Footwear having inner and outer midsoles

Abstract

The present invention relates to footwear having inner and outer midsoles. A footwear article includes an outer sole having a heel region, a midfoot region, and a forefoot region. The outer midsole is secured to the outer sole and extends only over the heel region and at least some of the midfoot region. The inner midsole is supported by the outer midsole and the outsole without being secured thereto and extends over the heel region, the midfoot region, and the forefoot region. The outer midsole is configured to surround the inner midsole in the heel region. The outsole may include lateral and medial arch portions for traction.

Description

[0001] This application is a divisional application of an application filed on May 5, 2015, with application number 201580028514.0 and invention name “Footwear having inner and outer midsoles”. Technical Field

[0002] The present disclosure relates to a sole assembly for an article of footwear. Background Art

[0003] Footwear typically includes a sole configured to be positioned under the wearer's foot to separate the foot from the ground or floor surface. The sole can be designed to provide a desired level of cushioning. Athletic shoes, in particular, sometimes use polyurethane foam, rubber, or other elastic materials in the sole to provide cushioning. Summary of the Invention

[0004] This application mainly involves but is not limited to the following aspects:

[0005] 1) A footwear product comprising:

[0006] an outsole having a heel region, a midfoot region, and a forefoot region;

[0007] an outer midsole layer secured to the outsole and extending only over the heel region and at least some of the midfoot region;

[0008] an inner midsole layer supported by, but not secured to, the outer midsole layer and the outsole; wherein the inner midsole layer extends over the heel region, the midfoot region, and the forefoot region; and

[0009] The outer midsole layer is configured to surround the periphery of the inner midsole layer in the heel area.

[0010] 2) The footwear article according to 1), further comprising:

[0011] An upper having a perimeter surrounded and secured by the outsole and the outer midsole layer to define a cavity, the inner midsole layer being selectively insertable and removable from the cavity.

[0012] 3) The footwear article according to 1) or 2), wherein the outsole has:

[0013] a bottom portion defining a ground contact surface;

[0014] an inner arcuate portion extending from the bottom portion on an inner side of the bottom portion; and

[0015] An outer arcuate portion extends from the bottom portion on an outer side of the bottom portion.

[0016] 4) The footwear article of 3), wherein the outsole has a plurality of spaced apart protrusions extending outwardly from the medial arch and from the lateral arch.

[0017] 5) The article of footwear according to 4), wherein the spaced projections extending from the medial arch extend further outward than the spaced projections extending from the lateral arch.

[0018] 6) The footwear article of 4) or 5), wherein the effective diameter of the spaced protrusions decreases in a direction away from the bottom portion.

[0019] 7) The footwear article according to any one of 3) to 6), wherein the medial arch portion and the lateral arch portion are each generally triangular in shape.

[0020] 8) The footwear article according to any one of 1) to 7), wherein the outer midsole layer is harder than the inner midsole layer.

[0021] 9) The article of footwear according to any one of 1) to 8), wherein the outer midsole layer is at least seven points harder on the Shore A durometer scale than the inner midsole layer.

[0022] 10) The footwear article according to any one of 1) to 8), wherein the inner midsole layer has a substantially uniform hardness.

[0023] 11) The article of footwear according to any one of 1) to 10), wherein the inner midsole layer has grooves extending over the forefoot region of the outsole.

[0024] 12) The footwear article of 11), wherein at least some of the grooves extend laterally from the medial side to the lateral side of the inner midsole layer.

[0025] 13) The footwear article of 12), wherein one of the grooves extends longitudinally and intersects at least some of the grooves extending laterally.

[0026] 14) The article of footwear according to any one of 1) to 13), wherein the inner midsole layer has spaced recesses extending over the forefoot region of the outsole.

[0027] 15) An article of footwear as described in any one of 1) to 14), wherein the outsole has a first part and a second part, the first part having a first hardness and the second part having a second hardness greater than the first hardness; and wherein the first part extends only over some of the forefoot area, and the second part extends around the first part and over the remaining part of the outsole.

[0028] 16) The footwear article according to any one of 1) to 15), wherein the outsole comprises:

[0029] inner wall portion;

[0030] an outer sidewall portion; and

[0031] A bottom portion having a ground contact surface extends from the inner sidewall portion to the outer sidewall portion and is defined by one edge of the inner sidewall portion and by another edge of the outer sidewall portion.

[0032] 17) The footwear article according to any one of 1) to 15), wherein the outsole comprises:

[0033] a bottom portion having a grounded surface;

[0034] an inner sidewall portion having a first side surface extending generally perpendicular to the ground contact surface; and

[0035] An outer sidewall portion has a second side surface extending generally perpendicular to the ground contact surface.

[0036] 18) The footwear article according to any one of 1) to 17), further comprising:

[0037] A shoe last molding unit is fixed to the outer midsole and the outsole so that the outer midsole is located between the shoe last molding unit and the outsole in the heel area and the shoe last molding unit is directly fixed to the outsole in the forefoot area.

[0038] 19) A footwear article comprising:

[0039] a unitary outsole having a base portion having a heel region, a midfoot region, and a forefoot region and defining a ground contact surface; wherein the outsole has a medial arch portion and a lateral arch portion extending from the base portion;

[0040] an outer midsole layer secured to the outsole and extending only over the heel region and at least some of the midfoot region;

[0041] a shoe last molding unit secured to the outer midsole and the outer sole such that the outer midsole is located between the shoe last molding unit and the outer sole at the heel region and is secured directly to the outer sole at the forefoot region;

[0042] an upper fixed to the last molding unit to define a cavity and surrounded by the outsole and the outer midsole along a periphery;

[0043] an inner midsole layer, the inner midsole layer being located in the cavity and supported on the last molding unit without being fixed to any of the last molding unit, the outsole, the outer midsole layer, and the upper; wherein the inner midsole layer extends over the heel region, the midfoot region, and the forefoot region;

[0044] wherein the outer midsole layer is configured to surround the periphery of the inner midsole layer in the heel region; and

[0045] Wherein the medial arch portion extends along the upper on a medial side of the upper, and the lateral arch portion extends along the upper on a lateral side of the upper.

[0046] 20) The footwear article according to 19), wherein the outer midsole layer and the inner midsole layer are ethylene vinyl acetate foam, and wherein the outer midsole layer is harder than the inner midsole layer.

[0047] 21) The footwear article of 19) or 20), wherein the outer midsole layer is at least seven points harder on the Shore A durometer scale than the inner midsole layer.

[0048] 22) The footwear article according to any one of 19) to 21), wherein the inner midsole layer has a substantially uniform hardness.

[0049] 23) The article of footwear as described in any one of 19) to 22), wherein the inner midsole layer has grooves in the surface that contacts the last molding unit in the forefoot area.

[0050] 24) The footwear article of 23), wherein at least some of the grooves extend laterally from the medial side to the lateral side of the inner midsole layer.

[0051] 25) The footwear article of 24), wherein one of the grooves extends longitudinally and intersects at least some of the grooves extending transversely.

[0052] 26) The article of footwear as described in any one of 23) to 25), wherein the surface of the inner midsole layer that contacts the last molding unit has spaced recesses extending over the forefoot area of ​​the outsole.

[0053] 27) An article of footwear as described in any one of 19) to 26), wherein the outsole has a first part and a second part, the first part having a first hardness and the second part having a second hardness greater than the first hardness; and wherein the first part extends only over some of the forefoot area, and the second part extends around the first part and over the remaining part of the outsole.

[0054] 28) The article of footwear according to any one of 19) to 27), wherein the outsole comprises:

[0055] a medial sidewall portion having a first side surface extending generally perpendicular to the ground contact surface at the forefoot region; and

[0056] A lateral sidewall portion has a second side surface extending generally perpendicular to the ground contact surface at the forefoot region.

[0057] 29) The footwear article according to any one of 19) to 27), wherein the outsole comprises:

[0058] inner wall portion;

[0059] an outer sidewall portion; and

[0060] The bottom portion extends from the inner sidewall portion to the outer sidewall portion and is defined by one edge of the inner sidewall portion and by another edge of the outer sidewall portion.

[0061] 30) The article of footwear as described in any one of 19) to 29), wherein the medial arch portion and the lateral arch portion are each generally triangular.

[0062] 31) The article of footwear as described in any of 19)-30), wherein the outsole has a plurality of spaced protrusions extending outwardly from the medial arch portion and from the lateral arch portion.

[0063] 32) The footwear article of 31) wherein the spaced protrusions extending from the medial arch portion extend further outward than the spaced protrusions extending from the lateral arch portion.

[0064] 33) The footwear article of 31) or 32), wherein the effective diameter of the spaced protrusions decreases in a direction away from the bottom portion. BRIEF DESCRIPTION OF THE DRAWINGS

[0065] Figure 1 is a schematic side view of the inside of an article of footwear.

[0066] Figure 2 yes Figure 1 A schematic side view of the outside of a footwear article.

[0067] Figure 3 yes Figure 1 Schematic diagram of a perspective view of an inner midsole layer of an article of footwear.

[0068] Figure 4 yes Figure 1 A schematic plan view of a sole assembly of a footwear article, wherein the upper is not shown.

[0069] Figure 5 is Figure 4 A schematic cross-sectional view of the sole assembly taken at midline 5-5 and showing the upper in partial dashed lines.

[0070] Figure 6 is Figure 4 A schematic cross-sectional view of the sole assembly taken at midline 6-6 and showing the upper in partial dashed lines.

[0071] Figure 7 is Figure 4 A schematic cross-sectional view of the sole assembly taken at midline 7-7, showing the strobel unit and upper in partial dashed lines.

[0072] Figure 8 is Figure 4 A schematic cross-sectional view of the sole assembly taken at midline 8-8, showing the strobel unit and upper in partial dashed lines.

[0073] Figure 9 is Figure 4 A schematic cross-sectional view of the sole assembly taken at midline 9-9, with the strobel unit and upper shown in partial dashed lines.

[0074] Figure 10 yes Figure 4 A schematic side view of the outer side of the sole assembly.

[0075] Figure 11 yes Figure 4 A schematic side view of the inner side of the sole assembly of the shoe.

[0076] Figure 12 yes Figure 4 Schematic bottom view of the sole assembly of the shoe, and showing the dotted lines separating the outsole parts with different hardness.

[0077] Figure 13 yes Figure 4 A front view schematic diagram of the sole assembly of the shoe.

[0078] Figure 14 yes Figure 4 Schematic diagram of the rear view of the sole assembly.

[0079] Figure 15 yes Figure 4 A bottom view of the inner midsole layer of the sole assembly.

[0080] Figure 16 yes Figure 15 A side view schematic diagram of the outer side of the inner, middle and bottom layers.

[0081] Figure 17 yes Figure 15 A schematic side view of the inner side of the inner middle bottom layer.

[0082] Figure 18 yes Figure 15 Schematic diagram of the front view of the inner bottom layer.

[0083] Figure 19 yes Figure 15 Schematic diagram of the rear view of the inner middle bottom layer.

[0084] Figure 20 is a schematic diagram of a partial cross-sectional view of a lateral arch portion of an outsole.

[0085] Figure 21 is a schematic diagram of a partial cross-sectional view of a medial arch portion of an outsole. DETAILED DESCRIPTION

[0086] A footwear article is disclosed that includes various features making it suitable for use in various activities, including athletic activities such as, but not limited to, running, rope climbing, and weightlifting. The footwear article includes an outsole having a heel region, a midfoot region, and a forefoot region. An outer midsole layer is secured to the outsole and extends only over the heel region and at least some of the midfoot region. An inner midsole layer is supported by the outer midsole layer and the outsole without being secured thereto and extends over the heel region, the midfoot region, and the forefoot region. Because the inner midsole layer is supported by the outer midsole layer and the outsole without being adhered or otherwise secured to any component of the footwear article, the inner midsole layer provides the desired cushioning and compliance without any undesirable rigidity. The outer midsole layer is configured to surround the periphery of the inner midsole layer in the heel region, thereby limiting lateral outward deformation of the inner midsole during use.

[0087] The strobel unit may be secured to the outer midsole and the outsole such that the outer midsole is located between the strobel unit and the outsole at the heel area and the strobel unit is secured directly to the outsole at the forefoot. The article of footwear may include an upper having a perimeter surrounded by and secured to the outer midsole and the outer midsole to define a cavity, wherein the midsole is selectively insertable into and removable from the cavity.

[0088] The footwear article may also include a bottom portion defining a ground contact surface, an inner arch extending from the bottom portion on the inside of the bottom portion, and an outer arch extending from the bottom portion on the outside of the bottom portion. The inner arch and the outer arch may each be generally triangular, or may be another shape. The outsole may have a plurality of spaced-apart protrusions extending outward from the inner arch and the outer arch. The effective diameter of the spaced-apart protrusions may decrease in a direction away from the bottom portion. The spaced-apart protrusions may extend further outward from the inner arch than from the outer arch. When the inside of the footwear article is used for activities such as rope climbing, the longer protrusions on the inner arch will provide a greater coefficient of friction, while the shorter protrusions on the outer arch will have a lower coefficient of friction, as may be required when using the outer arch during descents. In addition, the spaced-apart protrusions may be configured so that their effective diameter decreases in a direction away from the bottom portion. In other words, the spaced-apart protrusions are longest closest to the bottom portion of the outsole, where the greatest grip is needed during climbing.

[0089] The midsole layer is cooperatively configured to provide the desired performance advantages. For example, the outer midsole layer can be harder than the inner midsole layer. The outer midsole layer and the inner midsole layer can be ethylene vinyl acetate foam. In one embodiment, the outer midsole layer is at least seven points harder than the inner midsole layer on the Shore A durometer scale. The inner midsole layer can have a generally uniform hardness. As used herein, a component has a "generally uniform" hardness if the hardness does not vary by more than 10% throughout the component. The harder outer midsole layer around the perimeter of the inner midsole layer in the heel area provides stability and support, while the softer inner midsole layer provides a cushioned feel.

[0090] The inner midsole layer may have grooves extending over the forefoot region of the outsole. The grooves may be in the surface that contacts the strobel unit in the forefoot region. At least some of the grooves may extend laterally from the inner midsole layer's medial side to the outer side. One of the grooves may extend longitudinally and intersect at least some of the laterally extending grooves. The grooves may increase compliance and flexibility in the forefoot region. Additionally, the inner midsole layer may have spaced-apart recesses extending over the forefoot region of the outsole.

[0091] The outsole has a bottom portion that forms a ground contact surface. The bottom portion may include a first portion having a first hardness and a second portion having a second hardness greater than the first hardness. The first portion extends only over a portion of the forefoot region, and the second portion surrounds the first portion and extends over the remainder of the outsole. The softer first portion increases traction in the forefoot region.

[0092] The outsole may also have an inner sidewall portion and an outer sidewall portion. The bottom portion extends from the inner sidewall portion to the outer sidewall portion, with one edge defined by the inner sidewall portion and another edge defined by the outer sidewall portion. The inner sidewall portion may have a first side surface extending generally perpendicular to the ground-contacting surface of the bottom portion, and the outer sidewall portion may have a second side surface extending generally perpendicular to the ground-contacting surface of the bottom portion. The sidewall portion having first and second side surfaces extending generally perpendicular to the ground-contacting surface provides added stability to the article of footwear, for example, by preventing undesirable lateral movement during weightlifting, etc.

[0093] In one embodiment, an article of footwear includes a unitary outsole having a base portion, the base portion having a heel region, a midfoot region, and a forefoot region and defining a ground contact surface. The outsole has a medial arch portion and a lateral arch portion extending from the base portion. An outer midsole is secured to the outsole and extends only over the heel region and at least some of the midfoot region. A strobel unit is secured to the outer midsole and the outsole such that the outer midsole is positioned between the strobel unit and the outsole in the heel region and the strobel unit is secured directly to the outsole in the forefoot region. An upper is secured to the strobel unit to define a cavity and is surrounded by the outsole and the outer midsole along a perimeter. The inner midsole is within the cavity and supported on the strobel unit without being secured to any of the strobel unit, the outsole, the outer midsole, or the upper. The inner midsole layer extends over the heel region, the midfoot region, and the forefoot region. The outer midsole layer is configured to surround the periphery of the inner midsole layer in the heel region. The medial arch portion extends along the upper on the inner side of the upper, and the lateral arch portion extends along the upper on the outer side of the upper.

[0094] "A," "an," "the," "at least one," and "one or more" are used interchangeably to indicate that at least one of the items is present; unless the context clearly indicates otherwise, there may be multiple such items. Unless otherwise expressly or clearly indicated by the context (including the appended claims), all numerical values ​​for parameters (e.g., quantities or conditions) in this specification are to be understood as being modified in all instances by the term "about," regardless of whether "about" actually appears before the numerical value. "About" indicates that the numerical value allows for some slight imprecision (close to the exact value in value; approximately or reasonably close to the value; almost). If the imprecision provided by "about" is not understood in the art in its other conventional meaning, "about" as used herein at least indicates variations that may result from conventional methods of measuring and using such parameters. In addition, the disclosure of a range is to be understood as a specific disclosure of all values ​​within that range and further divided ranges.

[0095] The terms "comprising," "including," and "having" are inclusive, so they specify the presence of the stated features, steps, operations, elements, or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, or components. The order of steps, processes, and operations may be changed, and additional or alternative steps may be employed. As used in this specification, the term "or" includes any and all combinations of the associated listed items.

[0096] Those skilled in the art will recognize that terms such as "above," "below," "upward," "downward," "top," "bottom," etc. are used descriptively with respect to the drawings and are not meant to limit the scope of the invention as defined by the claims.

[0097] The above features and advantages and other features and advantages of the present disclosure are readily apparent from the following detailed description of the modes for carrying out the concepts of the present disclosure when taken in conjunction with the accompanying drawings,

[0098] Referring to the drawings, wherein like reference numerals refer to like parts throughout the several views, Figure 1 1 is a medial side view of an article of footwear 10 comprising an outer sole 14, an outer midsole 16, and an inner midsole 18 (e.g., Figure 3 As further disclosed herein, the inner midsole layer 18 is not adhered or otherwise secured to any component of the article of footwear 10, thereby preventing undesirable stiffness. The inner midsole layer 18 is less rigid than the outer midsole layer 16 to enhance cushioning for running or other activities, while the outer midsole layer 16 and the outsole 14 provide stability for activities such as weightlifting. In addition, the outsole 14 includes Figure 1 and Figure 2 The medial and lateral arch portions 20, 22 are shown extending upwardly along and secured to the medial side 24 of the upper 26 at a perimeter 30 of the upper 26, and extending upwardly along and secured to the lateral side 28 of the upper 26 to provide traction for activities such as rope climbing.

[0099] As used herein, the lateral side of a footwear component, such as lateral side 28 of upper 26, is the side that corresponds to the side of the wearer's foot of footwear 10 and is generally farther from the wearer's other foot (i.e., the side closer to the wearer's fifth toe). The fifth toe is generally referred to as the pinky toe. The medial side of a footwear component, such as medial side 24 of footwear 10, is the side that corresponds to the medial area of ​​the wearer's foot and is generally closer to the wearer's other foot (i.e., the side closer to the big toe of the wearer's foot). The big toe is generally referred to as the big toe. Both lateral side 28 and medial side 24 extend from the front-most portion 32 of upper 26 to the rear-most portion 34 of upper 26.

[0100] like Figure 1 、 9 As best shown in FIG. 12 , the outsole 14 has a heel region 36, a midfoot region 38, and a forefoot region 40. The midfoot region 38 is located between the heel region 36 and the forefoot region 40. For the purposes of this discussion, the heel region 36, the midfoot region 38, and the forefoot region 40 are defined as the rearmost third, the middle third, and the frontmost third, respectively, of the outsole 14. Thus, the forefoot region 40 extends from the frontmost region A of the outsole 14 to a lateral marking B, which is one-third of the way along the longitudinal axis L from the frontmost region A to the rearmost region D of the outsole 14. The middle region 38 extends from the lateral marking B to the lateral marking C, which is two-thirds of the way along the longitudinal axis L from the frontmost region A to the rearmost region D. The heel region extends from the lateral marking C to the rearmost region D.

[0101] Heel region 36 generally includes portions of outsole 14 that correspond to the back of a human foot, including the calcaneus bone, with the dimensions of the human foot corresponding to outsole 14 and article of footwear 10. Forefoot region 40 generally includes portions of outsole 14 that correspond to the toes and joints connecting the metatarsal bones to the phalanges of a human foot, with the dimensions of the human foot corresponding to outsole 14 and article of footwear 10. Midfoot region 38 generally includes portions of outsole 14 that correspond to the arch area of ​​a human foot, with the dimensions of the human foot corresponding to outsole 14 and article of footwear 10.

[0102] Figure 9 The outer midsole layer 16 is shown secured to the outsole 14 and extends only over the heel region 36 and a portion of the midfoot region 38. The inner midsole layer 18 is supported by the outer midsole layer 16 and the outsole 14, but is not secured thereto. In other words, the inner midsole layer 18 is not adhered, stitched, bonded, welded, or otherwise secured to any other component of the article of footwear 10. Instead, the inner midsole layer 18 is simply placed on a strobel unit 42 within a cavity 41 defined and bounded by the upper 26 and the strobel unit 42. The strobel unit 42 is stitched to the upper 26. Alternatively, heat stitching, bonding, or other methods of securing the footwear upper 26 to the strobel unit 42 may be used. The strobel unit 42 is also directly adhered or bonded to an upwardly facing surface 46 of the outer midsole layer 16 in the heel area 36, ​​directly adhered or bonded to the portion of the midfoot area 38 not covered by the outer midsole layer 16, and directly adhered or bonded to an upwardly facing surface 48 of the outsole 14 in the forefoot area 40. The upper 26 can be constructed of multiple separate parts and materials, such as fabrics, textiles, leather, plastics, etc. Figure 1As shown, in the illustrated embodiment, upper 26 includes a relatively rigid polymer heel counter 27 , a leather portion 29 , a textile mesh portion 31 , a polymer toe cap 33 , a cloth lining 35 , and a nylon drawstring 37 .

[0103] like Figure 3 and Figure 9 As shown, the inner midsole layer 18 is a full-length midsole layer so that when placed in the cavity 41, it extends over the heel area 36, ​​the midfoot area 38, and the forefoot area 40. The inner midsole layer 18 can therefore be selectively inserted or removed from the cavity 41 and is referred to as a drop-in midsole. Because the inner midsole layer 18 is not fixed to any component of the footwear article 10, it can exhibit some minimal relative movement relative to the strobel unit 42, the outer midsole layer 16, and the outsole 14 under some load forces. This reduces rigidity and creates a sense of flexibility during wear. However, the inner midsole layer 18 is supported by the outer midsole layer 16 and the outsole 14, and is relatively constrained by the outer midsole layer 16 and the upper 26. As shown in FIG. Figure 4 and Figure 8 As shown, the outer midsole layer 16 is configured to surround a perimeter 50 of the inner midsole layer 18 at the heel region 36 .

[0104] As discussed further herein, the outer midsole layer 16 is stiffer than the inner midsole layer 18. For example, in one embodiment, the outer midsole layer 16 is 7 points stiffer than the inner midsole layer 18 when the hardness is measured on the Shore A scale. Both the inner midsole layer 18 and the outer midsole layer 16 can be polymer foams, such as ethylene vinyl acetate (EVA) foam. The inner midsole layer 18 can be a lighter weight, lower density foam than the outer midsole layer 16. The inner midsole layer 18 is configured to have a generally uniform hardness that provides adequate cushioning and compliance under the wearer's heel, while the surrounding outer midsole layer 16 is stiffer to provide lateral support, resilience, and energy absorption at the heel area 36. As Figure 3 As shown, the inner midsole layer 18 has a textile lining 39 secured to a foot-receiving surface 44 (ie, the upper surface).

[0105] On the other hand, the outer sole 14 does not have a uniform hardness. Specifically, Figure 12 A boundary H is shown that generally separates a first portion 52 of the outsole from a second portion 54 of the outsole 14. The first portion 52 extends over only some of the forefoot region 40 and generally coincides with the pressure-bearing area beneath the ball of the wearer's foot. The second portion 54 includes the entire remainder of the outsole 14. The first portion 52 has a first hardness and the second portion 54 has a second hardness that is greater than the first hardness. The first portion 52 is softer than the second portion 54 and has a greater coefficient of friction relative to the ground surface GS than the harder rubber of the second portion 54, as shown. Figure 9As shown. Thus, first portion 52 is more compliant and provides greater traction against forces transmitted from the ball of the wearer's foot through forefoot region 40, such as during lateral movements and / or climbing. Outsole 14 may be thermoplastic rubber or another durable material. The material used for outsole 14 may be selected to provide a desired combination of durability and flexibility.

[0106] like Figure 9-12 As shown, outsole 14 has a bottom portion 60 defining a ground contact surface GCS. Ground contact surface GCS includes bottom portion 60 configured to contact the wearer's footwear 10 when the wearer is wearing the footwear 10 for most activities in which the wearer is typically upright, such as running or weightlifting. Figure 9 Those parts of the ground surface that are in contact with GS. Figure 9 and Figure 12 As shown, bottom portion 60 has a plurality of molded grounding elements 62 of varying sizes, most or all of which have a hexagonal shape. Other shapes of grounding elements may be used within the scope of the present disclosure. Grounding elements 62 extend outwardly from base 64 of outsole 14. Thus, those of grounding elements 62 that contact the ground surface GS establish a ground contact surface GS. Figure 10 、 11 , 13 and 14, the ground contact element 62 is configured so that the ground contact surface GCS of the outsole 14 is substantially flat from the medial side 66 of the outsole 14 to the lateral side 68 of the outsole 14 when the article of footwear 10 is positioned upright as shown and not being worn, i.e., when the outsole 14 is unloaded, or when the outsole 14 is bearing the weight of a person wearing the article of footwear 10 and standing upright. Figure 9 、 13 As shown in Figures 14 and 14, not all of ground contact elements 62 may contact ground contacting surface GCS at once, and as the wearer's foot moves relative to the ground, different portions of outsole 14 will contact the ground.

[0107] At any given location along the longitudinal axis L of the outsole 14, the large flatness of the ground contact surface GCS from the medial side 66 to the lateral side 68 contributes to the stability of the footwear 10. Specifically, the footwear 10 is relatively difficult to roll up laterally due to the large width and flatness of the bottom portion 60. In addition, as Figure 5As shown, outsole 14 has a medial sidewall portion 70 having a first side surface 72 extending generally perpendicular to bottom contact surface GCS. Outsole 14 also has a lateral sidewall portion 74 having a second side surface 76 extending generally perpendicular to bottom contact surface GCS. Medial sidewall portion 70 and lateral sidewall portion 74 are adjacent to forefoot region 40 of outsole 14. Edge E1 is defined by bottom portion 60 and medial sidewall portion 70 at angled surface 73 and located between bottom portion 60 and medial sidewall portion 70, similar to a chamfer, and edge E2 is defined by bottom portion 60 and lateral sidewall portion 74 at angled surface 77 and located between them, similar to as shown in FIG. Figure 12 By providing angled surfaces 73, 77 with edges E1, E2, rather than a more rounded transition from the bottom 60 to the sidewall portions 70, 74, the stability and resistance to lateral rolling of the outsole 14 is improved.

[0108] Figure 1 、 2 , 6-7, and 10-12 show the medial arch portion 20 extending from the bottom portion 60 on the medial side 24 of the bottom portion 60 and the arch portion 22 extending from the bottom portion 60 on the lateral side 26 of the bottom portion 60. The medial arch portion 20 and the lateral arch portion 22 are generally triangular in shape and extend upward along the side of the upper 26 approximately halfway to apexes A1 and A2, respectively.

[0109] A plurality of spaced-apart protrusions 80 extend outwardly from a base 82 of the outsole 14 at the medial and lateral arcuate portions 20, 22, as shown. Figure 1 and 2 As shown. Similar to ground contact element 62, protrusion 80 is hexagonal in shape, but other shapes may also be used. In fact, when footwear 10 is used for rope climbing, for example, protrusion 80 serves as ground contact element for both medial arch 20 and lateral arch 22. During rope climbing, medial arch 20 typically presses against the rope and provides traction during the ascent. During descent, the climber can reposition their foot so that lateral arch 22 contacts the rope. Generally, greater traction is required when climbing than when descending. During descent, an experienced climber may desire contact between the rope and lateral arch 22, but may also wish to use lateral arch 22 as a sliding support against the rope to increase descent speed. Therefore, a higher coefficient of friction is required at medial arch 20 than at lateral arch 22. To accommodate these requirements, the spaced protrusions 80 on medial arch 20 extend further outward from base 82 than the spaced protrusions 80 on lateral arch 22. Figure 21 Shown in a larger view Figure 7 The lateral and medial arch parts of the . Figure 7 and Figure 20The longest spaced protrusions 80 on the inner arcuate portion 20 are shown extending a distance D1 from the base 82, while Figure 20 The longest spaced protrusions 80 on the outer arcuate portion 22 are shown extending a small distance D2 from the base 82. The distances D1, D2 outward from the base 82 are measured along the respective central axes C1, C2 of the protrusions 80.

[0110] exist Figure 1 、 Figure 2 and Figure 7 As is apparent from the figure, the spaced protrusions 80 on either the inner or outer arcuate portions 20, 22 extend further outward near the base portion 60, and their outward extension decreases in the direction farther away from the base portion 60 (i.e., the protrusions 80 closer to the apex A1 or A2 extend less outward than those protrusions 80 closer to the base portion 60). In addition to decreasing extension length, the effective diameter of the spaced protrusions 80 also decreases in the direction away from the base portion 60. In other words, the effective diameter of the protrusions 80 closer to the apex A1 or A2 is smaller than that of the protrusions 80 closer to the base portion 60. Figure 1 and Figure 2 Protrusions near base portion 60 are shown having effective diameter 88A, while protrusions closer to apex A1 or A2 have smaller effective diameters 88B. As used herein, the effective diameter of a hexagonal protrusion 80 is the diameter of a circular protrusion having an equivalent surface area to the hexagonal faces of the protrusion.

[0111] like Figure 15 As shown, inner midsole layer 18 has grooves 90, 92 formed in a forefoot portion 93 of inner midsole layer 18. When inner midsole layer 18 is placed in cavity 41 of article of footwear 10, grooves 90, 92 extend over forefoot region 40 of outsole 14. Grooves 90, 92 are in bottom surface 94 of inner midsole layer 18, which contacts strobel unit 42 in forefoot region 40. Grooves 90 are transverse grooves because they extend transversely from inner side 95 of inner midsole layer 18 to outer side 96 of inner midsole layer 18. Grooves 92 are longitudinal grooves because they extend longitudinally and intersect at least some of transverse grooves 92. Grooves 90, 92 increase the compliance and flexibility of inner midsole layer 18 in forefoot region 40.

[0112] Figure 15Also shown is a bottom surface 94 of the inner midsole layer 18 having spaced-apart recesses 98, only some of which are labeled with reference numerals. The spaced-apart recesses 98 are in the bottom surface 94 of the inner midsole layer 18, which contacts the strobel unit 42 in the forefoot region 40, and thus extend over the forefoot region 40 of the outsole 14 when the inner midsole layer 18 is placed in the cavity 41. The spaced-apart recesses 98 increase the compliance of the material of the inner midsole layer 18 in the forefoot region 40. Furthermore, the spaced-apart recesses 98 increase the coefficient of friction of the inner midsole layer 18 on the strobel unit 42 relative to the relatively smooth midfoot portion 99 of the inner midsole layer 18. The increased coefficient of friction in the forefoot region 93 helps limit sliding movement of the inner midsole layer 18 relative to the strobel unit 42 . Figure 15 The pattern of the spaced-apart recesses 98 in the outer sole 14 (e.g. Figure 12 The first portion 52 (shown) has a softer rubber than the second portion 54. Thus, the grooves 90, 92, the spaced-apart recesses 98, and the first portion 52 are all arranged in the forefoot region 40 to increase compliance, flexibility, and cushioning in the forefoot region 40 of the article of footwear 10.

[0113] Figure 15 The bottom midsole layer 18 is also shown having transverse grooves 100 in a heel region 102 of the bottom midsole layer 18. The grooves 100 are generally shallower than the grooves 90. The grooves 100 help increase the compliance and coefficient of friction of the bottom midsole layer 18 in the heel region 102 relative to the relatively smooth midfoot portion 99 of the bottom midsole layer 18. When the bottom midsole layer 18 is placed in the cavity 41, the increased coefficient of friction in the heel region 102 helps limit sliding movement of the bottom midsole layer 18 relative to the strobel unit.

[0114] Figure 16-19 The inner midsole layer 18 is shown having outer and inner sidewall portions 106A, 106B, both having longitudinally extending pleats 108 generally in the forefoot portion 93, and as shown in FIG. Figure 17 The pleats 108 are shown partially extending into the midfoot portion 99. The pleats 108 may also be referred to as alternating ridges and valleys. The pleats 108 increase the compliance of the forefoot portion 93 of the inner midsole layer 18. Figure 16 and 17 As can be seen in FIG. 1 , the foot contact portion 100 of the heel region 102 continues from the bottom surface 94 of the inner midsole layer 18 to the sidewall portions 106A, 106B.

[0115] While several modes for implementing many aspects of the present teachings have been described in detail, those skilled in the art to which these teachings pertain will recognize various alternative aspects for implementing the present teachings within the scope of the appended claims.

Claims

1. A footwear article comprising: a unitary outsole having a bottom portion with a heel region, a midfoot region, and a forefoot region; an outer midsole layer secured to the outsole and extending only over the heel region and at least some of the midfoot region; as well as an inner midsole layer, the inner midsole layer being supported by the outer midsole layer and the outsole without being fixed to the outer midsole layer and the outsole; in: The inner midsole layer has grooves extending over the forefoot region of the outsole; the inner midsole layer having spaced recesses extending over the forefoot region of the outsole; The outsole has a first portion and a second portion; the first portion extends over only some of the forefoot region, and the second portion surrounds the first portion and extends over a remaining portion of the outsole; The first portion has a first hardness and the second portion has a second hardness greater than the first hardness; The first portion conforms to the pattern of the spaced-apart recesses; The second portion surrounds the first portion; The grooves are in a forefoot portion of the inner midsole layer, and at least some of the grooves extend laterally from a medial side to a lateral side of the inner midsole layer; and One of the grooves extends longitudinally and intersects at least some of the grooves extending transversely.

2. The article of footwear according to claim 1, further comprising: A shoe last molding unit is fixed to the outer midsole and the outsole so that the outer midsole is located between the shoe last molding unit and the outsole in the heel area and the shoe last molding unit is directly fixed to the outsole in the forefoot area.

3. The article of footwear according to claim 2, further comprising: an upper fixed to the last molding unit to define a cavity and surrounded by the outsole and the outer midsole along a periphery; wherein the inner midsole layer is disposed in the cavity and supported on the last molding unit without being fixed to any of the last molding unit, the outsole, the outer midsole layer, or the upper, and The inner midsole layer extends over the heel region, the midfoot region, and the forefoot region.

4. The footwear article according to claim 3, wherein: The outer midsole layer is configured to surround the periphery of the inner midsole layer in the heel area; and The outer mid bottom layer is harder than the inner mid bottom layer.

5. The article of footwear according to claim 1, wherein: The inner mid-bottom layer has a substantially uniform hardness.

6. The article of footwear according to claim 1, wherein: The inner midsole layer has additional transverse grooves in a heel portion of the inner midsole layer.

7. The article of footwear according to claim 1, wherein: The inner middle bottom layer has an outer side wall portion and an inner side wall portion; Both the lateral sidewall portion and the medial sidewall portion of the inner midsole layer have corrugations extending longitudinally in a forefoot portion of the inner midsole layer and partially extending into a midfoot portion of the inner midsole layer.

8. The article of footwear according to claim 1, wherein: The spaced recesses and the grooves are in the bottom surface of the inner midsole layer.

9. A footwear article comprising: vamp; An outsole, the outsole comprising: the heel area, midfoot area, and forefoot area; a bottom portion defining a ground contact surface; an inner arcuate portion extending from the bottom portion on an inner side of the bottom portion; an outer arcuate portion extending from the base portion on an outer side of the base portion; and in: The outsole has a plurality of spaced apart protrusions extending outwardly from the medial and lateral arched portions; and The medial arch portion and the lateral arch portion are each generally triangular in shape and extend upward along the side of the upper about halfway up the upper to a vertex of the triangle. an outer midsole layer secured to the outsole and extending only over the heel region and at least some of the midfoot region; and an inner midsole layer supported by the outer midsole layer and the outsole without being secured thereto; wherein the inner midsole layer extends over the heel region, the midfoot region, and the forefoot region, wherein the outer midsole layer is configured to surround a periphery of the inner midsole layer in the heel region, The shoe upper has a periphery surrounded and fixed by the outer sole and the outer midsole to define a cavity, and the inner midsole can be selectively inserted into and removed from the cavity.

10. The article of footwear according to claim 9, wherein: The outsole has a first portion and a second portion, the first portion having a first hardness and the second portion having a second hardness greater than the first hardness; and wherein the first portion extends only over some of the forefoot area and the second portion surrounds the first portion and extends over the remainder of the outsole.

11. The article of footwear according to claim 9, wherein: The outsole comprises: inner wall portion; an outer sidewall portion; and The bottom portion extends from the inner sidewall portion to the outer sidewall portion and is defined by one edge of the inner sidewall portion and by another edge of the outer sidewall portion.

12. The article of footwear according to claim 9, wherein: The outsole comprises: a medial sidewall portion having a side surface extending generally perpendicular to the ground contact surface at the forefoot region; as well as A lateral sidewall portion has a side surface extending generally perpendicular to the ground contact surface at the forefoot region.

13. The article of footwear according to claim 9, wherein: The spaced protrusions are hexagonal in shape.

14. A footwear article comprising: an outsole having a heel region, a midfoot region, a forefoot region, a bottom portion defining a ground contact surface, and a medial arch portion extending upwardly from the bottom portion on a medial side of the bottom portion; wherein the inner arcuate portion is generally triangular; wherein the medial arcuate portion of the outsole has a base and a plurality of spaced projections extending outwardly from the base; wherein the outsole further comprises a lateral arched portion extending upwardly from the bottom portion, the lateral arched portion being generally triangular in shape; wherein the outer arcuate portion has a base and a plurality of spaced projections extending outwardly from the base; and wherein the plurality of protrusions extending outwardly from the base of the inner arcuate portion extend outwardly further than the plurality of protrusions extending outwardly from the base of the outer arcuate portion, an outer midsole layer secured to the outsole and extending only over the heel region and at least some of the midfoot region; an inner mid-bottom layer, the inner mid-bottom layer being supported by the outer mid-bottom layer and the outsole without being fixed thereto; wherein the inner midsole layer extends over the heel region, the midfoot region, and the forefoot region, wherein the outer midsole layer is configured to surround a periphery of the inner midsole layer in the heel region; and an upper having a perimeter surrounded and secured by the outsole and the outer midsole layer to define a cavity, the inner midsole layer being selectively insertable and removable from the cavity, wherein the bottom portion extends from an inner sidewall portion of the outsole to an outer sidewall portion of the outsole and is defined by one edge by the inner sidewall portion and by another edge by the outer sidewall portion, wherein the medial arch portion extends along the upper on a medial side of the upper, and the lateral arch portion extends along the upper on a lateral side of the upper, and The medial arch portion and the lateral arch portion respectively extend upward along the side of the shoe upper for approximately half the distance of the shoe upper to reach the vertex of the triangle.

15. The article of footwear according to claim 14, wherein: Each of the plurality of protrusions has a hexagonal shape.

16. The article of footwear according to claim 14, wherein: The article of footwear has a forefoot region, a midfoot region, and a heel region, and the bottom portion has ground contact elements in the forefoot region, the midfoot region, and the heel region.

17. The article of footwear according to claim 16, wherein: The grounding elements and the protrusions have a hexagonal shape.

18. An article of footwear comprising: vamp; an outsole having a bottom portion defining a ground contact surface, a medial arch portion extending from the bottom portion on a medial side of the bottom portion, a medial sidewall portion, and a lateral sidewall portion, wherein the bottom portion extends from the medial sidewall portion to the lateral sidewall portion and defines one edge by the medial sidewall portion and another edge by the lateral sidewall portion, the medial sidewall portion having a first side surface extending generally perpendicular to the ground contact surface at a forefoot region and the lateral sidewall portion having a second side surface extending generally perpendicular to the ground contact surface at the forefoot region; wherein the inner arcuate portion is generally triangular; wherein the inner arcuate portion has a base and a plurality of spaced-apart protrusions extending outwardly from the base; wherein the outsole further includes a lateral arcuate portion extending upwardly from the bottom portion on a lateral side of the bottom portion, the lateral arcuate portion being generally triangular in shape; wherein the medial arch portion extends along the upper on a medial side of the upper, and the lateral arch portion extends along the upper on a lateral side of the upper; wherein the bottom portion has the forefoot region, the midfoot region, and the heel region, and has ground contact elements in the forefoot region, the midfoot region, and the heel region; and an outer midsole layer secured to the outsole and extending only over the heel region and at least some of the midfoot region; and an inner midsole layer supported by the outer midsole layer and the outsole without being secured thereto; wherein the inner midsole layer extends over the heel region, the midfoot region, and the forefoot region, wherein the outer midsole layer is configured to surround a periphery of the inner midsole layer in the heel region, wherein the upper has a perimeter surrounded and secured by the outsole and the outer midsole layer to define a cavity, the inner midsole layer being selectively insertable and removable from the cavity; and The medial arch portion and the lateral arch portion respectively extend upward along the side of the shoe upper for approximately half the distance of the shoe upper to reach the vertex of the triangle.

19. The article of footwear according to claim 18, wherein: Each of the plurality of protrusions has a hexagonal shape.

20. The article of footwear according to claim 18, wherein: The grounding element and the plurality of protrusions are hexagonal in shape.

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