be rotated into place, and may be held in a desired position relative to the midsole 30 due to engagement between the projections 50, 52 and the recesses 94, 96 of the cushion 32. When the article of footwear 10 reaches its end-of-life, a force may similarly be exerted on the cushion 32 to rotate the cushion 32 relative to the midsole 30 to remove the cushion 32 from the midsole 30 via the first window 46 or the second window 48 in an effort to more easily and efficiently recycle the midsole 30 and the cushion 32.

With particular reference to FIGS. 11 and 12, an article of footwear 10c is provided. In view of the substantial similarity in structure and function of the article of footwear 10c with respect to the article of footwear 10, like reference numerals will be used hereinafter and in the drawings to identify like components while like reference numerals containing the letter extension “c” will be used to identify those components that have been modified.

The article of footwear 10c includes a sole structure 100c having a midsole 30c defining a cavity 44. The cavity 44 includes a first plurality of projections 50c and a second plurality of projections 52c. The first plurality of projections 50c includes projections 50c that extend in a direction from a top surface 54 of the cavity 44 in a direction away from the upper 200. Similarly, the second plurality of projections 52c includes projections 52c that extend in a direction from a bottom surface 56 of the cavity 44 in a direction toward the upper 200. Each projection 50c of the first plurality of projections 50c is aligned with a respective projection 52c of the second plurality of projections 52c and, further, includes a distal end 58 that is spaced apart from a distal end 60 of the respective projection 52c. As shown in FIG. 11, each projection 50c, 52c may include a rounded or arcuate end 62c opposing a respective window 46, 48. Finally, each projection 50c, 52c is elongate and extends across a majority of the cavity 44 between the first window 46 and the second window 48.

The projections 50c, 52c are similar to the projections 50, 52, respectively, with the exception of an end of the projections 50c, 52c proximate to the arcuate ends 62c. Specifically, and as shown in FIGS. 11 and 12, the distal ends of the projections 50c, 52c include a bevel 300 having an angled surface 302 that extends from the respective distal ends 58, 60 to an approximate midpoint of the curved ends 62a. The bevel 300 and the resulting angled surface 302 facilitate insertion of the bladder 32 into a respective one of the windows 46, 48. For example, when the bladder 32 is inserted into one of the windows 46, 48 (FIGS. 6 and 7) and subsequently rotated into place (FIG. 8) in a similar fashion as described above with respect to the article of footwear 10, the bladder 32 will engage the angled surfaces 302 of the projections 50c, 52c. As will be described in more detail below, the bevels 300 result in a reduction in thickness of the projections 50c, 52c proximate to the windows 46, 48, which, in turn, reduces the force required to insert the bladder 32 into the cavity 44 and to rotate the bladder 32 into the position shown in FIG. 8.

The angled surfaces 302 oppose one another such that a gap between the opposing angled surfaces 302 is greater than a gap between surfaces of the distal ends 58, 60. Specifically, the gap between the angled surfaces 302 is greater than the gap between the projections 50c, 52c proximate to the central, longitudinal axis A₁₀of the sole structure 100c. As such, the degree to which the bladder 32 must be compressed and/or the projections 50c, 52c must be compressed to fully insert the bladder 32 into the cavity 44 and to rotate the bladder 32 into the position shown in FIG. 8 is reduced. Additionally, engaging an outer surface of the bladder 32 with the angled surfaces 302 helps guide the bladder 32 into the cavity 44.

During installation of the bladder 32 into the cavity 44 of the midsole 30c, the bladder 32 is initially positioned relative to the sole structure 100c in a similar fashion as is shown in FIG. 6 with respect to the article of footwear 10. Specifically, the bladder 32 may be attached to the midsole 30c by inserting the bladder 32 into one of the windows 46, 48 of the midsole 30c. The first window 46 and the second window 48 are sized such that a cross-sectional size of each window 46, 48 is smaller than a maximum corresponding cross-sectional size of the bladder 32. Accordingly, and as will be described below, the bladder 32 is either compressed or temporarily deformed during insertion of the bladder 32 into a respective one of the windows 46, 48. While the bladder 32 could be installed into the cavity 44 via the first window 46 or the second window 48, the bladder 32 will be described as being inserted into the cavity 44 at the first window 46. Further, while the bladder 32 is described and shown as being inserted into one of the first window 46 or the second window 48 at the medial side 16 or the lateral side 18 of the sole structure 100c, the bladder 32 could be inserted into any aperture formed through a side surface of the midsole 30c that is in communication with the cavity 44. For example, an aperture having a similar size and shape as the windows 44, 46 may be provided at a sidewall of the midsole 30c within the heel region 24 at the posterior end 14 that is in communication with the cavity 44. The bladder 32 could be inserted into the cavity 44 via such an aperture.

The bladder 32 may be positioned adjacent to the first window 46 such that the first distal end 86a, 88a of the first segment 76 and the second segment 78, respectively, engage an outer, perimeter edge of the midsole 30c that defines the first window 46. At this point, a force may be applied to the first segment 76 and the second segment 78 to move the distal ends 86a, 88a in a direction toward one another in an effort to fit the distal ends 86a, 88a into the first window 46. Movement of the distal ends 86a, 88a in a direction toward one another may be caused by the bladder 32 being compressed and/or temporarily deformed to fit into the first window 46. Compression and/or temporary deformation of the bladder 32 may be facilitated by providing an opening to the first window 46 with a bevel or taper to facilitate such compression and/or deformation during insertion of the bladder 32 into the first window 46.

Once the distal ends 86a, 88a are sufficiently inserted into the first window 46, the distal ends 86a, 88a engage the angled surfaces 302 of the projections 50c, 52c. At this point, the angled surfaces 302 of the bevel 300 guide the bladder 32 and function as a ramp, directing further movement of the bladder 32 into the cavity 44 and between the distal ends 58, 60. The force may be applied to the bladder 32 to move the bladder 32 relative to and within the cavity 44 in a direction extending between the medial side 16 and the lateral side 18; substantially perpendicular to the longitudinal axis A₁₀of the article of footwear 10c, as shown in FIG. 7 with respect to the article of footwear 10. The force required to insert the bladder 32 into the cavity 44 of the midsole 30c is reduced compared to the force required to insert the bladder 32 into the cavity of the midsole 30 due to the increased distance between the projections 50c, 52c at the opposing bevels 300. Further, insertion of the bladder 32 into the cavity 44 and into the position shown in FIG. 7 is facilitated by the angled surfaces 302 of the bevels 300 guiding the bladder 32.

Once the bladder 32 is in the position shown in FIG. 7, a rotational force may be applied to the bladder 32 to rotate the bladder 32 ninety degrees (90°) relative to and within the cavity 44 into the position shown in FIG. 8, whereby the distal ends 86a, 88a are facing in a direction toward the anterior end 12 and the distal ends 86b, 88b are facing in a direction toward the posterior end 14. At this point, the first segment 76 and the second segment 78 are substantially parallel to the longitudinal axis A₁₀of the article of footwear 10c. Because the cavity 44 includes a greater cross-sectional size than the first window 46 and the second window 48, when the bladder 32 is moved into the position shown in FIG. 8, the bladder 32 is allowed to return to a relaxed or expanded state from the compressed or deformed state due to the resilient nature of the bladder 32 and/or a pressure of the fluid disposed within the chamber 70. While the cavity 44 is described as including a greater cross-sectional size than the first window 46 and the second window 48, a maximum vertical height of the cavity 44 (i.e., in a direction substantially perpendicular to the second surface 42 of the midsole 30c) may be less than or greater than a thickness of the bladder 32. Further, a maximum medio-lateral width of the bladder 32 (i.e., extending in a direction between the first segment 76 and the second segment 78) may be less than a maximum medio-lateral width (i.e., extending in a direction between the medial side 16 and the lateral side 18) of the cavity 44.

When the bladder 32 is in the position shown in FIG. 8, the first projections 50c are received within and substantially fill respective ones of the first recesses 94 and the second projections 52c are received within and substantially fill respective ones of the second recesses 96. In so doing, portions of the web area 72 are located between opposing distal ends 58, 60 of the respective projections 50c, 52c within the respective recesses 94, 96. Insertion of the projections 50c, 52c into the respective recesses 94, 96 helps to fix a position of the bladder 32 relative to the midsole 30c so that the bladder 32 remains in a desired position relative to the midsole 30c during use.

The bladder 32 is held in place due to engagement between the projections 50c, 52c and the recesses 94, 96, as the projections 50c, 52c include a complimentary shape to the shape of the recesses 94, 96. Accordingly, when the bladder 32 is rotated into position relative to the midsole 30c, the projections 50c, 52c substantially fill each recess 94, 96. In addition, one or more of the top surface 54 and the bottom surface 56 of the cavity 44 may include a texture to increase frictional engagement between the bladder 32 and the surfaces 54, 56 of the cavity 44 in an effort to maintain a desired position of the bladder 32 within the cavity 44.

With reference to FIG. 12, the bladder 32 is shown in the position of the bladder 32 in FIG. 8 such that the projections 50c, 52c are respectively received within the recesses 94, 96. As shown in FIG. 12, even though the projections 50c, 52c include a bevel 300 at each end, the overall length of the projections 50c, 52c as compared to the projections 50, 52, respectively, has not changed. This is due to the fact that each projection 50c, 52c sill includes a rounded or arcuate end 62c. In other words, the length of the projections 50c, 52c, as measured between the rounded ends 62c of each projection 50c, 52c is the same as the length of the projections 50, 52 as measured between the rounded ends 62. The only difference being that the rounded ends 62c include a reduced height with respect to the rounded ends 62 due to the bevel 300 located at each end of the projections 50c, 52c.

While the sole structure 100c is described and shown as including the projections 50c, 52c, the sole structure 100c could include only the projections 50c or could only include the projections 52c. Further, the sole structure 100c could include any combination of the projections 50, 50c, 52, 52c. For example, the sole structure 100c could include a single projection 50 and a single projection 50c, could include a single projection 52 and a single projection 52c, or could include one of each of the projections 50, 50c, 52, 52c. Finally, the sole structure 100c could include hybrid projections that include one end that is free from a bevel 300 and another, opposite end that includes a bevel 300. Such hybrid projections could be implemented if the bladder 32 is inserted at the same window 46, 48 during installation. For example, if the bladder 32 is always installed at the window 46, the ends of the projections 50c and/or 52c opposing the window 46 could include a bevel 300 while the ends of the hybrid projections opposing the other window 48 include ends that are free from a bevel, as shown in the sole structure 100.

While the projections 50c, 52c are described as including a bevel 300, the projections 50c, 52c could alternatively include a taper in place of the bevels 300 or could be rounded at the locations of the bevels 30. Additionally, because the midsole 30a may have a unitary construction that may be formed via a 3D printing process, one or more of the projections 50c, 52c at a location of the bevels 300 could be formed such that the projections 50c, 52c are softer at the location of the bevels 30 and the rounded ends 62c. Providing the projections 50c, 52c with a softer construction at the location of the bevels 300 and the rounded ends 62c further facilitates insertion of the bladder 32 into the cavity 44 by more easily allowing the projections 50c, 52c to deform when the bladder 32 engages and exerts a force on the projections 50c, 52c at the angled surfaces 302. Finally, the projections 50, 52 of the article of footwear 10 could also include a softer material at the rounded ends 62 to facilitate compression of the projections 50, 52 when the bladder 32 is inserted into the windows 46, 48.

The following Clauses provide an exemplary configuration for a sole structure for an article of footwear, an article of footwear, and a related method of manufacturing described above.

Clause 1. A sole structure for an article of footwear comprises a midsole including a cavity having a first projection extending from a first surface within the cavity in a first direction and a second projection extending from a second surface within the cavity in a second direction toward the first projection and a cushion including a first recess provided on a first side of the cushion and a second recess provided on an opposite, second side of the cushion, the first recess receiving the first projection and the second recess receiving the second projection.

Clause 2. The sole structure of Clause 1, wherein the first projection is aligned with the second projection.

Clause 3. The sole structure of any of the preceding Clauses, wherein a distal end of the first projection opposes and is aligned with a distal end of the second projection.

Clause 4. The sole structure of any of the preceding Clauses, wherein at least one of the first projection and the second projection is elongate and extends between a first end and a second end along a longitudinal axis of the at least one of the first projection and the second projection, at least one of the first end and the second end including a bevel.

Clause 5. The sole structure of Clause 4, wherein the first projection substantially fills the first recess and the second projection substantially fills the second recess.

Clause 6. The sole structure of any of the preceding Clauses, wherein the cushion is a bladder.

Clause 7. The sole structure of Clause 6, wherein the bladder includes a first barrier layer joined to a second barrier layer to define a chamber, the chamber having a plurality of segments defined by a web area of the bladder.

Clause 8. The sole structure of Clause 7, wherein a portion of the web area is disposed between a distal end of the first projection and a distal end of the second projection.

Clause 9. The sole structure of Clause 6, wherein the bladder is pressurized.

Clause 10. An article of footwear incorporating the sole structure of any of the preceding Clauses.

Clause 11. A method comprising forming a midsole including a cavity and a first projection extending in a first direction from a first surface of the midsole within the cavity, forming a cushion including a first recess disposed on a first side of the cushion, inserting the cushion into the cavity of the midsole, and rotating the cushion within the cavity until the first projection is received by the first recess.

Clause 12. The method of Clause 11, wherein forming the midsole includes forming a second projection extending in a second direction from a second surface of the midsole within the cavity toward the first projection.

Clause 13. The method of Clause 12, further comprising aligning the second projection with the first projection.

Clause 14. The method of Clause 13, wherein aligning the second projection with the first projection includes opposing a distal end of the second projection with a distal end of the first projection.

Clause 15. The method of any of the preceding Clauses, wherein forming a midsole having a first projection includes forming the midsole with an elongate projection.

Clause 16. The method of any of the preceding Clauses, further comprising substantially filling the first recess with the first projection when the first projection is received by the first recess.

Clause 17. The method of any of the preceding Clauses, wherein forming a cushion includes forming a bladder.

Clause 18. The method of Clause 17, wherein forming a bladder includes joining a first barrier layer to a second barrier layer to define a chamber having a plurality of segments defined by a web area of the bladder, the web area of the bladder defining the first recess.

Clause 19. The method of Clause 17, further comprising pressurizing the bladder.

Clause 20. The method of any of the preceding Clauses, further comprising incorporating the midsole and the cushion into an article of footwear.

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.

	Number	Date	Country
	63595894	Nov 2023	US
	63584822	Sep 2023	US

SOLE STRUCTURE FOR ARTICLE OF FOOTWEAR AND RELATED METHOD OF ASSEMBLY

Information

Publication Number

Date Filed

Date Published

Inventors

Original Assignees

CPC

International Classifications

Abstract

Description

Claims

CROSS REFERENCE TO RELATED APPLICATIONS

Provisional Applications (2)