TREA

SOLE STRUCTURE FOR ARTICLE OF FOOTWEAR

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Information

  • Patent Application
  • 20240197034
  • Publication Number
    20240197034
  • Date Filed
    December 18, 2023
    a year ago
  • Date Published
    June 20, 2024
    6 months ago
Information
Abstract
A sole structure for an article of footwear, the sole structure defining a footbed and a ground-engaging surface and including a chassis extending from an anterior end of the sole structure to a posterior end of the sole structure, and a bladder supported within the chassis and extending from a first end in a forefoot region of the sole structure to a second end exposed at the posterior end of the sole structure, the bladder including a first curved portion in the forefoot region and a substantially flat portion at the posterior end of the sole structure.
Description
FIELD

The present disclosure relates generally to a sole structure for an article of footwear.


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 incorporate a fluid-filled bladder to provide cushioning to the foot by compressing resiliently under an applied load to attenuate ground-reaction forces. Sole structures may also include a comfort-enhancing insole or a sockliner located within a void proximate to the bottom portion of the upper and a strobel attached to the upper and disposed between the midsole and the insole or sockliner.


Midsoles employing bladders typically include a bladder formed from two barrier layers of polymer material that are sealed or bonded together. The bladders may contain air, and 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.





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 lateral side perspective view of an article of footwear including an example of a sole structure in accordance with principles of the present disclosure;



FIG. 2 is a medial side perspective view of the article of footwear of FIG. 1;



FIG. 3 is a top perspective exploded view of the sole structure of FIG. 1;



FIG. 4 is a bottom perspective exploded view of the sole structure of FIG. 1;



FIG. 5 is a front elevation view of the sole structure of FIG. 1;



FIG. 6 is a rear elevation view of the sole structure of FIG. 1;



FIG. 7 is a bottom plan view of the sole structure of FIG. 1;



FIG. 8 is a top plan view of the sole structure of FIG. 1;



FIG. 9 is a lateral cross-sectional view of the sole structure of FIG. 1, taken along Line 9-9 of FIG. 8;



FIG. 10 is a lateral cross-sectional view of the sole structure of FIG. 1, taken along Line 10-10 of FIG. 8;



FIG. 11 is a lateral cross-sectional view of the sole structure of FIG. 1, taken along Line 11-11 of FIG. 8;



FIG. 12 is a longitudinal cross-sectional view of the sole structure of FIG. 1, taken along Line 12-12 of FIG. 8;



FIG. 13 is a lateral side elevation view of an example of a bladder of the sole structure of FIG. 1;



FIG. 14 is a lateral side perspective view of an article of footwear including an example of a sole structure in accordance with principles of the present disclosure;



FIG. 15 is a medial side perspective view of the article of footwear of FIG. 14;



FIG. 16 is a top perspective exploded view of the sole structure of FIG. 14;



FIG. 17 is a bottom perspective exploded view of the sole structure of FIG. 14;



FIG. 18 is a front elevation view of the sole structure of FIG. 14;



FIG. 19 is a rear elevation view of the sole structure of FIG. 14;



FIG. 20 is a bottom plan view of the sole structure of FIG. 14;



FIG. 21 is a top plan view of the sole structure of FIG. 14;



FIG. 22 is a lateral cross-sectional view of the sole structure of FIG. 14, taken along Line 22-22 of FIG. 21;



FIG. 23 is a lateral cross-sectional view of the sole structure of FIG. 14, taken along Line 23-23 of FIG. 21



FIG. 24 is a lateral cross-sectional view of the sole structure of FIG. 14, taken along Line 24-24 of FIG. 21;



FIG. 25 is a longitudinal cross-sectional view of the sole structure of FIG. 14, taken along Line 25-25 of FIG. 21; and



FIG. 26 is a lateral side elevation view of an example of a bladder of the sole structure of FIG. 14.





Corresponding reference numerals indicate corresponding parts throughout the drawings.


DETAILED DESCRIPTION

Example configurations will now be described more fully with reference to the accompanying drawings. Example configurations are provided so that this disclosure will be thorough, and will fully convey the scope of the disclosure to those of ordinary skill in the art. Specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of configurations of the present disclosure. It will be apparent to those of ordinary skill in the art that specific details need not be employed, that example configurations may be embodied in many different forms, and that the specific details and the example configurations should not be construed to limit the scope of the disclosure.


The terminology used herein is for the purpose of describing particular exemplary configurations only and is not intended to be limiting. As used herein, the singular articles “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of features, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. Additional or alternative steps may be employed.


When an element or layer is referred to as being “on,” “engaged to,” “connected to,” “attached to,” or “coupled to” another element or layer, it may be directly on, engaged, connected, attached, or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” “directly attached to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.


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


In one configuration, a sole structure for an article of footwear defines a footbed and a ground-engaging surface and includes a chassis that extends from an anterior end of the sole structure to a posterior end of the sole structure. A bladder is supported within the chassis and extends from a first end in a forefoot region of the sole structure to a second end exposed at the posterior end of the sole structure. The bladder includes a first curved portion in the forefoot region and a substantially flat portion at the posterior end of the sole structure.


The article of footwear may include one or more of the following optional features. For example, the bladder may be exposed along at least one of a medial side of the sole structure or a lateral side of the sole structure. In some examples, the bladder may be continuously exposed along the at least one of the medial side of the sole structure or the lateral side of the sole structure from the first end of the bladder to the second end of the bladder. In some configurations, the bladder may be continuously exposed along the medial side of the sole structure and the lateral side of the sole structure. Optionally, the bladder has a constant thickness from the first end to the second end. In some implementations, the first curved portion may define a concave curvature relative to a footbed of the sole structure and may extend from the first end to a mid-foot region of the sole structure.


In some configurations, the chassis may include a first cushioning element disposed between the bladder and the footbed and a second cushioning element disposed between the bladder and the ground-engaging surface. Optionally, the sole structure includes an outsole defining the ground-engaging surface and including a first portion attached to the second cushioning element. In some examples, the outsole may include a second portion attached to the bladder.


In another aspect of the disclosure, a sole structure for an article of footwear defines a footbed and a ground-engaging surface and includes a bladder that extends from a first end in a forefoot region of the sole structure to a second end at a posterior end of the sole structure. The bladder includes a peripheral surface. A chassis supports the bladder in an interior portion and includes a peripheral channel exposing the peripheral surface of the bladder from a mid-foot region of the sole structure to the posterior end of the sole structure.


The article of footwear may include one or more of the following optional features. For example, the bladder may be exposed along at least one of a medial side of the sole structure or a lateral side of the sole structure. Additionally or alternatively, the peripheral channel may extend continuously from a first end in a forefoot region of the sole structure on a medial side, around the posterior end, and to a second end in the forefoot region on a lateral side. In some examples, the bladder is continuously exposed through the peripheral channel.


In some configurations, the bladder may have a constant thickness from the first end to the second end. In some examples, the bladder may include a first curved portion defining a concave curvature relative to a footbed of the sole structure and extending from the first end to a mid-foot region of the sole structure. In some implementations, the bladder may include a second curved portion disposed between the first curved portion and a substantially flat portion in the mid-foot region and defining a convex curvature relative to the footbed. In some examples, the chassis may include a first cushioning element disposed between the bladder and the footbed and a second cushioning element disposed between the bladder and the ground-engaging surface. Optionally, the sole structure includes an outsole defining the ground-engaging surface and including a first portion attached to the second cushioning element. In some configurations, the outsole includes a second portion attached to the bladder.


Referring to FIGS. 1-13, an article of footwear 10 is provided, which includes a sole structure 100 and an upper 200 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. The forefoot region 12 may include a toe portion 12T corresponding to the phalanges and a ball portion 12B corresponding to the metatarsophalangeal joint (i.e., “the ball”) of the foot. 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. 7. 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.


With reference to FIGS. 1-4, 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 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 may be described as including a bladder 106 and a chassis 108 (FIG. 10), where the chassis 108 is configured to be attached to the upper 200 and provides an interface between the upper 200, the bladder 106, and the outsole 104. In the illustrated example, the bladder 106 is supported within the chassis 108 between the outsole 104 and the upper 200.


Generally, the bladder 106 of the sole structure 100 is supported within the chassis 108 and is configured to attenuate forces associated with impacts along the length of the foot. The bladder 106 of the midsole 102 includes an opposing pair of barrier layers 114, 116, which are joined to each other along a peripheral seam 120 to define a chamber 118. In the illustrated configuration, the barrier layers 114, 116 include a first, upper barrier layer 114 defining an upper surface of the bladder 106 and a second, lower barrier layer 116 defining a lower surface of the bladder 106. Alternatively, the chamber 118 can be produced from any suitable combination of one or more barrier layers, as described in greater detail below.


In some implementations, the upper barrier layer 114 and the lower barrier layer 116 cooperate to define a geometry (e.g., thicknesses, width, and lengths) of the chamber 118. For example the peripheral seam 120 may bound and extend around the chamber 118 to seal the fluid (e.g., air) within the chamber 118. Thus, the chamber 118 is associated with an area of the bladder 106 where interior surfaces of the upper and lower barrier layers 114, 116 are not joined together and, thus, are separated from one another. In the illustrated example, the bladder 106 includes a peripheral surface 115 that defines a peripheral profile of the bladder 106 and extends between a top surface defined by the upper barrier layer 114 and a bottom surface defined by the lower barrier layer 116.


As shown in FIGS. 9-12, a space formed between opposing interior surfaces of the upper and lower barrier layers 114, 116 defines an interior void of the chamber 118. Similarly, exterior surfaces of the upper and lower barrier layers 114, 116 define an exterior profile of the chamber 118. Thicknesses T118 of the chamber 118 are defined by the distance between the upper and lower barrier layers 114, 116 of the bladder 106.


As used herein, the term “barrier layer” (e.g., barrier layers 114, 116) encompasses both monolayer and multilayer films. In some embodiments, one or both of barrier layers the 114, 116 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 114, 116 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 114, 116 can independently be transparent, translucent, and/or opaque. As used herein, the term “transparent” for a barrier layer and/or a fluid-filled chamber means that light passes through the barrier layer in substantially straight lines and a viewer can see through the barrier layer. In comparison, for an opaque barrier layer, light does not pass through the barrier layer and one cannot see clearly through the barrier layer at all. A translucent barrier layer falls between a transparent barrier layer and an opaque barrier layer, in that light passes through a translucent layer but some of the light is scattered so that a viewer cannot see clearly through the layer.


The barrier layers 114, 116 can each be produced from an elastomeric material that includes one or more thermoplastic polymers and/or one or more cross-linkable polymers. In an aspect, the elastomeric material can include one or more thermoplastic elastomeric materials, such as one or more thermoplastic polyurethane (TPU) copolymers, one or more ethylene-vinyl alcohol (EVOH) copolymers, and the like.


As used herein, “polyurethane” refers to a copolymer (including oligomers) that contains a urethane group (—N(C═O)O—). These polyurethanes can contain additional groups such as ester, ether, urea, allophanate, biuret, carbodiimide, oxazolidinyl, isocynaurate, uretdione, carbonate, and the like, in addition to urethane groups. In an aspect, one or more of the polyurethanes can be produced by polymerizing one or more isocyanates with one or more polyols to produce copolymer chains having (—N(C═O)O—) linkages.


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


In particular aspects, the polyurethane polymer chains are produced from diisocynates including HMDI, TDI, MDI, H12 aliphatics, and combinations thereof. In an aspect, the thermoplastic TPU can include polyester-based TPU, polyether-based TPU, polycaprolactone-based TPU, polycarbonate-based TPU, polysiloxane-based TPU, or combinations thereof.


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


The barrier layers 114, 116 may include two or more sublayers (multilayer film) such as shown in Mitchell et al., U.S. Pat. No. 5,713,141 and Mitchell et al., U.S. Pat. No. 5,952,065, the disclosures of which are incorporated by reference in their entirety. In embodiments where the barrier layers 114, 116 include two or more sublayers, examples of suitable multilayer films include microlayer films, such as those disclosed in Bonk et al., U.S. Pat. No. 6,582,786, which is incorporated by reference in its entirety. In further embodiments, barrier layers 114, 116 may each independently include alternating sublayers of one or more TPU copolymer materials and one or more EVOH copolymer materials, where the total number of sublayers in each of the barrier layers 114, 116 includes at least four (4) sublayers, at least ten (10) sublayers, at least twenty (20) sublayers, at least forty (40) sublayers, and/or at least sixty (60) sublayers.


The chamber 118 can be produced from the barrier layers 114, 116 using any suitable technique, such as thermoforming (e.g. vacuum thermoforming), blow molding, extrusion, injection molding, vacuum molding, rotary molding, transfer molding, pressure forming, heat sealing, casting, low-pressure casting, spin casting, reaction injection molding, radio frequency (RF) welding, and the like. In an aspect, the barrier layers 114, 116 can be produced by co-extrusion followed by vacuum thermoforming to produce an inflatable chamber 118, which can optionally include one or more valves (e.g., one way valves) that allows the chamber 118 to be filled with the fluid (e.g., gas).


The chamber 118 can be provided in a fluid-filled (e.g., as provided in footwear 10) or in an unfilled state. The chamber 118 can be filled to include any suitable fluid, such as a gas or liquid. In an aspect, the gas can include air, nitrogen (N2), or any other suitable gas. In other aspects, the chamber 118 can alternatively include other media, such as pellets, beads, ground recycled material, and the like (e.g., foamed beads and/or rubber beads). The fluid provided to the chamber 118 can result in the chamber 118 being pressurized. Alternatively, the fluid provided to the chamber 118 can be at atmospheric pressure such that the chamber 118 is not pressurized but, rather, simply contains a volume of fluid at atmospheric pressure.


The fluid-filled chamber 118 desirably has a low gas transmission rate to preserve its retained gas pressure. In some embodiments, the fluid-filled chamber 118 has a gas transmission rate for nitrogen gas that is at least about ten (10) times lower than a nitrogen gas transmission rate for a butyl rubber layer of substantially the same dimensions. In an aspect, fluid-filled chamber 118 has a nitrogen gas transmission rate of 15 cubic-centimeter/square-meter·atmosphere·day (cm3/m2·atm·day) or less for an average film thickness of 500 micrometers (based on thicknesses of the barrier layers 114, 116). In further aspects, the transmission rate is 10 cm3/m2·atm·day or less, 5 cm3/m2·atm·day or less, or 1 cm3/m2·atm·day or less.


The interior void of the chamber 118 may receive a tensile element 122 therein. The tensile element 122 may include a series of tensile strands 124 extending between an upper tensile sheet 126 and a lower tensile sheet 128. The upper tensile sheet 126 may be attached to the upper barrier layer 114 while the lower tensile sheet 128 may be attached to the lower barrier layer 116. In this manner, when the chamber 118 receives a pressurized fluid, the tensile strands 124 of the tensile element 122 are placed in tension. Because the upper tensile sheet 126 is attached to the upper barrier layer 114 and the lower tensile sheet 128 is attached to the lower barrier layer 116, the tensile strands 124 retain a desired shape of the chamber 118 when the pressurized fluid is injected into the interior void of the chamber 118.


With reference to FIGS. 12 and 13, the bladder 106 may be described as having a length extending from a first end 130 to a second end 132. When the bladder 106 is incorporated into the sole structure (FIG. 12), the first end 130 defines an anterior-most point of the bladder 106 and the second end 132 defines a posterior-most point of the bladder 106. The bladder 106 further includes a first arcuate or curved portion 134 disposed adjacent to the first end 130, a second arcuate or curved portion 136 disposed adjacent to the first curved portion 134, and a substantially flat portion 138 extending from the second curved portion 136 to the second end 132. In other words, the second curved portion 136 is disposed between and connects the first curved portion 134 and the substantially flat portion 138.


Referring still to FIGS. 12 and 13, when the bladder 106 is incorporated into the sole structure 100, the first curved portion 134 defines a concave curvature relative to a footbed of the sole structure 100 such that the concave curvature defines a concave surface opposing the upper 200. Here, the first curved portion 134 extends from the first end 130 of the bladder 106 in the toe portion 12r of the forefoot region 12, through a metatarsophalangeal (MTP) point PMTP associated with the metatarsophalangeal joint of the foot, and to a first transition point PT1 in the mid-foot region 14. As shown, the MTP point PMTP defines a lowermost point of the first curved portion 134. The first curved portion 134 may define a constant radius of curvature extending continuously from the first end 130 to the first transition point PT1.


The second curved portion 136 defines a convex curvature relative to the footbed of the sole structure 100 (i.e., concave with respect to the ground-engaging surface) such that the convex curvature defines a convex surface that opposes the upper 200. As shown in FIG. 13, the second curved portion 136 extends from the first transition point PT1 in the mid-foot region 14 to a second transition point PT2 in the mid-foot region 14. Optionally, the second curved portion 136 may define a constant radius of curvature R136 from the first transition point PT1 to the second transition point PT2.


The substantially flat portion 138 of the bladder 106 defines an elongate portion of the bladder 106 extending from the second transition point PT2 to the second end 132 of the bladder 106. Thus, the substantially flat portion 138 extends from the mid-foot region 14 to the heel region 16. As discussed in greater detail below, when the bladder 106 is incorporated into the sole structure 100, the substantially flat portion 138 extends to and is exposed at the posterior end 20 of the sole structure 100.


As best shown in FIGS. 3 and 4, the bladder 106 may include a peripheral rib 140 extending continuously along an outer perimeter of the bladder 106. Here, the peripheral rib 140 is defined by a portion of the bladder 106 adjacent to the peripheral seam 120 having a greater thickness T140 (FIG. 9) than the interior portion of the bladder 106 associated with the tensile element 122. In the illustrated example, the peripheral rib 140 is continuous and completely bounds the outer periphery of the bladder 106. Thus, the peripheral rib 140 is associated with a portion of the bladder 106 that defines the peripheral surface 115.


Referring now to FIGS. 1-4, the bladder 106 of the midsole 102 is disposed within the chassis 108 between the upper cushioning element 110 and the lower cushioning element 112. The upper cushioning element 110 extends from a first end 150 at the anterior end 18 of the sole structure 100 to a second end 152 at the posterior end 20 of the sole structure 100. The upper cushioning element 110 includes a top side 154 configured to face the upper 200 and define the footbed of the article of footwear 10. The upper cushioning element 110 further includes a lower side 156 disposed on an opposite side from the top side 154 (i.e., facing away from the upper 200) and configured to interface with the upper barrier layer 114 of the bladder 106. A peripheral side surface 158 of the upper cushioning element 110 extends between the top side 154 and the lower side 156 and defines a peripheral profile of the upper cushioning element 110.


As best shown in FIG. 4, the lower side 156 of the upper cushioning element 110 includes an upper toe pad 160 disposed at the first end 150 and an upper pocket 162 extending between the upper toe pad 160 and the second end 152. The upper toe pad 160 may be described as having a thickness depending or protruding from the lower side 156 and having a length extending along the peripheral side surface 158 around the first end 150 of the upper cushioning element 110, from a first end on the medial side 22 to a second end on the lateral side 24. Thus, when the sole structure 100 is assembled, the upper toe pad 160 encompasses the first end 130 of the bladder 106 and defines an anterior end of the upper pocket 162.


The upper pocket 162 is generally configured to interface with or receive the upper barrier layer 114 of the bladder 106. In the illustrated example, the upper pocket 162 includes an upper peripheral channel 164 extending continuously along a periphery of the upper pocket 162. The upper peripheral channel 164 has a profile (e.g., size, shape) corresponding to a profile of a portion of the peripheral rib 140 defined by the upper barrier layer 114 such that the upper peripheral channel 164 is configured to receive an upper portion of the peripheral rib 140 when the sole structure 100 is assembled.


Referring to FIGS. 1 and 2, the peripheral side surface 158 of the upper cushioning element 110 includes a plurality of wings 166a-166d that protrude laterally outwardly (i.e., transverse to the longitudinal axis A100) and at least partially encompass a peripheral portion of the peripheral rib 140. For example, the upper cushioning element 110 includes a medial forefoot wing 166a extending over the peripheral rib 140 in the forefoot region 12 along the medial side 22, a lateral forefoot wing 166b extending over the peripheral rib 140 in the forefoot region 12 along the lateral side 24, a medial heel wing 166c extending over the peripheral rib 140 in the heel region along the medial side 22, and a lateral heel wing 166d extending over the peripheral rib 140 in the heel region along the lateral side 24. A referred to herein, the wings 166a-166d are defined as extending over the rib 140 to a greater extent than a portion of the peripheral wall 158 disposed between respective pairs of the medial side wings 166a, 166c and the lateral side wings 166b, 166d. For instance, as best shown in FIGS. 9-11, along the medial side 22, the medial forefoot wing 166a (FIG. 9) and the medial heel wing 166c (FIG. 11) encompass a greater portion of the peripheral rib 140 than the intermediate portion (FIG. 12) disposed between the medial forefoot wing 166a and the medial heel wing 166c in the mid-foot region 14. Likewise, along the lateral side 24, the lateral forefoot wing 166b (FIG. 9) and the lateral heel wing 166d (FIG. 11) encompass a greater portion of the peripheral rib 140 than the intermediate portion (FIG. 12) disposed between the lateral forefoot wing 166b and the lateral heel wing 166d in the mid-foot region 14. Thus, the wings 166a-166d provide additional engagement between the upper cushioning element 110 and bladder 106, thereby increasing stability along regions of the foot that experience greater loads during lateral movements (e.g., cutting, turning).


With continued reference to FIGS. 1-4, the lower cushioning element 112 extends from a first end 170 at the anterior end 18 of the sole structure 100 to a second end 172 at the posterior end 20 of the sole structure 100. The lower cushioning element 112 includes an upper side 174 configured to face the bladder 106 and a bottom side 176 disposed on an opposite side from the upper side 174 (i.e., facing away from the upper) and configured to interface with the outsole 104. A peripheral side surface 178 extends between the upper side 174 and the bottom side 176 and defines a peripheral profile of the lower cushioning element 112.


As best shown in FIG. 3, the upper side 174 of the lower cushioning element 112 includes a lower toe pad 180 disposed at the first end 170 and a lower pocket 182 extending between the toe pad 180 and the second end 172. When the sole structure 100 is assembled, the lower toe pad 180 cooperates with the upper toe pad 160 of the upper cushioning element 110 to provide a solid cushioning element in the toe portion 12r of the sole structure.


The lower pocket 182 is generally configured to receive the lower barrier layer 116 of the bladder 106. In the illustrated example, the lower pocket 182 includes a lower peripheral channel 184 extending continuously along a periphery of the lower pocket 182. The lower peripheral channel 184 has a profile (e.g., size, shape) corresponding to a profile of a portion of the peripheral rib 140 defined by the lower barrier layer 116 such that the lower peripheral channel 184 is configured to receive a lower portion of the peripheral rib 140 when the sole structure 100 is assembled.


The lower cushioning element 112 may include a first pair of forefoot apertures 186 arranged in the forefoot region. As shown, the apertures 186 are generally aligned with each other in a lateral direction (e.g., perpendicular to the longitudinal axis A100). Here, the apertures are arranged on opposite sides of the longitudinal axis A100. Each of the apertures 186 extends through a thickness of the lower cushioning element 112 from the upper side 174 to the bottom side 176. As shown, each of the apertures 186 has a teardrop-shaped profile that tapers in width along a direction of the longitudinal axis A100 from the anterior end 18 to the posterior end 20.


The lower cushioning element 112 may further include a heel recess or relief 188 formed in the bottom side 176 in the heel region 16. As shown, the heel relief 188 includes a teardrop profile that tapers in width along a direction of the longitudinal axis A100 from the posterior end 20 to the anterior end 18. Thus, the heel relief 188 includes a first width (i.e., measured from medial side to lateral side) at a first end in the heel region 16 associated with a calcaneus bone of the foot and a second width at a second end disposed adjacent to or within the mid-foot region 14. The heel relief 188 provides a relief region in the lower cushioning element 112 within which the bladder 106 may flex when a load is applied to the sole structure 100 by the heel of the foot, thereby providing a “trampoline” effect within the heel region 16 of the sole structure 100.


As described above, the cushioning elements 110, 112 include a resilient polymeric material, such as foam or rubber, to impart properties of cushioning, responsiveness, and energy distribution to the foot of the wearer. Example resilient polymeric materials for the cushioning elements 110, 112 may include those based on foaming or molding one or more polymers, such as one or more elastomers (e.g., thermoplastic elastomers (TPE)). The one or more polymers may include aliphatic polymers, aromatic polymers, or mixtures of both; and may include homopolymers, copolymers (including terpolymers), or mixtures of both.


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


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


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


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


In further aspects, the one or more polymers may include one or more polyamide copolymers (e.g., polyamide-polyether copolymers) and/or one or more polyurethanes (e.g., cross-linked polyurethanes and/or thermoplastic polyurethanes). Examples of suitable polyurethanes include those discussed above for barrier layers 114, 116. Alternatively, the one or more polymers may include one or more natural and/or synthetic rubbers, such as butadiene and isoprene.


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


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


The resilient polymeric material may be formed using a molding process. In one example, when the resilient polymeric material is a molded elastomer, the uncured elastomer (e.g., rubber) may be mixed in a Banbury mixer with an optional filler and a curing package such as a sulfur-based or peroxide-based curing package, calendared, formed into shape, placed in a mold, and vulcanized.


In another example, when the resilient polymeric material is a foamed material, the material may be foamed during a molding process, such as an injection molding process. A thermoplastic polymeric material may be melted in the barrel of an injection molding system and combined with a physical or chemical blowing agent and optionally a crosslinking agent, and then injected into a mold under conditions which activate the blowing agent, forming a molded foam.


Optionally, when the resilient polymeric material is a foamed material, the foamed material may be a compression molded foam. Compression molding may be used to alter the physical properties (e.g., density, stiffness and/or durometer) of a foam, or to alter the physical appearance of the foam (e.g., to fuse two or more pieces of foam, to shape the foam, etc.), or both.


The compression molding process desirably starts by forming one or more foam preforms, such as by injection molding and foaming a polymeric material, by forming foamed particles or beads, by cutting foamed sheet stock, and the like. The compression molded foam may then be made by placing the one or more preforms formed of foamed polymeric material(s) in a compression mold, and applying sufficient pressure to the one or more preforms to compress the one or more preforms in a closed mold. Once the mold is closed, sufficient heat and/or pressure is applied to the one or more preforms in the closed mold for a sufficient duration of time to alter the preform(s) by forming a skin on the outer surface of the compression molded foam, fuse individual foam particles to each other, permanently increase the density of the foam(s), or any combination thereof. Following the heating and/or application of pressure, the mold is opened and the molded foam article is removed from the mold.


With reference to FIGS. 1, 2, 6, and 9-11, when the sole structure 100 is assembled, an upper surface of the bladder 106 defined by the upper barrier layer 114 is attached to the upper cushioning element 110 within an interior region associated with the upper pocket 162 such that the peripheral surface 115 of the bladder 106 (i.e., the portion extending between the upper and lower surfaces defined by the barrier layers 114, 116) is inwardly offset from the peripheral side surface 158 of the upper cushioning element 110. In other words, the upper cushioning element 110 may be described as including an upper peripheral portion 168 that overhangs or extends outwardly from the peripheral surface 115 of the bladder 106. Likewise, a lower surface of the bladder 106 defined by the lower barrier layer 116 is attached to the lower cushioning element 112 within an interior region associated with the lower pocket 182 such that the peripheral surface 115 of the bladder 106 is inwardly offset from the peripheral side surface 178 of the lower cushioning element 112. Thus, like the upper cushioning element 110, the lower cushioning element 112 may be described as including a lower peripheral portion 190 that extends outwardly from the peripheral surface 115 of the bladder 106.


As shown in the figures, the lower peripheral portion 190 is spaced apart from and opposes the upper peripheral portion 168 to define a peripheral channel 192 of the chassis 108 that extends continuously along the sole structure 100 from a first end 193a defined by the toe pads 160, 180 on the medial side 22, around the second end 132 of the bladder 106, and to a second end 193b defined by the top pads 160, 180 on the lateral side 24. Thus, upper cushioning element 110 and the lower cushioning element 112 are not directly attached to each other in the ball portion 12B, the mid-foot region 14, or the heel region 16. Instead, in these regions of the sole structure 100, the bladder 106 provides the only interface between the upper cushioning element 110 and the lower cushioning element 112. By utilizing the bladder 106 as the support interface between the upper cushioning element 110 and the lower cushioning element 112, the sole structure 100 provides a relatively high degree of lateral compliance by allowing the upper cushioning element 110 to shift independently from the lower cushioning element 112 in the mid-foot region 14 and the heel region 16. Further, by configuring the bladder 106 with an unconstrained peripheral surface 115, the bladder 106 may provide improved cushioning by allowing the peripheral surface 115 to expand or distend into the peripheral channel 192 under compressive loads.


The outsole 104 is attached to the bottom surface of the lower cushioning element 112 and is configured to provide the ground-engaging surface 28 of the sole structure 100. In the illustrated example, the outsole 104 includes a pair of forefoot apertures 196 aligned with and having the shape of the apertures 186 of the lower cushioning element 112 and a teardrop-shaped aperture 198 having a profile corresponding to the profile of the heel aperture of the lower cushioning element 112. Thus, the bottom side 176 of the lower cushioning element 112 is exposed through the aperture 198 at the ground-engaging surface 28, of the outsole 104 and the bladder 106 is exposed through the apertures 186, 196 at the ground-engaging surface 28.


The upper 200 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 the sole structure 100. The upper 200 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.


With particular reference to FIGS. 14-26, an article of footwear 10a is provided and includes a sole structure 100a and the upper 200 attached to the sole structure 100a. In view of the substantial similarity in structure and function of the components associated with the article of footwear 10 with respect to the article of footwear 10a, like reference numerals are used hereinafter and in the drawings to identify like components while like reference numerals containing letter extensions are used to identify those components that have been modified.


The sole structure 100a shown in FIGS. 14-26 is substantially similar to the sole structure 100 of FIGS. 1-13, except that a midsole 102a of the sole structure 100a includes a partial-length lower cushioning element 112a that extends from a first end 170a that is spaced apart from the anterior end 18 of the sole structure 100a to a second end 172a disposed at the posterior end 20 of the sole structure 100a. For example, the first end 170a of the lower cushioning element 112a terminates on a posterior side of the MTP point PMTP of the bladder 106. Thus, as best shown in FIG. 25, the lower cushioning element 112a is disposed between the bladder 106 and the outsole 104a from the posterior end 20 to the MTP point PMTP of the bladder 106 while the bladder 106 is attached directly to the outsole 104a from the MTP point PMTP to the first end 130 of the bladder 106. Further, the outsole 104a is attached directly to the upper toe cushion 160a formed on the lower side 156 of the upper cushioning element 110 in the toe region 12T.


The lower cushioning element 112a further includes an upper side 174a defining a lower pocket 182a and lower peripheral channel 184a substantially similar to the lower pocket 182 and the lower peripheral channel 184 described above, except that each of the lower pocket 182a and the lower peripheral channel 184a only interface with portions of the bladder 106 disposed in the mid-foot region 14 and the heel region 16. As with the lower cushioning element 112, the lower cushioning element 112a includes a bottom side 174a and a peripheral side surface 178a extending between the upper side 174a and the bottom side 176a. In this example, the lower cushioning element 112a includes a teardrop-shaped aperture 188a that extends through a thickness of the lower cushioning element 112a from the upper side 174a to the bottom side 176a in the heel region 16 and aligns with a corresponding aperture 198a formed in the outsole 104a.


In the example shown in FIGS. 14-26, the upper toe cushion 160a extends partially into the ball portion 12B of the forefoot region 12 and attaches directly to the outsole 104a while the first end 170a of the lower cushioning element 112a terminates in the mid-foot region 14. Thus, as best shown in FIGS. 14 and 15, a portion of the peripheral channel 192a of the chassis 108a is defined between the lower side 156 of the upper cushioning element 110a and the outsole 104a in the ball portion 12B of the sole structure 100a, while the portion of the peripheral channel 192a extending through the mid-foot region 14 and the heel region 16 is defined between the lower side 156 of the upper cushioning element 110a and the upper side 176a of the lower cushioning element 112a. In other words, the peripheral channel 192a is defined by the upper peripheral portion 168 of the upper cushioning element 110 and the outsole 104 in the forefoot region 12, and by the upper peripheral portion 168 and a lower peripheral portion 190a of the lower cushioning element 112a in the mid-foot region 14 and the heel region 16. By increasing the length of the upper toe pad 160a relative to the upper toe pad 160, and by also attaching the bladder 106 directly to the outsole 104a in the forefoot region 12, the sole structure 100a may be tuned to provide greater lateral stability in the forefoot region 12 relative to the sole structure 100 of FIGS. 1-14.


The following Clauses provide exemplary configurations for an article of footwear, a bladder for an article of footwear, or a sole structure for an article of footwear described above.

    • Clause 1. A sole structure for an article of footwear, the sole structure defining a footbed and a ground-engaging surface and including a chassis extending from an anterior end of the sole structure to a posterior end of the sole structure, and a bladder is supported within the chassis and extends from a first end in a forefoot region of the sole structure to a second end exposed at the posterior end of the sole structure, the bladder includes a first curved portion in the forefoot region and a substantially flat portion at the posterior end of the sole structure.
    • Clause 2. The sole structure of Clause 1, wherein the bladder is exposed along at least one of a medial side of the sole structure or a lateral side of the sole structure.
    • Clause 3. The sole structure of Clause 2, wherein the bladder is continuously exposed along the at least one of the medial side of the sole structure or the lateral side of the sole structure from the first end of the bladder to the second end of the bladder.
    • Clause 4. The sole structure of Clause 3, wherein the bladder is continuously exposed along the medial side of the sole structure and the lateral side of the sole structure.
    • Clause 5. The sole structure of any of the preceding Clauses, wherein the bladder has a constant thickness from the first end to the second end.
    • Clause 6. The sole structure of any of the preceding Clauses, wherein the first curved portion defines a concave curvature relative to a footbed of the sole structure and extends from the first end to a mid-foot region of the sole structure.
    • Clause 7. The sole structure of Clause 6, wherein the bladder includes a second curved portion disposed between the first curved portion and the substantially flat portion in the mid-foot region and defining a convex curvature relative to the footbed.
    • Clause 8. The sole structure of any of the preceding Clauses, wherein the chassis includes a first cushioning element disposed between the bladder and the footbed and a second cushioning element disposed between the bladder and the ground-engaging surface.
    • Clause 9. The sole structure of Clause 8, further including an outsole defining the ground-engaging surface and including a first portion attached to the second cushioning element.
    • Clause 10. The sole structure of Clause 9, wherein the outsole includes a second portion attached to the bladder.
    • Clause 11. A sole structure for an article of footwear, the sole structure defining a footbed and a ground-engaging surface and including a bladder extending from a first end in a forefoot region of the sole structure to a second end at a posterior end of the sole structure, the bladder including a peripheral surface, and a chassis supporting the bladder in an interior portion and including a peripheral channel exposing the peripheral surface of the bladder from a mid-foot region of the sole structure to the posterior end of the sole structure.
    • Clause 12. The sole structure of Clause 11, wherein the bladder is exposed along at least one of a medial side of the sole structure or a lateral side of the sole structure.
    • Clause 13. The sole structure of either Clause 11 or Clause 12, wherein the peripheral channel extends continuously from a first end in a forefoot region of the sole structure on a medial side, around the posterior end, and to a second end in the forefoot region on a lateral side.
    • Clause 14. The sole structure of Clause 13, wherein the bladder is continuously exposed through the peripheral channel.
    • Clause 15. The sole structure of any of Clauses 11-14, wherein the bladder has a constant thickness from the first end to the second end.
    • Clause 16. The sole structure of any of Clauses 11-15, wherein the bladder includes a first curved portion defining a concave curvature relative to a footbed of the sole structure and extending from the first end to a mid-foot region of the sole structure.
    • Clause 17. The sole structure of Clause 16, wherein the bladder includes a second curved portion disposed between the first curved portion and a substantially flat portion in the mid-foot region and defining a convex curvature relative to the footbed.
    • Clause 18. The sole structure of any of Clauses 11-17, wherein the chassis includes a first cushioning element disposed between the bladder and the footbed and a second cushioning element disposed between the bladder and the ground-engaging surface.
    • Clause 19. The sole structure of Clause 18, further comprising an outsole defining the ground-engaging surface and including a first portion attached to the second cushioning element.
    • Clause 20. The sole structure of Clause 19, wherein the outsole includes a second portion attached to the bladder.


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 for an article of footwear, the sole structure defining a footbed and a ground-engaging surface and comprising: a chassis extending from an anterior end of the sole structure to a posterior end of the sole structure; anda bladder supported within the chassis and extending from a first end in a forefoot region of the sole structure to a second end exposed at the posterior end of the sole structure, the bladder including a first curved portion in the forefoot region and a substantially flat portion at the posterior end of the sole structure.
  • 2. The sole structure of claim 1, wherein the bladder is exposed along at least one of a medial side of the sole structure or a lateral side of the sole structure.
  • 3. The sole structure of claim 2, wherein the bladder is continuously exposed along the at least one of the medial side of the sole structure or the lateral side of the sole structure from the first end of the bladder to the second end of the bladder.
  • 4. The sole structure of claim 3, wherein the bladder is continuously exposed along the medial side of the sole structure and the lateral side of the sole structure.
  • 5. The sole structure of claim 1, wherein the bladder has a constant thickness from the first end to the second end.
  • 6. The sole structure of claim 1, wherein the first curved portion defines a concave curvature relative to a footbed of the sole structure and extends from the first end to a mid-foot region of the sole structure.
  • 7. The sole structure of claim 6, wherein the bladder includes a second curved portion disposed between the first curved portion and the substantially flat portion in the mid-foot region and defining a convex curvature relative to the footbed.
  • 8. The sole structure of claim 1, wherein the chassis includes a first cushioning element disposed between the bladder and the footbed and a second cushioning element disposed between the bladder and the ground-engaging surface.
  • 9. The sole structure of claim 8, further comprising an outsole defining the ground-engaging surface and including a first portion attached to the second cushioning element.
  • 10. The sole structure of claim 9, wherein the outsole includes a second portion attached to the bladder.
  • 11. A sole structure for an article of footwear, the sole structure defining a footbed and a ground-engaging surface and comprising: a bladder extending from a first end in a forefoot region of the sole structure to a second end at a posterior end of the sole structure, the bladder including peripheral surface; anda chassis supporting the bladder in an interior portion and including a peripheral channel exposing the peripheral surface of the bladder from a mid-foot region of the sole structure to the posterior end of the sole structure.
  • 12. The sole structure of claim 11, wherein the bladder is exposed along at least one of a medial side of the sole structure or a lateral side of the sole structure.
  • 13. The sole structure of claim 11, wherein the peripheral channel extends continuously from a first end in a forefoot region of the sole structure on a medial side, around the posterior end, and to a second end in the forefoot region on a lateral side.
  • 14. The sole structure of claim 13, wherein the bladder is continuously exposed through the peripheral channel.
  • 15. The sole structure of claim 11, wherein the bladder has a constant thickness from the first end to the second end.
  • 16. The sole structure of claim 11, wherein the bladder includes a first curved portion defining a concave curvature relative to a footbed of the sole structure and extending from the first end to a mid-foot region of the sole structure.
  • 17. The sole structure of claim 16, wherein the bladder includes a second curved portion disposed between the first curved portion and a substantially flat portion in the mid-foot region and defining a convex curvature relative to the footbed.
  • 18. The sole structure of claim 11, wherein the chassis includes a first cushioning element disposed between the bladder and the footbed and a second cushioning element disposed between the bladder and the ground-engaging surface.
  • 19. The sole structure of claim 18, further comprising an outsole defining the ground-engaging surface and including a first portion attached to the second cushioning element.
  • 20. The sole structure of claim 19, wherein the outsole includes a second portion attached to the bladder.
CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority under 35 U.S.C. § 119(e) to U.S. Provisional Application No. 63/476,013, filed on Dec. 19, 2022. The disclosure of this prior application is considered part of the disclosure of this application and is hereby incorporated by reference in its entirety.

Provisional Applications (1)
Number Date Country
63476013 Dec 2022 US