SOLE STRUCTURE FOR ARTICLE OF FOOTWEAR

Abstract

A sole structure for an article of footwear having an upper includes a cushion member and a chassis. The cushion member extends from a forefoot region to a heel region of the sole structure. The cushion member includes a first series of lobes alternating with a first series of recesses along a length of the cushion member. The first series of lobes and the first series of recesses extend along one of a medial side of the sole structure and a lateral side of the sole structure. The chassis is disposed between the cushion member and the upper and includes a series of first supports alternating with a second series of recesses. The supports of the series of first supports are aligned and in contact with respective lobes of the first series of lobes and the second series of recesses are aligned with the first series of recesses.

Description

FIELD

The present disclosure relates generally to sole structures for articles of footwear, and more particularly, to sole structures incorporating a chassis for accommodating a cushion member.

BACKGROUND

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

Articles of footwear conventionally include an upper and a sole structure. The upper may be formed from any suitable material(s) to receive, secure, and support a foot on the sole structure. The upper may cooperate with laces, straps, or other fasteners to adjust the fit of the upper around the foot. A bottom portion of the upper, proximate to a bottom surface of the foot, attaches to the sole structure.

Sole structures generally include a layered arrangement extending between a ground surface and the upper. One layer of the sole structure includes an outsole that provides abrasion-resistance and traction with the ground surface. The outsole may be formed from rubber or other materials that impart durability and wear-resistance, as well as enhance traction with the ground surface. Another layer of the sole structure includes a midsole disposed between the outsole and the upper. The midsole provides cushioning for the foot and may be partially formed from a polymer foam material that compresses resiliently under an applied load to cushion the foot by attenuating ground-reaction forces. The midsole may additionally or alternatively incorporate a cushion member to increase durability of the sole structure, as well as to provide cushioning to the foot by compressing resiliently under an applied load to attenuate ground-reaction forces. The cushion member may be a fluid-filled bladder or a foam element. Sole structures may also include a comfort-enhancing insole or a sockliner located within a void proximate to the bottom portion of the upper and a strobel attached to the upper and disposed between the midsole and the insole or sockliner.

Midsoles employing fluid-filled bladders typically include a bladder formed from two barrier layers of polymer material that are sealed or bonded together. The fluid-filled bladders are pressurized with a fluid such as air, and may incorporate tensile members within the bladder to retain the shape of the bladder when compressed resiliently under applied loads, such as during athletic movements. Generally, bladders are designed with an emphasis on balancing support for the foot and cushioning characteristics that relate to responsiveness as the bladder resiliently compresses under an applied load. In such an aspect, the midsole may include a chassis for interfacing with the bladder so as to form a unitary structure.

DRAWINGS

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

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

FIG. 2A is an exploded, top perspective view of the sole structure of FIG. 1;

FIG. 2B is an exploded, bottom perspective view of the sole structure of FIG. 1;

FIG. 3 is a top perspective view of a first aspect of a cushion member for use in the sole structure of FIG. 1;

FIG. 4 is a bottom perspective view of the cushion member of FIG. 3;

FIG. 5A is a top plan view of the cushion member of FIG. 3;

FIG. 5B is a top plan view of another aspect of a cushion member for use in the sole structure of FIG. 1;

FIG. 5C is a top plan view of yet another aspect of a cushion member for use in the sole structure of FIG. 1;

FIG. 6A is a cross-sectional view of the cushion member shown in FIG. 5A taken along Line 6A-6A;

FIG. 6B is a cross-sectional view of the cushion member of FIG. 5B, taken along Line 6B-6B;

FIG. 6C is a cross-sectional view of the cushion member of FIG. 5C, taken along Line 6C-6C;

FIG. 7 is a cross-sectional view of the cushion member of FIG. 3, taken along Line 7-7 of FIG. 5A;

FIG. 8 is a cross-sectional view of the cushion member of FIG. 3 taken along Line 8-8 of FIG. 5A.

FIG. 9 is a top plan view of the sole structure of FIG. 1;

FIG. 10 is a bottom plan view of the sole structure of FIG. 1;

FIG. 11 is a cross-sectional view of the sole structure of FIG. 1, taken along Line 11-11 of FIG. 10;

FIG. 12 is a cross-sectional view of the sole structure of FIG. 1, taken along Line 12-12 of FIG. 10;

FIG. 13 is a cross-sectional view of the sole structure of FIG. 1, taken along Line 13-13 of FIG. 10;

FIG. 14 is a cross-sectional view of the sole structure of FIG. 1, taken along Line 14-14 of FIG. 10;

FIG. 15 is a cross-sectional view of the sole structure of FIG. 1, taken along Line 15-15 of FIG. 10; and

FIG. 16 is a cross-sectional view of the sole structure of FIG. 1, taken along Line 16-16 of FIG. 10.

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.

One aspect of the disclosure provides a sole structure. The sole structure includes a cushion member and a chassis. In some configurations, the cushion is a fluid-filled chamber comprising a cushion material. In another aspect, the cushion is a solid body comprising a cushion material. In yet another aspect, the cushion comprises a solid, textile or foam element encapsulated in a barrier membrane.

The cushion comprises or consists essentially of a cushion material including one or more polymers. In many examples, including when the cushion is a fluid-filled chamber, the cushion material comprises or consists essentially of a barrier membrane, the barrier membrane comprising a barrier material including one or more gas barrier compounds. The cushion member extends from a forefoot region of the sole structure to a heel region of the sole structure. The cushion member may include a first series of lobes alternating with a first series of recesses along a length of the cushion member. The first series of lobes and the first series of recesses extend along one of a medial side of the sole structure and a lateral side of the sole structure. The chassis is disposed between the cushion member and the upper. The chassis includes a series of first supports alternating with a second series of recesses along a length of the chassis, supports of the series of first supports are aligned and in contact with respective lobes of the first series of lobes and the second series of recesses are aligned with the first series of recesses.

Implementations of the disclosure may include one or more of the following optional features. In some implementations, the chassis includes a cushion support. The chassis may further include a plate mounted to a top surface of the cushion support between the upper and the cushion support. The plate may be longer than the cushion support.

In some configurations, at least one support of the series of first supports may include an upper portion extending in a direction toward the upper and outwardly from a body of the at least one support in the first series of supports.

In some configurations, the plate may be formed from a material having a higher rigidity than a material forming the cushion support, and the cushion support may be formed from foam. The plate may include a series of second supports configured to be aligned with the first series of lobes disposed in the forefoot region. In such an aspect, the cushion support may include an inner support configured to be aligned with an intermediate body portion disposed between the medial side and lateral side of the chassis.

In some configurations, the cushion member may further include a second series of lobes disposed between the medial side and lateral side of the sole structure, the second series of lobes defining a generally U-shaped recess.

In some configurations, the cushion member is one of a foam element and a fluid-filled bladder, the foam element being a solid unitary piece extending a length, width and height of the cushion member. The fluid-filled bladder may be formed of an opposing pair of barrier layers. In another configuration the cushion member includes a foam element encapsulated in an opposing pair of barrier layers. An article of footwear may incorporate the sole structure.

Another aspect of the disclosure provides a sole structure including a cushion member and a chassis. The cushion member includes: (i) a plurality of lobes arranged in series along a peripheral region of the sole structure from a forefoot region to a heel region of the cushion member and (ii) an interior chamber at least partially surrounded by the plurality of lobes and spaced apart from the plurality of lobes by a web area. The chassis includes a plurality of supports arranged in series along the peripheral region of the sole structure. Each of the supports includes a first portion defined by a first material and a second portion defined by a second material different than the first material.

Implementations of the disclosure may include one or more of the following optional features. In some implementations, the chassis comprises a cushion support disposed between the cushion member and the upper. The chassis may include a series of first supports alternating with a second series of recesses along a length of the cushion support. The supports of the series of first supports are aligned and in contact with respective lobes of the first series of lobes and the second series of recesses are aligned with the first series of recesses. The chassis may further include a plate mounted to a top surface of the cushion support between the upper and the cushion support. The plate may be longer than the cushion support.

In some configurations, at least one support of the series of first supports includes an upper portion extending in a direction toward the upper and outwardly from a body of the at least one support. One of the recesses of the first series of recesses may be configured to extend across a width of the cushion support between the medial side and the lateral side.

In some configurations, the cushion member may further include a second series of lobes disposed between the medial side and the lateral side so as to define a generally U-shaped recess. In such a configuration, the cushion support may include an inner support configured to be aligned with an intermediate body portion disposed between the medial side and lateral side of the chassis. In one aspect, the inner support is disposed in the forefoot region.

In some configurations, the cushion is a fluid-filled chamber. In another aspect, the cushion is a solid body. The cushion comprises or consists essentially of a cushion material including one or more polymers. In many examples, including when the cushion is a fluid-filled chamber, the cushion material comprises or consists essentially of a barrier membrane, the barrier membrane comprising a barrier material including one or more gas barrier compounds. In another configuration, the cushion member includes a foam element encapsulated in an opposing pair of barrier layers. An article of footwear may incorporate the chassis.

Materials described herein may differ in one or more of appearance, physical properties, and composition. The materials may differ in appearance in terms of color (including in hue or lightness or both), or in terms of level of transparency or translucency, or in both color and level of transparency or translucency. The materials may differ in one or more physical properties, such as in hardness or in elongation or in both hardness and elongation. The one or more physical properties may differ by at least 5 percent or at least 10 percent or at least 20 percent. The materials may differ in composition. For example, the materials may differ based on the classes or types of polymers present, may differ based on a concentration of the classes or types of polymers, or based on both. The materials may differ in composition based the additives present, or based on a concentration of the additives present, or based on both. Optionally, the concentrations of the one or more polymers and/or one or more additives can differ by at least 5 weight percent or at least 10 weight percent or at least 20 weight percent of the material.

Referring to FIGS. 1-16, an article of footwear 10 includes a sole structure 100 and an upper 300 attached to the sole structure 100. The article of footwear 10 may be divided into one or more regions. The regions may include a forefoot region 12, a mid-foot region 14, and a heel region 16 (shown in FIGS. 5A-5C). The forefoot region 12 may be further described as including a toe portion 12T corresponding to the phalanges of the foot, and a ball portion 12B corresponding to a metatarsophalangeal (MTP) joint. The mid-foot region 14 may correspond with an arch area of the foot, and the heel region 16 may correspond with rear portions of the foot, including a calcaneus bone. The footwear 10 may further include an anterior end 18 associated with a forward-most point of the forefoot region 12, and a posterior end 20 corresponding to a rearward-most point of the heel region 16. A longitudinal axis A₁₀ of the footwear 10 extends along a length of the footwear 10 from the anterior end 18 to the posterior end 20, and generally divides the footwear 10 into a medial side 22 and a lateral side 24, as shown in FIG. 10. Accordingly, the medial side 22 and the lateral side 24 respectively correspond with opposite sides of the footwear 10 and extend through the regions 12, 14, 16.

The article of footwear 10, and more particularly, the sole structure 100, may be further described as including an interior region 26 and a peripheral region 28, as indicated in FIG. 1. The peripheral region 28 is generally described as being a region between the interior region 26 and an outer perimeter of the sole structure 100. Particularly, the peripheral region 28 extends from the forefoot region 12 to the heel region 16 along each of the medial side 22 and the lateral side 24, and wraps around each of the forefoot region 12 and the heel region 16. Thus, the interior region 26 is circumscribed by the peripheral region 28, and extends from the forefoot region 12 to the heel region 16 along a central portion of the sole structure 100.

With reference to FIGS. 2A and 2B, the sole structure 100 includes a midsole 102 configured to provide cushioning characteristics to the sole structure 100, and an outsole 104 configured to provide a ground-engaging surface 30 of the article of footwear 10. Unlike conventional sole structures, the midsole 102 of the sole structure 100 may be formed compositely and include a plurality of subcomponents for providing desired forms of cushioning and support throughout the sole structure 100. For example, the midsole 102 includes a cushion member 106 and a chassis 108, where the chassis 108 is attached to the upper 300 and provides an interface between the upper 300 and the cushion member 106.

With reference to FIGS. 1-5C, a longitudinal axis A₁₀₆ (shown in FIGS. 5A-5C) of the cushion member 106 extends from a first end 110 in the forefoot region 12 to a second end 112 in the heel region 16. The cushion member 106 may be further described as including a top surface or side 114 and a bottom surface or side 116 formed on an opposite side of the cushion member 106 from the top side 114. As discussed in greater detail below with respect to FIGS. 6A-8, thicknesses T₁₀₆ of the cushion member 106, or of elements of the cushion member 106, are defined by a distance from the top side 114 to the bottom side 116.

The cushion member 106 is configured to provide cushioning for the foot by attenuating ground-reaction forces. In one aspect, the cushion member 106 is a fluid-filled bladder 106A and in another aspect, the cushion member 106 is a foam element 106B. The difference between the fluid-filled bladder 106A and the foam element 106B being the attenuation of ground-reaction forces. For instance, when the cushion member 106 is a fluid-filled bladder 106A, the fluid (air) is contained within the fluid-filled bladder 106A itself. Thus, the fluid within the fluid-filled bladder 106A is displaced at the location(s) of a ground-reaction and is forced into other areas of the fluid-filled bladder 106A in the form of a reaction force. However, in instances where the cushion member 106 is a foam element 106B, the ground-reaction forces are absorbed by the foam element at the point of impact. As such, the remaining portions of the foam element 106B do not experience the reaction force in the same way as the fluid-filled bladder 106A. Such a feature may be preferable for users who desire a more cushioned response in comparison to the cushioning provided by the fluid-filled bladder 106A.

As shown in the cross-sectional views of FIGS. 6A and 7-8, a depiction of the cushion member 106 is shown as a fluid-filled bladder 106A. The fluid-filled bladder 106A may be formed by an opposing pair of barrier layers 118, which can be joined to each other at discrete locations to define an overall shape of the bladder 106A. Alternatively, the bladder 106A may be produced from any suitable combination of one or more barrier layers. As used herein, the term “barrier layer” (e.g., barrier layers 118) encompasses both monolayer and multilayer films. In some embodiments, one or both of the barrier layers 118 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 118 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 118 can independently be transparent, translucent, and/or opaque. As used herein, the term “transparent” for a barrier layer and/or a bladder means that light passes through the barrier layer in substantially straight lines and a viewer can see through the barrier layer. In comparison, for an opaque barrier layer, light does not pass through the barrier layer and one cannot see clearly through the barrier layer at all. A translucent barrier layer falls between a transparent barrier layer and an opaque barrier layer, in that light passes through a translucent layer but some of the light is scattered so that a viewer cannot see clearly through the layer.

In one aspect, the airbags or bladders disclosed herein comprise or consist of a barrier membrane. As used herein, a barrier membrane is understood to be a membrane having a relatively low rate of transmittance of a fluid. When used alone or in combination with other materials in an airbag or bladder, the barrier membrane resiliently retains the fluid. Depending upon the structure and use of the airbag or bladder, the barrier membrane may retain the fluid at a pressure which is above, at, or below atmospheric pressure. In some aspects, the fluid is a liquid or a gas. Examples of gasses include air, oxygen gas (O₂), and nitrogen gas (N₂), as well as inert gasses. In one aspect, the barrier membrane is a nitrogen gas barrier material.

The gas transmission rate of the barrier membrane can be less than 4 or less than 3 or less than 2 cubic centimeters per square meter per atmosphere per day per day for a membrane having a thickness of from about 72 micrometers to about 320 micrometers, as measured at 23 degrees Celsius and 0 percent relative humidity. In another example, the gas transmission rate of the barrier membrane is from about 0.1 to about 3, or from about 0.5 to about 3, or from about 0.5 to about 3 cubic centimeters per square meter per atmosphere per day per day for a membrane having a thickness of from about 72 micrometers to about 320 micrometers, as measured at 23 degrees Celsius and 0 percent relative humidity. The gas transmission rate, such as the oxygen gas or nitrogen gas transmission rate, can be measured using ASTM D1434.

In one aspect, the barrier membrane comprise a multi-layered film comprising a plurality of layers, the plurality of layers comprising one or more barrier layers, the one or more barrier layers comprising a barrier material, the barrier material comprising or consisting essentially of one or more gas barrier compounds. The multi-layered film comprises at least 5 layers or at least 10 layers. Optionally, the multi-layered film comprises from about 5 to about 200 layers, from about 10 to about 100 layers, from about 20 to about 80 layers, from about 20 to about 50 layers, or from about 40 to about 90 layers.

In one aspect of a multi-layered film, the plurality of layers includes a series of alternating layers, in which the alternating layers include two or more barrier layers, each of the two or more barrier layers individually comprising a barrier material, the barrier material comprising or consisting essentially of one or more gas barrier compounds. In the series of alternating layers, adjacent layers are individually formed of materials which differ from each other at least in their chemical compositions based on the individual components present (e.g., the materials of adjacent layers may differ based on whether or not a gas barrier compound is present, or differ based on class or type of gas barrier compound present), the concentration of the individual components present (e.g., the materials of adjacent layers may differ based on the concentration of a specific type of gas barrier compound present), or may differ based on both the components present and their concentrations.

The plurality of layers of the multi-layered film can include first barrier layers comprising a first barrier material and second barrier layers comprising a second barrier material, wherein the first and second barrier materials differ from each other based as described above. The first barrier material can be described as comprising a first gas barrier component consisting of all the gas barrier compounds present in the first barrier material, and the second barrier material can be described as comprising a second barrier material component consisting of all the gas barrier compounds present in the second barrier material. In a first example, the first barrier component consists only of one or more gas barrier polymers, and the second barrier component consists only of one or more inorganic gas barrier compounds. In a second example, the first barrier component consists of a first one or more gas barrier polymers, and the second component consists of a second one or more gas barrier polymers, wherein the first one or more gas barrier polymers differ from the second one or more gas barrier polymers in polymer class, type, or concentration. In a third example, the first barrier component and the second barrier component both include the same type of gas barrier compound, but the concentration of the gas barrier compound differ, optionally the concentrations differ by at least 5 weight percent based on the weight of the barrier material. In these multi-layered films, the first barrier layers and the second barrier layers can alternate with each other, or can alternate with additional barrier layers (e.g., third barrier layers comprising a third barrier material, fourth barrier layers comprising a fourth barrier material, etc., wherein each of the first, second, third and fourth, etc., barrier materials differ from each other as described above.

The barrier material (including a first barrier material, a second barrier material, etc.) has a low gas transmittance rate. For example, when formed into a single-layer film consisting essentially of the barrier material, the single-layer film has a gas transmittance rate of less than 4 cubic centimeters per square meter per atmosphere per day per day for a membrane having a thickness of from about 72 micrometers to about 320 micrometers, as measured at 23 degrees Celsius and 0 percent relative humidity, and can be measured using ASTM D1434. The barrier material comprises or consists essentially of one or more gas barrier compounds. The one or more gas barrier compounds can comprise one or more gas barrier polymers, or can comprise one or more inorganic gas barrier compound, or can comprise a combination of at least one gas barrier polymer and at least one inorganic gas barrier compound. The combination of at least one gas barrier polymer and at least one inorganic gas barrier compound can comprise a blend or mixture, or can comprise a composite in which fibers, particles or platelets of the inorganic gas barrier compound are surrounded by the gas barrier polymer.

In one aspect, the barrier material comprises or consists essentially of one or more inorganic gas barrier compounds. The one or more inorganic gas barrier compounds can take the form of fibers, particulates, platelets, or combinations thereof. The fibers, particulates, platelets can comprise or consist essentially of nanoscale fibers, particulates, platelets, or combinations thereof. Examples of inorganic barrier compounds includes, for example, carbon fibers, glass fibers, glass flakes, silicas, silicates, calcium carbonate, clay, mica, talc, carbon black, particulate graphite, metallic flakes, and combinations thereof. The inorganic gas barrier component can comprise or consist essentially of one or more clays. Examples of suitable clays include bentonite, montmorillonite, kaolinite, and mixtures thereof. In one example, the inorganic gas barrier component consists of clay. Optionally, the barrier material can further comprise one or more additional ingredients, such as a polymer, processing aid, colorant, or any combination thereof. In aspects where the barrier material comprises or consists essentially of one or more inorganic barrier compounds, the barrier material can be described as comprising an inorganic gas barrier component consisting of all inorganic barrier compounds present in the barrier material. When one or more inorganic gas barrier compounds are included in the barrier material, the total concentration of the inorganic gas barrier component present in the barrier material can be less than 60 weight percent, or less than 40 weight percent, or less than 20 weight percent of the total composition. Alternatively, in other examples, the barrier material consists essentially of the one or more inorganic gas barrier materials.

In one aspect, the gas barrier compound comprises or consists essentially of one or more gas barrier polymers. The one or more gas barrier polymers can include thermoplastic polymers. In one example, the barrier material can comprise or consist essentially of one or more thermoplastic polymers, meaning that the barrier material comprises or consists essentially of a plurality of thermoplastic polymers, including thermoplastic polymers which are not gas barrier polymers. In another example, the barrier material comprises or consists essentially of one or more thermoplastic gas barrier polymers, meaning that all the polymers present in the barrier material are thermoplastic gas barrier polymers. The barrier material can be described as comprising a polymeric component consisting of all polymers present in the barrier material. For example, the polymeric component of the barrier material can consist of a single class of gas barrier polymer, such as, for example, one or more polyolefin, or can consist of a single type of gas barrier polymer, such as one or more ethylene-vinyl alcohol copolymers. Optionally, the barrier material can further comprise one or more non-polymeric additives, such as one or more filler, processing aid, colorant, or combination thereof.

Many gas barrier polymers are known in the art. Examples of gas barrier polymers include vinyl polymers such as vinylidene chloride polymers, acrylic polymers such as acrylonitrile polymers, polyamides, epoxy polymers, amine polymers, polyolefins such as polyethylenes and polypropylenes, copolymers thereof, such as ethylene-vinyl alcohol copolymers, and mixtures thereof. Examples of thermoplastic gas barrier polymers include thermoplastic vinyl homopolymers and copolymers, thermoplastic acrylic homopolymers and copolymers, thermoplastic amine homopolymers and copolymers, thermoplastic polyolefin homopolymers and copolymers, and mixtures thereof. In one example, the one or more gas barrier polymers comprise or consist essentially of one or more thermoplastic polyethylene copolymers, such as, for example, one or more thermoplastic ethylene-vinyl alcohol copolymers. The one or more ethylene-vinyl alcohol copolymers can include from about 28 mole percent to about 44 mole percent ethylene content, or from about 32 mole percent to about 44 mole percent ethylene content. In yet another example, the one or more gas barrier polymers can comprise or consist essentially of one or more one or more polyethyleneimine, polyacrylic acid, polyethyleneoxide, polyacrylamide, polyamidoamine, or any combination thereof.

In another aspect, in addition to the one or more barrier layers (e.g., including first barrier layers, second barrier layers, etc.), the multi-layered film further comprises one or more second layers, the one or more second layers comprising a second material. In one such configuration of the multi-layered film, the one or more barrier layers include a plurality of barrier layers alternating with a plurality of second layers. For example, each of the one or more barrier layers may be positioned between two second layers (e.g., with one second layer positioned on a first side of the barrier layer, and another second layer on a second side of the barrier layer, the second side opposing the first side).

The second material of the one or more second layers can comprise one or more polymers. Depending upon the class of gas barrier compounds used and the intended use of the multi-layered film, the second material may have a higher gas transmittance rate than the barrier material, meaning that the second material is a poorer gas barrier than the barrier material. In some aspects, the one or more second layers act as substrates for the one or more barrier layers, and may serve to increase the strength, elasticity, and/or durability of the multi-layered film. Alternatively or additionally, the one or more second layers may serve to decrease the amount of gas barrier material(s) needed, thereby reducing the overall material cost. Even when the second material has a relatively high gas transmittance rate, the presence of the one or more second layers, particularly when the one or more second layers are positioned between one or more barrier layers, may help maintain the overall barrier properties of the film by increasing the distance between cracks in the barrier layers, thereby increasing the distance gas molecules must travel between cracks in the barrier layers in order to pass through the multi-layered film. While small fractures or cracks in the barrier layers of a multi-layered film may not significantly impact the overall barrier properties of the film, using a larger number of thinner barrier layers can avoid or reduce visible cracking, crazing or hazing of the multi-layered film. The one or more second layers can include, but are not limited to, tie layers adhering two or more layers together, structural layers providing mechanical support to the multi-layered films, bonding layers providing a bonding material such as a hot melt adhesive material to the multi-layered film, and/or cap layers providing protection to an exterior surface of the multi-layered film.

In some aspects, the second material is an elastomeric material comprising or consisting essentially of at least one elastomer. Many gas barrier compounds are brittle and/or relatively inflexible, and so the one or more barrier layers may be susceptible to cracking when subjected to repeated, excessive stress loads, such as those potentially generated during flexing and release of a multi-layered film. A multi-layered film which includes one or more barrier layers alternating with second layers of an elastomeric material results in a multi-layered film that is better able to withstand repeated flexing and release while maintaining its gas barrier properties, as compared to a film without the elastomeric second layers present.

The second material comprises or consists essentially of one or more polymers. As used herein, the one or more polymers present in the second material are referred to herein as one or more “second polymers” or a “second polymer”, as these polymers are present in the second material. References to “second polymer(s)” are not intended to indicate that a “first polymer” is present, either in the second material, or in the multi-layered film as a whole, although, in many aspects, multiple classes or types of polymers are present. In one aspect, the second material comprises or consists essentially of one or more thermoplastic polymers. In another aspect, the second material comprises or consists essentially of one or more elastomeric polymers. In yet another aspect, the second material comprises or consists essentially of one or more thermoplastic elastomers. The second material can be described as comprising a polymeric component consisting of all polymers present in the second material. In one example, the polymeric component of the second material consists of one or more elastomers. Optionally, the second material can further comprise one or more non-polymeric additives, such as fillers, processing aids, and/or colorants.

Many polymers which are suitable for use in the second material are known in the art. Exemplary polymers which can be included in the second material (e.g., second polymers) include polyolefins, polyamides, polycarbonates, polyimines, polyesters, polyacrylates, polyesters, polyethers, polystyrenes, polyureas, and polyurethanes, including homopolymers and copolymers thereof (e.g., polyolefin homopolymers, polyolefin copolymers, etc.), and combinations thereof. In one example, the second material comprises or consists essentially of one or more polymers chosen from polyolefins, polyamides, polyesters, polystyrenes, and polyurethanes, including homopolymers and copolymers thereof, and combinations thereof. In another example, the polymeric component of the second material consists of one or more thermoplastic polymers, or one or more elastomers or one or more thermoplastic elastomers, including thermoplastic vulcanizates. Alternatively, the one or more second polymers can include one or more thermoset or thermosettable elastomers, such as, for example, natural rubbers and synthetic rubbers, including butadiene rubber, isoprene rubber, silicone rubber, and the like.

Polyolefins are a class of polymers which include monomeric units derived from simple alkenes, such as ethylene, propylene and butene. Examples of thermoplastic polyolefins include polyethylene homopolymers, polypropylene homopolymers polypropylene copolymers (including polyethylene-polypropylene copolymers), polybutene, ethylene-octene copolymers, olefin block copolymers; propylene-butane copolymers, and combinations thereof, including blends of polyethylene homopolymers and polypropylene homopolymers. Examples of polyolefin elastomers include polyisobutylene elastomers, poly(alpha-olefin) elastomers, ethylene propylene elastomers, ethylene propylene diene monomer elastomers, and combinations thereof.

Polyamides are a class of polymers which include monomeric units linked by amide bonds. Naturally-occurring polyamides include proteins such as wool and silk, and synthetic amides such as nylons and aramids. The one or more second polymers can include thermoplastic polyamides such as nylon 6, nylon 6-6, nylon-11, as well as thermoplastic polyamide copolymers.

Polyesters are a class of polymers which include monomeric units derived from an ester functional group, and are commonly made by condensing dibasic acids such as, for example, terephthalic acid, with one or more polyols. In one example, the second material can comprise or consist essentially of one or more thermoplastic polyester elastomers. Examples of polyester polymers include homopolymers such as polyethylene terephthalate, polybutylene terephthalate, poly-1,4-cyclohexylene-dimethylene terephthalate, as well as copolymers such as polyester polyurethanes.

Styrenic polymers are a class of polymers which include monomeric units derived from styrene. The one or more second polymers can comprise or consist essentially of styrenic homopolymers, styrenic random copolymers, styrenic block copolymers, or combinations thereof. Examples of styrenic polymers include 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.

Polyurethanes are a class of polymers which include monomeric units joined by carbamate linkages. Polyurethanes are most commonly formed by reacting a polyisocyanate (e.g., a diisocyanate or a triisocyanate) with a polyol (e.g., a diol or triol), optionally in the presence of a chain extender. The monomeric units derived from the polyisocyanate are often referred to as the hard segments of the polyurethane, while the monomeric units derived from the polyols are often referred to as the soft segments of the polyurethane. The hard segments can be derived from aliphatic polyisocyanates, or from organic isocyanates, or from a mixture of both. The soft segments can be derived from saturated polyols, or from unsaturated polyols such as polydiene polyols, or from a mixture of both. When the multi-layered film is to be bonded to natural or synthetic rubber, including soft segments derived from one or more polydiene polyols can facilitate bonding between the rubber and the film when the rubber and the film are crosslinked in contact with each other, such as in a vulcanization process.

Examples of suitable polyisocyanates from which the hard segments of the polyurethane can be derived include hexamethylene diisocyanate (HDI), isophorone diisocyanate (IPDI), butylenediisocyanate (BDI), bisisocyanatocyclohexylmethane (HMDI), 2,2,4-trim ethyl hex am ethylene diisocyanate (TMDI), bisisocyanatomethylcyclohexane, bisisochanatomethyltricyclodecane, norbornane diisocyanate (NDI), cyclohexane diisocyanate (CHDI), 4,4′-dicyclohexhylmethane diisocyanate (H12MDI), diisocyanatododecane, lysine diisocyanate, toluene diisocyanate (TDI), TDI adducts with trimethylolpropane (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 any combination thereof. In one aspect, the polyurethane comprises or consists essentially of hard segments derived from toluene diisocyanate (TDI), or from methylene diphenyl diisocyanate (MDI), or from both.

The soft segments of the polyurethane can be derived from a wide variety of polyols, including polyester polyols, polyether polyols, polyester-ether polyols, polycarbonate polyols, polycaprolactone polyethers, and combinations thereof. In one aspect, the polyurethane comprises or consist essentially of monmeric units derived from C₄-C₁₂ polyols, or C₆-C₁₀ polyols, or C₈ or lower polyols, meaning polyols with 4 to 12 carbon molecules, or with 6 to 10 carbon molecules, or with 8 or fewer carbon molecules in their chemical structures. In another aspect, the polyurethane comprises or consists essentially of monomeric units derived from polyester polyols, polyester-ether polyols, polyether polyols, and any combination thereof. In yet another aspect, the polyurethane comprises or consists essentially of soft segments derived from polyols or diols having polyester functional units. The soft segments derived from polyols or diols having polyester functional units can comprise about 10 to about 50, or about 20 to about 40, or about 30 weight percent of the soft segments present in the polyurethane.

The multi-layered films can be produced by various means such as co-extrusion, lamination, layer-by-layer deposition, and the like. When co-extruding one or more barrier layers alone or with one or more second layers, selecting materials (e.g., a first barrier material and a second barrier material, or a single barrier material and a second material) having similar processing characteristics such as melt temperature and melt flow index, can reduce interlayer shear during the extrusion process, and can allow the alternating barrier layers and second layers to be co-extruded while retaining their structural integrities and desired layer thicknesses. In one example, the one or more barrier materials and optionally the second material when used, can be extruded into separate individual films, which can then be laminated together to form the multi-layered films.

The multi-layered films can be produced using a layer-by-layer deposition process. A substrate, which optionally can comprise a second material or a barrier material, can be built into a multi-layered film by depositing a plurality of layers onto the substrate. The layers can include one or more barrier layers (e.g., first barrier layers, second barrier layers, etc.). Optionally, the layers can include one or more second layers. The one or more barrier layers and/or second layers can be deposited by any means known in the art such as, for example, dipping, spraying, coating, or another method. The one or more barrier layers can be applied using charged solutions or suspensions, e.g., cationic solutions or suspensions or anionic solutions or suspensions, including a charged polymer solution or suspension. The one or more barrier layers can be applied using a series of two or more solutions having opposite charges, e.g., by applying a cationic solution, followed by an anionic solution, followed by a cationic solution, followed by an anionic solution, etc.

The barrier membranes, including the multi-layered films, have an overall thickness of from about 40 micrometers to about 500 micrometers, or about 50 micrometers to about 400 micrometers, or about 60 micrometers to about 350 micrometers. In one aspect, each individual layer of the plurality of layers of the multi-layered film has a thickness of from about 0.001 micrometers to about 10 micrometers. For example, the thickness of an individual barrier layer can range from about 0.001 micrometers to about 3 micrometers thick, or from about 0.5 micrometers to about 2 micrometers thick, or from about 0.5 micrometers to about 1 micrometer thick. The thickness of an individual second layer can range from about 2 micrometers to about 8 micrometers thick, or from about 2 micrometers to about 4 micrometers thick.

In a further aspect, thickness of the films and/or their individual layers can be measured by any method known in the art such as, for example, ASTM E252, ASTM D6988, ASTM D8136, or using light microscopy or electron microscopy.

In some aspects, the barrier membranes, including the multi-layered films, have a Shore hardness of from about 35 A to about 95 A, optionally from about 55 A to about 90 A. In these aspects, hardness can be measured using ASTM D2240 using the Shore A scale.

In one aspect, when a co-extrusion process is used to form the barrier membrane from a plurality of alternating barrier layers and second layers, the barrier material has a melt flow index of from about 5 to about 7 grams per 10 minutes at 190 degrees Celsius when using a weight of 2.16 kilograms, while the second material has a melt flow index of from about 20 to about 30 grams per 10 minutes at 190 degrees Celsius when using a weight of 2.16 kilograms. In a further aspect, the melt flow index of the barrier material is from about 80 percent to about 120 percent of the melt flow index of the barrier material per 10 minutes when measured at 190 degrees Celsius when using a weight of 2.16 kilograms. In these aspects, melt flow index can be measured using ASTM D1238. Alternatively or additionally, the barrier material or the second material or both have a melting temperature of from about 165 degrees Celsius to about 183 degrees Celsius, or from about 155 degrees Celsius to about 165 degrees Celsius. In one such example, the barrier material has a melting temperature of from about 165 degrees Celsius to about 183 degrees Celsius, while the second material has a melting temperature of from about 155 degrees Celsius to about 165 degrees Celsius. Further in these aspects, melting temperature can be measured using ASTM D3418.

In the shown embodiment, the barrier layers 118 include a first, upper barrier layer 118 forming the top side 114 of the bladder 106A, and a second, lower barrier layer 118 forming the bottom side 116 of the bladder 106A. In the illustrated example, interior, opposing surfaces (i.e. facing each other) of the barrier layers 118 are joined together at discrete locations to form a web area 120 and a peripheral seam 122. The peripheral seam 122 extends around the outer periphery of the bladder 106A and defines an outer peripheral profile of the bladder 106A. As shown in FIGS. 3-5A, 6A, 7 and 8, the upper and lower barrier layers 118 are spaced apart from each other between the web area 120 and the peripheral seam 122 to define a plurality of chambers 126a-126c, 128a-128b each forming a respective portion of an interior void 130 of the bladder 106A.

The bladder 106A may include a plurality of U-shaped or horseshoe-shaped chambers 126a-126c such as shown in Chan et al., U.S. patent application Ser. No. 17/133,732, the disclosure of which is incorporated by reference in its entirety. As discussed in greater detail below, portions of these chambers 126a-126c extend along the medial and lateral sides 22, 24 in the peripheral region 28. Accordingly, these chambers 126a-126c may be referred to as peripheral chambers 126a-126c. The peripheral chambers 126a-126c include a heel peripheral chamber 126a, a forefoot peripheral chamber 126b, and a toe peripheral chamber 126c. Generally, the peripheral chambers 126a-126c are arranged in series along the longitudinal axis A₁₀₆ from the first end 110 of the bladder 106A to the second end 112 of the bladder 106A. Accordingly, the chambers 126a-126c are aligned with each other along the direction of the length of the bladder 106A.

With reference to FIGS. 3-5A, one or more of the peripheral chambers 126a-126c may have a variable cross-sectional area from end to end. In addition to the peripheral chambers 126a-126c, the bladder 106A includes one or more interior chambers 128a, 128b disposed in the interior region 26 of the bladder 106A. Here, each of the interior chambers 128a, 128b is at least partially surrounded by a respective one of the peripheral chambers 126a, 126b. The peripheral chambers 126a-126c and the interior chambers 128a, 128b bound an interior void 130. Generally, each of the interior chambers 128a, 128b extends from a first end 132a, 132b connected to an intermediate segment 134a, 134b of an adjacent one of the peripheral chambers 126b, 126c, to a terminal second end 136a, 136b adjacent to the posterior end 20 of the respective one of the peripheral chambers 126a, 126b. The intermediate segments 134a, 134b fluidly couple the medial side 22 of the bladder 106A to the lateral side 24 of the bladder 106A.

As shown, the heel peripheral chamber 126a, the forefoot peripheral chamber 126b and the toe peripheral chamber 126c include a series of lobes 138a-138i that are interconnected to each other and are disposed along the periphery of the bladder 106A. The series of lobes 138a-138i extend in a direction along the longitudinal axis A₁₀₆ of the bladder 106A. Each of the lobes 138a-138i has a variable cross-sectional area so as to taper from a midpoint of the respective lobe 138a-138i to the ends of the respective lobes 138a-138i. For example, each of the lobes 138a-138i includes a first end 140a-140i having a first cross-sectional area, a second end 142a-142i having a second cross-sectional area, and an intermediate portion 144a-144i disposed between the first end 140a-140i and the second end 142a-142i and having a third cross-sectional area that is greater than the first cross-sectional area and the second cross-sectional area. Accordingly, each of the lobes 138a-138i tapers towards the respective first end 140a-140i and second end 142a-142i from the intermediate portion 144a-144i so as to define a first series of recesses 146a-146h, wherein each recess 146a-146h is disposed between a pair of adjacent lobes 138a-138i so as to alternate with the series of lobes 138a-138i along the length of the chambers 126a-126c. In some examples, both the width and the thickness of each of the lobes 138a-138i tapers from the intermediate portion 144a-144i.

In the illustrated example of the bladder 106A, the plurality of the lobes 138a-138i are arranged end-to-end in series along the peripheral region 28 such that the cross-sectional area of the heel peripheral chamber 126a alternates between larger and smaller sizes. As shown, the series of lobes 138a-138i includes a first pair of toe lobes 138a, 138b disposed on the toe peripheral chamber 126c, a pair of forefoot lobes 138c, 138d disposed on the forefoot peripheral chamber 126b, a pair of mid-foot lobes 138e, 138f disposed in the mid-foot region 14 at an anterior end of the heel peripheral chamber 126a, a pair of heel lobes 138g, 138h disposed in the heel region 16 between the mid-foot lobes 138e, 138f and the second end 112, and a posterior lobe 138i disposed at the second end 112 of the bladder 106A. The mid-foot lobes 138e, 138f, the heel lobes 138g, 138h, and the posterior lobe 138i define a first series 148 of lobes 138e-138i that form the heel peripheral chamber 126a. The pair of toe lobes 138a, 138b and the pair of forefoot lobes 138c, 138d define a second series 150 of lobes. The pair of toe lobes 138a, 138b are spaced apart from each other to define a generally U-shaped recess as viewed along a plane defined by a width and length of the chassis 108.

The mid-foot lobes 138e, 138f of the heel peripheral chamber 126a include a medial mid-foot lobe 138e disposed at the anterior end of the heel region 16 on the medial side 22 of the bladder 106, and a lateral mid-foot lobe 138f disposed at the anterior end of heel region 16 on the lateral side 24 of the bladder 106A. Each of the medial mid-foot lobe 138e and the lateral mid-foot lobe 138f extends from a respective first end 140e, 140f and along the peripheral region 28 to its respective second end 142e, 142f.

With continued reference to FIGS. 3-5A, the posterior lobe 138i is disposed at the second end 112 of the bladder 106A and the intermediate portion 144i of the posterior lobe 138i is aligned with the longitudinal axis A₁₀₆ of the bladder 106A. In the illustrated example, the posterior lobe 138i extends from a first end 140i on the medial side 22 of the bladder 106A to a second end 142i on the lateral side 24 of the bladder 106A. As discussed above, the intermediate portion 144i has a greater cross-sectional area than each of the first end 140i and the second end 142i.

The heel lobes 138g, 138h of the heel peripheral chamber 126a include a medial heel lobe 138g disposed on the medial side 22 of the bladder 106A, and a lateral heel lobe 138h disposed on the lateral side 24 of the bladder 106A. As shown, first ends 140g, 140h of the heel lobes 138g, 138h are connected to the second ends 142e, 142f of the medial and lateral mid-foot lobes 138e, 138f, respectively. The second end 142g of the medial heel lobe 138g is connected to the first end 140i of the posterior lobe 138i. Likewise, the second end 142f of the lateral heel lobe 138h is connected to the second end 142i of the posterior lobe 138i. Similar to the mid-foot lobes 138e, 138f and the posterior lobe 138i, the heel lobes 138e-138h, provide the heel peripheral chamber 126a with protruding portions along the medial and lateral sides 22, 24 of the bladder 106A.

With continued reference to FIGS. 3-5A, the posterior lobe 138i is disposed at the second end 112 of the bladder 106A and the intermediate portion 144i of the posterior lobe 138i is aligned with the longitudinal axis A₁₀₆ of the bladder 106A. In the illustrated example, the posterior lobe 138i extends from a first end 140i on the medial side 22 of the bladder 106A to a second end 142i on the lateral side 24 of the bladder 106A. As discussed above, the intermediate portion 144i has a greater cross-sectional area than each of the ends 140i, 142i.

The heel lobes 138g, 138h of the heel peripheral chamber 126a include a medial heel lobe 138g disposed on the medial side 22 of the bladder 106A, and a lateral heel lobe 138h disposed on the lateral side 24 of the bladder 106A. As shown, first ends 140g, 140h of the heel lobes 138g, 138h are connected to the second ends 142e, 142f of the medial and lateral mid-foot lobes 138e, 138f, respectively. The second end 142g of the medial heel lobe 138g is connected to the first end 140i of the posterior lobe 138i. Likewise, the second end 142h of the lateral heel lobe 138h is connected to the second end 142i of the posterior lobe 138i. Similar to the mid-foot lobes 138e, 138f and the posterior lobe 138i, the heel lobes 138g, 138h provide the heel peripheral chamber 126a with protruding portions along the medial and lateral sides 22, 24 of the bladder 106A.

The intermediate segments 134a, 134b extend across the width of the bladder 106A. The intermediate segment 134b is adjacent to the mid-foot region 14 and connects the pair of forefoot lobes 138c, 138d to each other. As shown, the intermediate segment 134b extends along an arcuate path from the medial side 22 to the lateral side 24. Intermediate segment 134a separates the toe portion 12T from the mid-foot region 14 and connects the second ends 142a, 142b of the pair of toe lobes 138a, 138b to each other. As shown, the intermediate segment 134a extends along an arcuate path from the medial side 22 to the lateral side 24 so as to help form a U-shaped recess between the pair of toe lobes 138a, 138b.

Referring still to FIGS. 3-5A, the forefoot peripheral chamber 126b includes the pair of forefoot lobes 138c, 138d that extend through the ball portion 12B of the forefoot region 12, and are disposed between the heel peripheral chamber 126a and the toe peripheral chamber 126c. Specifically, the forefoot lobes 138c, 138d include a medial forefoot lobe 138c and a lateral forefoot lobe 138d. A first recess 146a is formed where the second end 142a of the medial toe lobe 138a joins with the first end 140c of the medial forefoot lobe 138c. Likewise, a second recess 146b is formed where the second end 142b of the lateral toe lobe 138b joins with the first end 140d of the lateral forefoot lobe 138d. A third recess 146c is formed where the second end 142c of the medial forefoot lobe 138c joins with the first end 140e of the medial mid-foot lobe 138e. Likewise, a fourth recess 146d is formed where the second end 142d of the lateral forefoot lobe 138d joins with the first end 140f of the lateral mid-foot lobe 138f.

In some examples, one or both of the forefoot lobes 138c, 138d of the forefoot peripheral chamber 126b may be bulbous, whereby a size (e.g., cross-section, width, thickness) of the intermediate portion 144c, 144d is greater than the first end 140c, 140d and the second end 142c, 142d. For example, in the illustrated configuration, a width of each of the first ends 140c, 140d and the second ends 142c, 142d increases from the respective intermediate portion 144c, 144d such that the first ends 140c, 140d and the second ends 142c, 142d converge inwardly towards the longitudinal axis A₁₀₆ of the bladder 106A. With continued reference to FIGS. 3-5A, one or both of the toe lobes 138a, 138b of the toe peripheral chamber 126c may be bulbous, whereby a size (e.g., cross-section, width, thickness) of the intermediate portion 144a, 144b is greater than the first end 140a, 140b and the second end 142a, 142b.

Unlike the heel peripheral chamber 126a and the forefoot peripheral chamber 126b, which are fully attached to the web area 120, the toe peripheral chamber 126c may only be partially attached to the web area 120. For example, the toe lobes 138a, 138b of the toe peripheral chamber 126c may project beyond the web area 120, such that each of the distal ends of the toe lobes 138a, 138b is free-hanging. Accordingly, each of the toe lobes 138a, 138b may move independent of the other. In another configuration, the toe lobes 138a, 138b of the toe peripheral chamber 126c may be formed to have a substantially circular shape (not shown).

As shown in FIG. 5A, a forefoot interior chamber 128a extends along the longitudinal axis A₁₀₆ from a first end 132a connected to the intermediate segment 134a of the toe peripheral chamber 126c, to a terminal second end 136a adjacent to the intermediate segment 134b of the forefoot peripheral chamber 126b. As shown, an outer perimeter of the forefoot interior chamber 128a is inwardly offset from an inner perimeter of the forefoot peripheral chamber 126b by a substantially constant distance. In the illustrated example, the forefoot interior chamber 128a includes a necked portion 152 adjacent to the first end 132a, which extends between the recesses 146a, 146b of the forefoot peripheral chamber 126b. The second end 136a of the forefoot interior chamber 128a may also be bulbous, and is circumscribed by the forefoot lobes 138c, 138d of the forefoot peripheral chamber 126b.

A heel interior chamber 128b extends along the longitudinal axis A₁₀₆ from a first end 132b connected to the intermediate segment 134b of the forefoot peripheral chamber 126b, to a terminal second end 136b adjacent to the posterior lobe 138i of the heel peripheral chamber 126a. An outer perimeter of the heel interior chamber 128b is inwardly offset from an inner perimeter of the heel peripheral chamber 126a by a substantially constant distance. As such, a width of the heel interior chamber 128b may increase along the direction from the first end 132b to the second end 136b.

The interior chambers 128a, 128b are attached to the respective peripheral chambers 126a, 126b by the web area 120, such that each of the interior chambers 128a, 128b is surrounded by a portion the web area 120. Accordingly, the web area 120 includes a first portion 154a having a substantially U-shape surrounding the heel interior chamber 128a, and a second portion 154b having a substantially U-shape surrounding the forefoot interior chamber 128b. As shown, the first U-shaped portion 154a of the web area 120 extends between and attaches the outer perimeter of the heel interior chamber 128a and the inner perimeter of the heel perimeter chamber 126a. Likewise, the second U-shaped portion 154b extends between and attaches the outer perimeter of the forefoot interior chamber 128b and the inner perimeter of the forefoot peripheral chamber 126b. As illustrated, with respect to the aforementioned portions of the web area 120, the term “U-shaped” is not limited strictly to shapes having two straight legs connected by a constant curvature, but instead refers to any shape the extends from a first end along a general first direction, and then turns back and extends along the first direction to a second end adjacent to or across from the first end. Thus, the U-shaped portions of the web area could also be described as being horseshoe-shaped, bell-shaped, or hairpin-shaped, for example.

Adjacent ones of the chambers 126a-126c, 128a-128b are separated from each other by the portions of the web area 120, such that pockets or spaces 156a-156c, 158a-158c are formed on opposite sides 114, 116 of the bladder 106A between adjacent ones of the chambers 126a-126c, 128a-128b, as best shown in FIGS. 6A, 7 and 8. In other words, the bladder 106A includes a series of upper pockets 156a-156c formed by the web area 120 and adjacent chambers 126a-126c, 128a-128b on the top side 114 of the bladder 106A, and a series of lower pockets 158a-158c are formed by the web area 120 and adjacent chambers 126a-126c, 128a-128b on the bottom side 116 of the bladder 106A.

With continued reference to FIG. 5A, the first and second ends 140a-140i, 142a-142i of the series of lobes 138a-138i and the first ends 132a, 132b of the interior chambers 128a, 128b form a plurality of conduits fluidly coupling adjacent ones of the peripheral chambers 126a-126c to each other. Accordingly, the portions of the interior void 130 formed by each of the peripheral chambers 126a-126c and the interior chambers 128a, 128b are in fluid communication with each other, such that fluid can be transferred between the peripheral chambers 126a-126c.

With reference now to FIGS. 5B and 6B, another aspect of the cushion member 106 is provided wherein the cushion member 106 is a foam element 106B. In one aspect, the foam element 106B is a solid unitary piece extending a length, width and height of the cushion member 106. In such an aspect, the top side 114 and the bottom side 116 of the foam element 106B defines the shape of the foam element 106B. The foam element 106B comprises a foam material comprising one or more polymers, examples of which are provided below. As shown in FIGS. 5B and 6B, the shape of the foam element 106B is the same as the shape of the cushion member 106 shown throughout the figures. In other words, the foam element 106B may comprise or consist essentially of a foam material having a shape that is identical to the shape defined by the barrier membranes 118 shown in FIGS. 5A and 6A. It should be noted that foam element 106B may have the same shape as the peripheral chambers 126a-126c and interior chambers 128a, 128b described with respect to the fluid-filled bladder 106A, but does not enclose a space or define an inner void, as the foam element 106B is formed as a unitary piece. Features such as the web area 120 of the fluid-filled bladder 106A are also formed of a resilient polymeric material when the cushion 106 is formed as a foam element 106B. The polymeric material may be formed to provide substantially the same cushioning and load bearing characteristics as the fluid-filled bladder 106A shown in FIGS. 5A and 6A; however, the ground-reacting forces may be different, as described above. Namely, the ground-reacting forces are primarily dissipated by the foam element 106B as opposed to being distributed throughout the fluid-filled bladder 106A. As such, an applied load is generally absorbed rather than dissipated or otherwise attenuated to other locations of the cushion member 106.

With reference now to FIGS. 5C and 6C, another aspect of the cushion member 106 is provided wherein the cushion member 106 includes a foam element 106B formed as a solid body that comprises a foam material comprising one or more polymers received within and between the barrier layers 118 so as to be encapsulated. The polymeric material and associated barrier layers 118 may be formed to provide substantially the same cushioning and load bearing characteristics as the fluid-filled bladder 106A shown in FIGS. 5A and 6A; however, the ground-reacting forces are different due to the foam element 106B disposed therein. In essence, the combination of the barrier layers 118 and encapsulated foam element 106B provides a hybrid cushion that shares properties of the fluid-filled bladder 106A and the foam element 106B. Namely, an applied load will (i) cause displacement of fluid trapped between the barrier layers 118 and (ii) be absorbed by the polymeric material of the foam element 106B. Encapsulating the polymeric material within the barrier layers 118 helps keep the polymeric material of the foam element 106B clean and dry and helps the foam element 106B retain a desired shape. Regardless of whether the cushion member 106 includes barrier layers 118 and a polymeric material or just a polymeric material defining the cushion member 106, the thickness T₁₀₆ of the cushion member 106 shown in FIG. 6C is the same as the thickness T₁₀₆ of the cushion member 106 shown in FIGS. 6A and 6B. Accordingly, a discussion of the details of the cushion member 106 applies to an aspect where the cushion member 106 is a fluid-filled chamber, the cushion member 106 comprises a foam material comprising one or more polymers, or is formed of a foam material comprising one or more polymers encapsulated within barrier layers 118.

With continued reference to FIGS. 2A and 2B, the chassis 108 is configured to interface with the cushion member 106 to provide a unitary midsole 102. It should be appreciated that the chassis 108 is configured to interface with any aspect of the cushion member 106 described herein. The chassis 108 extends from a first end 160 at the anterior end 18 of the sole structure 100 to a second end 162 at the posterior end 20 of the sole structure 100. The chassis 108 further includes a top surface 164 defining a portion of a footbed, and a bottom surface 166 formed on the opposite side of the chassis 108 than the top surface 164 and configured to interface with the top side 114 of the cushion member 106.

The chassis 108 may be formed as a unitary piece, or may be formed of a plurality of elements as discussed in greater detail below. The chassis 108 includes a series of supports 168a-168g extending along a length of the chassis 108. In particular, a plurality of medial supports 168a, 168c, 168e and 168g extends along a medial side 22 of the chassis 108, a plurality of lateral supports 168b, 168d, 168f and 168h extends along a lateral side 24 of the chassis 108, and a posterior support 168i is disposed at the posterior end 20 of the chassis 108. The posterior support 168i is disposed between the series of lateral supports 168a, 168c, and 168e and the series of medial supports 168b, 168d and 168f. The series of supports 168a-168i alternate with a series of recesses 170a-170f, which also extends along the length of the chassis 108. In particular, medial recesses 170a, 170c and 170e of the second series of recesses 170a-170f extend along the medial side 22 of the chassis 108 and lateral recesses 170b, 170d and 170f of the second series of recesses 170a-170f extend along the lateral side 24 of the chassis 108.

A lateral mid-foot recess 170c and a medial mid-foot recess 170d cooperate to define a mid-foot continuous recess 172 (FIG. 11) extending the width of the chassis 108. Likewise, lateral forefoot recess 170a and medial forefoot recess 170b cooperate to define a forefoot continuous recess 174 (FIG. 11) extending the width of the chassis 108. The chassis 108 may further include a pair of inner supports 176a, 176b disposed in the forefoot region 12. Each of the inner supports 176a, 176b is illustratively shown as having a generally triangular-shaped cross-section as taken along a width of the inner supports 176a, 176b. A forefoot inner support 176a is formed on the bottom surface 166 of the chassis 108 and is disposed in the forefoot continuous recess 174 so as to be disposed between the lateral forefoot recess 170a and the medial forefoot recess 170b. A toe inner support 176b is disposed at the anterior end 18 of the chassis 108. The bottom surface 166 of the forefoot inner support 176a is generally concave so as to be configured to engage a top surface of the intermediate segment 134a of the cushion member 106. Likewise, the bottom surface 166 of toe inner support 176b is also generally concave so as to be configured to engage a top surface of intermediate segment 134b of the cushion member 106.

The series of supports 168a-168i are aligned and in contact with the series of lobes 138a-138i. As such, a distal end of each of the supports 168a-168i is generally concave so as to receive a top surface of a respective one of the lobes 138a-138i. The supports 168c-168i define a first series 178 of supports configured to be aligned with and contact the first series 148 of lobes 138e-138i. The supports 168a-168b define a second series 180 of supports configured to be aligned with the second series 150 of lobes 138a-138b disposed in the toe portion 12T of the forefoot region 12.

In an aspect where the chassis 108 is formed by multiple elements, the chassis 108 may include a cushion support 182, a plate 184 and an insert 186. In such an aspect, the first series 178 of supports 168c-168i are formed by the assembly of the plate 184 to the cushion support 182 and the second series 180 of supports 168a-168b are formed solely by the plate 184. In such an aspect, the portions of the plate 184 and the cushion support 182 collectively form the first series 178 of supports 168c-168i when assembled together and cooperate to engage the top surface of a respective first series 148 of lobes 138a-138i.

With continued reference to FIGS. 2A and 2B, the chassis 108 may be configured to support the periphery of a user's foot. In such an aspect, the chassis 108 may further include an upper portion 188a-188i disposed on at least one support of the series of supports 168a-168i. The upper portion 188a-188h is disposed along the periphery of the chassis 108 and is curved along both the width and the height of the chassis 108 so as to conform to the shape of the bottom of a foot. The upper portion 188a-188i includes a series of medial upper portions 188a, 188c, 188e, 188g and a series of lateral upper portions 188b, 188d, 188f, 188h extending along a periphery of the respective medial side 22 and lateral side 24 of the chassis 108. An upper posterior portion 188i is disposed on the posterior end 20 of the chassis 108 and the series of medial upper portions 188a, 188c, 188e, 188g and the series of upper lateral portions 188b, 188d, 188f, 188h are respectively arranged in series from opposite ends of the upper posterior portion 188i. The upper posterior portion 188i forms a cup for assisting in the support of the back of a heel. A height to the upper portions 188a-188i may be the same or may be varied. In aspects where the chassis 108 is formed as a unitary piece, the upper portion 188a-188h is contiguous with the series of supports 168a-168i. In aspects where the chassis 108 is formed of multiple elements, such as a cushion support 182, a plate 184 and an insert 186, the upper portion 188a-188h may be defined by the plate 184.

As described above, the series of first supports 178 may be formed by a combination of the cushion support 182 and the plate 184. The plate 184 further includes a medial support arm 190 and a lateral support arm 192 extending from the ends of the upper posterior portion 182i. A distal end of each of the medial support arm 190 and lateral support arm 192 is spaced apart from each other so as to define an insert pocket 194. The medial support arm 190 includes a series of inner medial flanges 196a-196d that are spaced apart from each other so as to form a series of inward medial depressions 198a-198c alternating with a respective inner medial flange 196a-196d. Each of the inner medial flanges 196a-196d is disposed on an inner surface of the medial support arm 190 and extends towards a center of the plate 184 so as to be generally orthogonal to the upper portions 188. The lateral support arm 192 includes a series of inner lateral flanges 200a-200d. The inner lateral flanges 200a-200d are spaced apart from each other so as to form a series of inward lateral depressions 202a-202d alternating with a respective inner lateral flange 200a-200c. The inner lateral flanges 200a-200d are disposed on an inner surface of the lateral support arm 192 and extend towards a center of the plate 184. The insert pocket 194 has a shape defined by the inner medial flanges 196a-196d, inward medial depressions 198a-198c, the inner lateral flanges 200a-200d and the inward lateral depressions 200a-200c so as to fittingly receive the insert 186 as shown in FIG. 9.

With continued reference to FIGS. 2A and 2B, the insert 186 has a periphery edge configured to be seated between the medial support arm 190 and the lateral support arm 192 of the plate 184 so as to fit within the insert pocket 194. The insert 186 is a unitary body having a series of wings 204a-204h extending along the periphery of the medial side 22 and lateral side 24 of the insert 186. The wings 204a-204h are spaced apart from each other so as define a peripheral edge that is configured to be seated within the insert pocket 194. An anterior wing 204a is disposed on the first end 110 of the chassis 108 and is generally orthogonal to the body of the insert 186. A posterior wing 204h is disposed on the second end 112 of the chassis 108 and is configured to be seated against a portion of the upper posterior portion 182i of the plate 184. The plate 184 is mounted to a top surface of the cushion support 182 so as to be disposed between the upper 300 and the cushion support 182. The plate 184 is longer than the cushion support 182 and the lateral and medial supports 168a, 168b are formed on a bottom surface of the plate 184.

The chassis 108 includes ridges 206a-206c that are configured to be seated in a respective one of the upper pockets 156a-156c of the cushion member 106 when the chassis 108 is assembled to the cushion member 106. The anterior ridge 206a has a generally C-shaped structure configured to receive interior chamber 128b. The intermediate ridge 206b and the posterior ridge 206c collectively form a generally U-shaped dimension so as to define a depression 208a-208c extending longitudinally between elongated portions of the intermediate ridge 206b and the posterior ridge 206c. The depression 208a-208c is configured to receive heel interior chamber 128b. In the illustrated example, the ridges 206a-206c may be configured to fully extend into the web area 120 of the upper pockets 156a-156c in some areas and spaced apart from the web area 120 of the upper pockets 156a-156c in other areas when the midsole 102 is assembled. Thus, the portion of the bottom side 116 defining the ridges 206a-206c may contact the web area 120 in selected locations. In other examples, one or more of the ridges 206a-206c may be configured so that the distal ends are spaced apart from the web area 120, or may be omitted from the chassis.

With reference now to FIGS. 9 and 10, an aspect of the chassis 108 is provided, wherein the chassis 108 is formed of the cushion support 182, the plate 184, and the insert 186. The cushion support 182, the plate 184, and the insert 186 may be secured to each other to form a unitary piece using any technique such as adhesives, welding, or the like. Alternatively, the cushion support 182, the plate 184 and the insert 186 may be simply mounted to each other and held by an attachment to the outsole 104 and the upper 300.

With reference now to FIG. 11, the chassis 108 and the outsole 104 are shown assembled to the cushion member 106. The ridges 206a-206c are shown contacting the web area 120. The plate 184 is longer than the cushion support 182 wherein the anterior wing 204a extends beyond the posterior end of the cushion support 182. The outsole 104 is mounted to a bottom surface of the cushion member 106 so as to protect the cushion member 106 during an engagement with a ground surface. The ridges 206a-206c have an arcuate bottom surface 166 that is configured to engage the top surface of the respective interior chambers 128a, 128b. Inner support 176a is seated against a top surface of forefoot interior chamber 128a and inner support 176b is seated against the top surface of the heel interior chamber 128b. The mid-foot continuous recess 172 and the forefoot continuous recess 174 extend across the width of the chassis 108. The mid-foot continuous recess 172 and the forefoot continuous recess 174 are positioned so as to facilitate a flex of the outsole 104.

With reference now to FIG. 12, a cross-sectional view taken along Line 12-12 of FIG. 10 is provided. FIG. 12 shows the engagement of the toe lobes 138a, 138b with the chassis 108. In such an aspect, the second series 180 of supports 168a-168b are formed fully by the plate 184. The plate 184 and insert 186 are assembled together to form a unitary piece. A top surface of the plate 184 is contiguous and generally seamless with a top surface of the insert 186 to define a profile of the footbed. The cushion support 182 does not extend to the toe lobes 138a, 138b. A gap 210 is formed between the pair of toe lobes 138a, 138b. The gap 210 allows for the toe lobes 138a, 138b to flex freely relative to lobes 138c-138i which are connected at a respective first end 140a-140i and second end 142a-142i.

With reference now to FIG. 13, a cross-sectional view taken along Line 13-13 of FIG. 10 is provided. The chassis 108 is fully seated against the top surface of the cushion member 106. The medial support 168c and lateral support 168d are engaged with the pair of forefoot lobes 138c, 138d. The medial support 168c is formed by an assembly of the cushion support 182 and the plate 184, wherein the cushion support 182 defines an inner portion of the medial support 168c and the plate 184 defines an outer portion of the medial support 168c. Likewise, the cushion support 182 defines an inner portion of the lateral support 168d and the plate 184 defines an outer portion of the lateral support 168d. The anterior ridge 206a is seated against the web area 120 defining upper pockets 156b. The area of the cushion support 182 between the medial side 22 and the lateral side 24 of the anterior ridge 206a is arcuate so as to be seated against the top surface of the forefoot interior chamber 128a.

With reference now to FIG. 14, a cross-sectional view taken along Line 14-14 of FIG. 10 is provided. The medial support 168e and the lateral support 168f are aligned with and contact a top surface of a respective one of the pair of mid-foot lobes 138e, 138f. The medial support 168e and the lateral support 168f are dimensioned to be fully seated against the respective mid-foot lobes 138e, 138f. The medial support 168e is formed by an assembly of the cushion support 182 and the plate 184, wherein the cushion support 182 defines an inner portion of the medial support 168e and the plate 184 defines an outer portion of the medial support 168e. Likewise, the cushion support 182 defines an inner portion of the lateral support 168f and the plate 184 defines an outer portion of the lateral support 168f The area of the cushion support 182 between the medial side 22 and lateral side 24 of the intermediate ridge 206b is arcuate so as to be seated against the top surface of interior chamber 128a. FIG. 14 shows an aspect where the bottom surface of the intermediate ridge 206b is spaced apart from the web area 120.

With reference now to FIG. 15, a cross-sectional view taken along Line 15-15 of FIG. 10 is provided. The cross-sectional view is taken along the recesses 146e, 146f of the cushion member 106 and the recesses 170e, 170f that form the forefoot continuous recess 174 formed on the chassis 108. Accordingly, the chassis 108 is spaced apart from the cushion member 106 so as to facilitate increased flexibility about Line 15-15.

With reference now to FIG. 16, a cross-sectional view taken along Line 16-16 of FIG. 10 is provided. The medial support 168g and the lateral support 168h are aligned with and contact a top surface of a respective one of the pair of heel lobes 138g, 138h. The medial support 168g and the lateral support 168h are dimensioned to be fully seated against the respective heel lobes 138g, 138h. The lateral support 168h is formed by an assembly of the cushion support 182 and the plate 184, wherein the cushion support 182 defines an inner portion of the lateral support 168h and the plate 184 defines an outer portion of the lateral support 168h. Likewise, the cushion support 182 defines an inner portion of the medial support 168g and the plate 184 defines an outer portion of the medial support 168g. The posterior ridge 206c is seated within upper pocket 156a. The area of the cushion support 182 between the medial side 22 and the lateral side 24 of the posterior ridge 206c is arcuate so as to be seated against the top surface of heel interior chamber 128b. FIG. 16 shows an aspect where the bottom surface of the posterior ridge 206c is spaced apart from the web area 120.

The components 182, 184, 186 of the chassis 108 may include a chassis material comprising one or more polymers, such as foam or rubber, to impart properties of cushioning, responsiveness, and energy distribution to the foot of the wearer. In the illustrated example, the cushion support 182 comprises a first foam material, the plate 184 comprises a second foam material, and the insert 186 comprises a third foam material, which are substantially the same, or which differ from each other in one or more of appearance, physical properties, and composition as described above. For example, the cushion material and the plate material may provide greater cushioning and impact distribution than the insert material, while the insert material has a greater stiffness than the cushioning material and/or the plate material in order to provide increased lateral stiffness to the peripheral region 28 of the upper 300.

With reference again to FIG. 2B and FIGS. 11-16, in one aspect of the plate 184, each support in the series of supports 168a-168g extend outwardly and downwardly from a periphery of the plate 184 and the upper portion 188a-188i extend upwardly and outwardly from the periphery the plate 184. Each support in the series of supports 168a-168g is aligned with a corresponding upper portion 188c-188i so as to define a generally V-shaped cross-section. The series of supports 168a-168g and the corresponding upper portion 188c-188i cooperate with each other to provide a compressive and reactive force in response to a load. As an example, the series of supports 168a-168g and the corresponding upper portion 188c-188i function as a spring in response to a compressive load.

The chassis material comprises one or more polymers. Example chassis materials include foamed or solid materials, including molded foamed and molded solid materials.

The various materials described herein (e.g., the outsole material, the cushion material, the chassis material, etc.) comprise, consist of, or consist essentially of one or more polymers. The one or more polymers may include one or more thermoplastic polymers, one or more thermosetting or thermosettable polymers (i.e., polymers which are capable of being crosslinked, but which have not yet been crosslinked), or one or more thermoset polymers. The one or more polymers may include one or more elastomers, including thermoplastic elastomers (TPEs) or thermoset elastomers, or both. 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). Examples of suitable polyurethanes include those discussed above for barrier layers 118. Alternatively, the one or more polymers may include one or more natural and/or synthetic rubbers, such as polybutadiene and polyisoprene.

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

In some configurations, the foamed material may be a crosslinked foamed material. In these configurations, a peroxide-based crosslinking agent such as dicumyl peroxide may be used. Furthermore, the foamed 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 material may be formed using a molding process. In one example, when the material includes a molded elastomer, the uncured material (e.g., uncured 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 material is a foamed material, the material may be foamed during a molding process, such as an injection molding process. A thermoplastic 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 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 material, by forming foamed particles or beads by foaming a material, by cutting foamed sheet stock, and the like. The compression molded foam may then be made by placing the one or more foam preforms in a compression mold, and applying sufficient pressure to the one or more foam preforms to compress the one or more foam preforms in a closed mold. Once the mold is closed, sufficient heat and/or pressure is applied to the one or more foam preforms in the closed mold for a sufficient duration of time to alter the foam preform(s) by forming a skin on the outer surface of the compression molded foam, or fusing individual foam particles to each other, or increasing the density of the foam(s) which is retained in the finished product, 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.

In some examples, the outsole 104 extends over the midsole 102 to provide increased durability and resiliency. In the illustrated example, the outsole 104 is provided as an outsole material that is overmolded onto the cushion member 106 to provide increased durability to the exposed portions of the cushion member 106. Accordingly, the outsole material differs from the cushion material, and includes at least one of a different thickness, a different hardness, and a different abrasion resistance than the bottom side 116 of the cushion member 106. In some examples, the outsole 104 may be formed integrally with the bottom side 116 of the cushion member 106 using an overmolding process. In other examples, the outsole 104 may be formed separately from the bottom side 116 of the cushion member 106 and may be adhesively bonded to the lower barrier layer 118.

The upper 300 is attached to the sole structure 100 and includes interior surfaces that define an interior void configured to receive and secure a foot for support on sole structure 100. The upper 300 may be formed from one or more materials that are stitched or adhesively bonded together to form the interior void. Suitable materials of the upper may include, but are not limited to, mesh, textiles, foam, leather, and synthetic leather. The materials may be selected and located to impart properties of durability, air-permeability, wear-resistance, flexibility, and comfort.

The following Clauses provide exemplary configurations for a cushion member, a sole structure, and an article of footwear described above.

Clause 1. A sole structure, for an article of footwear having an upper, comprises a cushion member and a chassis. The cushion member extends from a forefoot region of the sole structure to a heel region of the sole structure and includes a first series of lobes alternating with a first series of recesses along a length of the fluid-filled chamber. The first series of lobes and the first series of recesses extend along one of a medial side of the sole structure and a lateral side of the sole structure. The chassis is disposed between the cushion member and the upper and includes a series of first supports alternating with a second series of recesses along a length of the chassis. The supports of the series of first supports are aligned and in contact with respective lobes of the first series of lobes and the second series of recesses are aligned with the first series of recesses.

Clause 2. The sole structure of Clause 1, wherein the chassis includes a cushion support.

Clause 3. The sole structure of Clause 2, wherein the chassis further includes a plate mounted to a top surface of the cushion support between the upper and the cushion support.

Clause 4. The sole structure of Clause 3, wherein the plate is longer than the cushion support.

Clause 5. The sole structure of Clause 3, wherein at least one support of the series of first supports includes an upper portion extending in a direction toward the upper and outwardly from a body of the at least one support.

Clause 6. The sole structure of Clause 3, wherein the plate is formed from a material having a higher rigidity than a material forming the cushion support.

Clause 7. The sole structure of any of Clause 3, wherein the cushion support is formed from foam.

Clause 8. The sole structure of Clause 3, wherein the plate includes a series of second supports configured to be aligned with the first series of lobes disposed in the forefoot region.

Clause 9. The sole structure of Clause 3, wherein the cushion member further includes a second series of lobes disposed between the medial side and lateral side of the sole structure, the second series of lobes defining a generally U-shaped recess.

Clause 10. The sole structure of Clause 9, wherein the cushion support includes an inner support configured to be aligned with an intermediate chamber disposed between the medial side and lateral side of the chassis.

Clause 11. The sole structure of Clause 1, wherein the cushion member is one of a foam element and a fluid-filled bladder, the foam element being a solid unitary piece extending a length, width and height of the cushion member.

Clause 12. The sole structure of Clause 11, wherein the fluid-filled bladder is formed of an opposing pair of barrier layers.

Clause 13. The sole structure of Clause 1, wherein the cushion member includes a foam element encapsulated in an opposing pair of barrier layers.

Clause 14. An article of footwear incorporating the sole structure of any of the preceding Clauses.

Clause 15. A sole structure comprises a cushion member including (i) a plurality of lobes arranged in series along a peripheral region of the sole structure from a forefoot region to a heel region of the cushion member and (ii) an interior chamber at least partially surrounded by the plurality of lobes and spaced apart from the plurality of lobes by a web area; and a chassis including a plurality of supports arranged in series along the peripheral region of the sole structure, each of the supports including a first portion defined by a first material and a second portion defined by a second material different than the first material.

Clause 16. The sole structure of Clause 15, wherein the chassis includes a cushion support.

Clause 17. The sole structure of Clause 16, wherein the chassis further includes a plate attached on an opposite side of the cushion support than the cushion member.

Clause 18. The sole structure of Clause 17, wherein the plate is longer than the cushion support.

Clause 19. The sole structure of Clause 18, wherein at least one of the supports in the plurality of supports includes an upper portion extending in a direction outwardly from a body of the at least one support.

Clause 20. The sole structure of Clause 19, wherein the plate includes a first material having a first stiffness and the cushion support includes a second material having a second stiffness that is less than the first stiffness.

Clause 21. The sole structure of Clause 20, wherein the first material includes a first polymeric material and the second material includes a second polymeric material.

Clause 22. The sole structure of Clause 21, wherein at least one of the supports is supported by one of the lobes in the forefoot region.

Clause 23. The sole structure of Clause 22, wherein the cushion member further includes a second series of lobes disposed between a medial side and a lateral side of the sole structure, the second series of lobes defining a generally U-shaped recess.

Clause 24. The sole structure of Clause 23, wherein the cushion member includes an inner support configured to be aligned with an intermediate chamber disposed between the medial side and lateral side of the chassis.

Clause 25. The sole structure of Clause 15, wherein the cushion member is one of a foam element and a fluid-filled bladder, the foam element being a solid unitary piece extending a length, width and height of the cushion member.

Clause 26. The sole structure of Clause 25, wherein the fluid-filled bladder is formed of an opposing pair of barrier layers.

Clause 27. The sole structure of Clause 15, wherein the cushion member includes a foam element encapsulated in an opposing pair of barrier layers.

Clause 28. An article of footwear incorporating the sole structure of any of the preceding Clauses.

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.

Claims

1. A sole structure comprising: a cushion member including a first series of lobes arranged from a forefoot region to a heel region along one of a medial side and a lateral side of the sole structure; anda chassis including a first series of supports each aligned and in contact with a respective lobe of the first series of lobes, a first portion of each of the first series of supports including a first material and a second portion of each of the supports including a second material different than the first material.

2. The sole structure of claim 1, wherein the chassis includes a cushion support.

3. The sole structure of claim 2, wherein the chassis further includes a plate attached on an opposite side of the cushion member than the cushion member.

4. The sole structure of claim 3, wherein the plate is longer than the cushion support.

5. The sole structure of claim 3, wherein at least one of the supports includes an upper portion extending in a direction outwardly from a body of the at least one support in the first series of supports.

6. The sole structure of claim 3, wherein at least one of the supports in the first series of supports is supported by one of the lobes in the forefoot region.

7. The sole structure of claim 3, wherein the cushion member further includes a second series of lobes disposed between the medial side and the lateral side of the sole structure, the second series of lobes defining a generally U-shaped recess.

8. The sole structure of claim 7, wherein the cushion support includes an inner support configured to be aligned with an intermediate chamber disposed between the medial side and lateral side of the chassis.

9. The sole structure of claim 1, wherein the cushion member is one of a foam element and a fluid-filled bladder, the foam element being a solid unitary piece extending a length, width and height of the cushion member.

10. An article of footwear incorporating the sole structure of claim 1.

11. A sole structure comprising: a cushion member including (i) a plurality of lobes arranged in series along a peripheral region of the sole structure from a forefoot region to a heel region of the cushion member and (ii) an interior chamber at least partially surrounded by the plurality of lobes and spaced apart from the plurality of lobes by a web area; anda chassis including a plurality of supports arranged in series along the peripheral region of the sole structure, each of the supports including a first portion defined by a first material and a second portion defined by a second material different than the first material.

12. The sole structure of claim 11, wherein the chassis includes a cushion support.

13. The sole structure of claim 12, wherein the chassis further includes a plate attached on an opposite side of the cushion support than the cushion member.

14. The sole structure of claim 13, wherein the plate is longer than the cushion support.

15. The sole structure of claim 14, wherein at least one of the supports in the plurality of supports includes an upper portion extending in a direction outwardly from a body of the at least one support.

16. The sole structure of claim 13, wherein the plate includes a first material having a first stiffness and the cushion support includes a second material having a second stiffness that is less than the first stiffness.

17. The sole structure of claim 11, wherein the cushion member further includes a second series of lobes disposed between a medial side and a lateral side of the sole structure, the second series of lobes defining a generally U-shaped recess.

18. The sole structure of claim 11, wherein the cushion member includes an inner support configured to be aligned with an intermediate chamber disposed between a medial side and a lateral side of the chassis.

19. The sole structure of claim 11, wherein the cushion member is one of a foam element and a fluid-filled bladder, the foam element being a solid unitary piece extending a length, width and height of the cushion member.

20. An article of footwear incorporating the sole structure of claim 11.