Sole structure for an article of footwear

Abstract

A sole structure for an article of footwear includes a cushioning element including a first material and a cradle including a second material. The cradle is attached to the cushioning element and includes a first plate disposed against the cushioning element and a second plate spaced apart from the cushioning element, the second plate including an aperture portion. The sole structure further includes a bladder disposed within the cradle, the bladder including a first portion contacting the first plate and a second portion extending through the aperture of the second plate.

Description

[0001] Cross-reference to related applications

[0002] This application claims priority to U.S. Provisional Application US63 / 064,534, filed August 12, 2020, pursuant to 35 U.S.SC §119(e). The disclosure of that earlier application is considered part of the disclosure of this application, and the entire contents thereof are incorporated herein by reference. Technical Field

[0003] This invention generally relates to a sole structure for footwear articles. Background Technology

[0004] This section provides background information relating to this disclosure, which is not necessarily prior art.

[0005] Footwear typically consists of an upper and a sole structure. The upper can be formed from any suitable material (of various kinds) to receive, secure, and support the foot within the sole structure. The upper can be fitted with laces, straps, or other fasteners to adjust the fit around the foot. The bottom portion of the upper, closest to the sole surface of the foot, is attached to the sole structure.

[0006] The sole construction typically comprises a layered arrangement extending between the ground and the upper. One layer of the sole construction includes an outsole, which provides abrasion resistance and traction to the ground. The outsole can be formed of rubber or other materials that impart durability and abrasion resistance, as well as enhanced traction. Another layer of the sole construction includes a midsole layer disposed between the outsole and the upper. The midsole layer provides cushioning for the foot and may be partially formed of a polymer foam material that elastically compresses under applied load to cushion the foot by attenuating ground reaction forces. The midsole layer may incorporate fluid-filled bladders to cushion the foot by elastically compressing under applied load to attenuate ground reaction forces. The sole construction may also include an insole or insole for enhanced comfort, located within a gap near the bottom portion of the upper, and the sole construction includes a strobel attached to the upper and disposed between the midsole layer and the insole or insole.

[0007] Insoles using bladders typically consist of a bladder formed by two sealed or bonded polymer material barrier layers. The bladder may contain air and is designed to emphasize a balance of support and cushioning characteristics for the foot, with cushioning properties related to responsiveness when the bladder elastically compresses under applied loads. Summary of the Invention

[0008] In one construction, a sole structure for footwear is provided, the sole structure comprising: a cushioning element comprising a first material; a support comprising a second material, attached to the cushioning element, and including (i) a first plate disposed abutting against the cushioning element, and (ii) an opening disposed opposite to the first plate; an outsole comprising an inner surface facing the cushioning element; and a bladder disposed within the support, comprising a first portion and a second portion, the first portion contacting the first plate, and the second portion extending through the opening and contacting the inner surface of the outsole.

[0009] In another configuration, a sole structure for footwear is provided, comprising a cushioning element comprising a first material and a support comprising a second material. The support is attached to the cushioning element and includes a first plate disposed abutting against the cushioning element and a second plate spaced apart from the cushioning element, the second plate including an opening. The sole structure also includes a bladder disposed within the support, the bladder including a first portion contacting the first plate and a second portion extending through an opening in the second plate.

[0010] The sole construction may include one or more of the following optional features. For example, the outsole may be disposed adjacent to the second plate on the side of the support opposite to the cushioning element. In this configuration, the second portion of the bladder may contact the outsole. Additionally or alternatively, the second plate may surround the second portion of the bladder.

[0011] In one configuration, a first plate and a second plate may partially define a receiving portion of a support that extends continuously from a first side to a second side through the support. The support may include an arcuate first end support connecting the first plate and the second plate at a first end of the support. The first end support may be spaced apart from the bladder. Additionally or alternatively, the support may include an arcuate second end support connecting the first plate and the second plate at a second end of the support. The first end support and the second end support may be spaced apart from the bladder. The first end support may have different dimensions than the second end support.

[0012] In another configuration, a sole structure for footwear articles is provided, the sole structure comprising: a cushioning element; a support received by the cushioning element and defining a receiving portion extending continuously through the support from a first side of the sole structure to a second side of the sole structure; and a pouch comprising a first portion disposed within the receiving portion and a second portion extending through the support.

[0013] The sole structure may include one or more of the following optional features. In one configuration, the outsole may be positioned on the side of the support opposite the cushioning element. In this configuration, a second portion of the bladder may contact the outsole via the support.

[0014] In one configuration, the stent may include a first plate surrounding a second portion of the sac. The second plate may be spaced apart from the first plate. In this configuration, the first portion of the sac may contact the second plate.

[0015] The stent may include an arcuate first end support connecting a first plate and a second plate at a first end of the stent. The first end support may be spaced apart from the bladder. Alternatively or additionally, the stent may include an arcuate second end support connecting the first plate and the second plate at a second end of the stent. The first and second end supports may be spaced apart from the bladder. The first end support may have a different size than the second end support. Attached Figure Description

[0016] The accompanying drawings described herein are for illustrative purposes only and are not intended to limit the scope of this disclosure. In the drawings:

[0017] Figure 1 This is an external perspective view of a footwear item according to the principles of the present invention;

[0018] Figure 2 yes Figure 1 An inside perspective view of footwear;

[0019] Figure 3 yes Figure 1 A front view of the outside of a footwear item;

[0020] Figure 4 yes Figure 1 A top view of footwear items;

[0021] Figure 5 yes Figure 1 An exploded perspective view of the bottom of the sole structure of footwear.

[0022] Figure 6 yes Figure 5 Exploded perspective view of the top of the shoe sole structure;

[0023] Figure 7 It is along Figure 4 The line 7-7 was cut Figure 1 A cross-sectional view of footwear items;

[0024] Figure 8 It is along Figure 3 The line cut from 8-8 Figure 1 A cross-sectional view of footwear items;

[0025] Figure 9 It is along Figure 3 The line 9-9 was cut off Figure 1 A cross-sectional view of footwear items;

[0026] Figure 10 It is along Figure 3 The line 10-10 cut Figure 1 A cross-sectional view of footwear items;

[0027] Figure 11 This is a top view of the bladder of the sole structure according to the principle of the present invention; and

[0028] Figure 12 It is along Figure 11 The line 12-12 cut Figure 11 A cross-sectional view of the bladder.

[0029] Throughout the accompanying figures, corresponding reference numerals denote the corresponding parts. Detailed Implementation

[0030] Exemplary embodiments will now be described more fully with reference to the accompanying drawings. Exemplary embodiments are provided so that this disclosure will be thorough and will fully convey the scope of the disclosure to those skilled in the art. Numerous specific details, such as examples of particular components, apparatus, and methods, are set forth to provide a thorough understanding of the construction of this disclosure. It will be apparent to those skilled in the art that specific details are not required, that the exemplary constructions may be implemented in many different forms, and that the specific details and exemplary constructions should not be construed as limiting the scope of this disclosure.

[0031] The terminology used herein is for the purpose of describing particular exemplary embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” may also be intended to include the plural forms unless the context clearly indicates otherwise. The terms “comprising,” “including,” “containing,” and “having” are inclusive and thus specify the presence of features, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, steps, operations, elements, components, and / or combinations thereof. Unless expressly identified as the order of execution, the method steps, processes, and operations described herein should not be construed as necessarily having to be performed in the specific order discussed or shown. Additional or alternative steps may be employed.

[0032] When an element or layer is referred to as being “on top of” another element or layer, or “joined to,” “connected to,” “attached to,” or “linked to” another element or layer, it may be directly located, joined, connected, attached to, or linked to the other element or layer, or there may be intermediate elements or layers present. Conversely, when an element is referred to as being “directly on” another element or layer, or “directly joined to,” “directly connected to,” “directly attached to,” or “directly linked to” another element or layer, there may be no intermediate elements or layers present. Other terms used to describe relationships between elements should be interpreted in a similar manner (e.g., “between” vs. “directly between,” “adjacent” vs. “directly adjacent,” etc.). As used herein, the term “and / or” includes any and all combinations of one or more of the associated listed items.

[0033] The terms first, second, third, etc., may be used herein to describe various elements, components, regions, layers, and / or parts. These elements, regions, layers, and / or parts should not be limited by these terms. These terms are used only to distinguish one element, component, region, layer, or part from another. Unless the context clearly indicates otherwise, terms such as “first,” “second,” and other numerical terms used herein do not imply order or sequence. Therefore, without departing from the teachings of the exemplary embodiments, the first element, component, region, layer, or part discussed below may be referred to as the second element, component, region, layer, or part.

[0034] refer to Figure 1-10 A footwear article 10 is provided, comprising a sole structure 100 and an upper 200 attached to the sole structure 100. The footwear article 10 may be divided into one or more regions. The regions may include a forefoot region 12, a midfoot region 14, and a heel region 16. The forefoot region 12 corresponds to the metatarsophalangeal joints (i.e., the "ball"). The midfoot region 14 may correspond to the arch region of the foot, while the heel region 16 may correspond to the rear portion of the foot, including the calcaneus. The footwear 10 may also include a front end 18 associated with the foremost point of the forefoot region 12 and a rear end 20 corresponding to the rearmost point of the heel region 16. Figure 5 As shown, the longitudinal axis A10 of the footwear 10 extends along the length of the footwear 10 from the front end 18 to the rear end 20, and generally divides the footwear 10 into an outer side 22 and an inner side 24. Therefore, the outer side 22 and the inner side 24 correspond to opposite sides of the footwear 10 and extend through regions 12, 14, and 16, respectively.

[0035] Referring to Figure 3, the sole structure 100 includes a sole interlayer 102 configured to provide cushioning properties to the sole structure 100 and an outsole 104 configured to provide a ground contact surface 30 for the footwear article 10. Unlike conventional sole structures, the sole interlayer 102 of the sole structure 100 can be compositely formed and includes multiple sub-components for providing the desired form of cushioning and support throughout the sole structure 100. For example, the sole interlayer 102 can be described as including a bladder 106 and a base 108, wherein the base 108 is configured to attach to the upper 200 and provide an interface between the upper 200, the bladder 106, and the outsole 104.

[0036] Overall, the bladder 106 of the sole structure 100 is supported within the heel region 16 of the base 108 and is configured to dampen impact-related forces within the heel region 16. The bladder 106 of the sole interlayer 102 includes a pair of opposing barrier layers 114, 116, which are connected to each other at discontinuous locations to define a chamber 118, a ventral region 120, and a peripheral seam 122. In the illustrated embodiment, the barrier layers 114, 116 include a first upper barrier layer 114 and a second lower barrier layer 116. Alternatively, the chamber 118 may be made of any suitable combination of one or more barrier layers, as described in more detail below.

[0037] In some embodiments, the upper barrier layer 218a and the lower barrier layer 218b cooperate to define the geometry of the chamber 118 (e.g., thickness, width, and length). For example, the web region 120 and the peripheral seam 122 may cooperate to define the chamber 118 and extend around the chamber 118 to seal the fluid (e.g., air) within the chamber 118. Thus, the chamber 118 is associated with a region of the bladder 106 where the inner surfaces of the upper barrier layer 114 and the lower barrier layer 116 are not connected together and are therefore separated from each other.

[0038] like Figure 7 and 9 As shown, the space formed between the opposing inner surfaces of the upper barrier layer 114 and the lower barrier layer 116 defines the inner cavity of the chamber 118. Similarly, the outer surfaces of the upper barrier layer 114 and the lower barrier layer 116 define the outer contour of the chamber 118. The thickness T118 of the chamber 118 is defined by the distance between the upper barrier layer 114 and the lower barrier layer 116 of the bladder 106.

[0039] like Figure 11As best shown, chamber 118 includes a plurality of segments 130, 132 that cooperate to provide responsive and supportive properties to the midsole 102. Specifically, segments 130, 132 can be described as a pair of pads 130 included on opposite sides of the bladder 106, which are connected to each other (i.e., in fluid communication) via one or more conduits 132. When assembled into the sole structure 100, the pads 130 of chamber 118 are configured to be at least partially exposed along the peripheral edge of the sole structure 100.

[0040] refer to Figure 7 Each pad 130 includes a tubular body 134, a first terminal 136 disposed at a first end of the tubular body 134, and a second terminal 138 disposed at the end of the tubular body 134 opposite to the first terminal 136. The tubular body 134 defines a generally circular cross-section extending along the longitudinal axis A130 of the pad 130. As shown, the thickness T118 of the chamber 118 increases continuously along the longitudinal axis A130 from a first thickness T118-1 at the first terminal 136 to a second thickness T118-2 at the second terminal 138. Therefore, the thickness of the chamber 118 can be described as tapering along the direction from the second terminal 138 to the first terminal 136.

[0041] like Figure 12 As shown, the first terminal 136 and the second terminal 138 of each pad 130 are substantially dome-shaped, and each includes a composite curvature associated with a corresponding upper barrier layer 114 and lower barrier layer 116. For example, the first terminal 136 of each pad 130 is formed in a position where the end portion of the upper barrier layer 114 converges with the lower barrier layer 116 and connects to the lower barrier layer 116 at a peripheral seam 122 to close the front end of the tubular body 134. Still referring to... Figure 12 Each pad 130 has a second terminal 138 formed in such a position that the other end portion of the upper barrier layer 114 converges with the lower barrier layer 116 and is connected to the lower barrier layer 116 at a peripheral seam 122 to close the opposite ends of the tubular body 134.

[0042] As described above, each pad 130 defines a corresponding longitudinal axis A130 extending from the first terminal 136 to the second terminal 138. Figure 11As best shown, the pads 130 are spaced apart from each other along a direction transverse to the longitudinal axis A106 of the pouch 106. Therefore, when the pouch 106 is assembled within the sole structure 100, the pads 130 are spaced apart from each other along the transverse direction of the footwear article 10, such that the first pad of the pads 130 extends along the outer side 22, and the second pad of the pads 130 extends along the inner side 24. Furthermore, the longitudinal axes A130 of the pads 130 converge from each other along a direction from the rear end 20 to the front end 18, and converge with the longitudinal axis A10 of the footwear article 10. Therefore, the transverse distance D1 between the pads 130 is greater at the second end 138 than at the first end 136.

[0043] Continue to refer to Figure 11 and 12 The chamber 118 also includes at least one conduit 132 that extends between and fluidly connects the pads 130. In the illustrated example, the chamber 118 includes a plurality of conduits 132 that interconnect tubular bodies 134 of the pads 130. Each conduit 132 extends along a corresponding longitudinal axis A132, which is transverse to the longitudinal axis A130 of the pads 130. Figure 11 and 12 As shown, the conduit 132 includes a first conduit 132 extending between the tubular bodies 134 of the pad 130 adjacent to the first terminal 136, a second conduit 132 extending between the tubular bodies 134 of the pad 130 adjacent to the second terminal 138, and a third conduit 132 disposed between the first and second conduits 132 and connecting the middle portion of the tubular bodies 134. Therefore, the first and second conduits 132 are located on opposite sides of the third conduit 132.

[0044] like Figure 9 and 12 As shown, the conduit 132 is defined by the cooperation of an upper barrier layer 114 and a lower barrier layer 116. Figure 12 As shown, an upper blocking layer 114 and a lower blocking layer 116 are formed to provide a plurality of semi-cylindrical conduits 132, each conduit having a substantially similar third thickness T118-3, which is less than the first thickness T118-1 and the second thickness T118-2 of the pad 130. The profile of each conduit 132 is substantially defined by the upper blocking layer 114, whereby the upper blocking layer 114 is molded to define the curved upper portion of each conduit 132, while the lower blocking layer 116 is provided for the substantially flat lower portion of each conduit 132. Although the lower blocking layer 114 is initially provided in a substantially flat state, when the chamber 118 is pressurized and the lower blocking layer 116 is biased away from the upper blocking layer 114, the lower blocking layer 116 can bulge from the web region 120, as shown. Figure 7 As shown.

[0045] refer to Figure 7 and11 A web region 120 is formed at the junction of the upper barrier layer 114 and the lower barrier layer 116, and extends and connects them between each segment 130, 132 of the chamber 118. Specifically, the web region 120 includes a front portion that extends and connects the first ends 136 of the respective pads 130, and defines a first terminal edge at the front end of the sac 106. A rear portion of the web region 120 extends and connects the second ends 138 of the pads 130, and forms a second terminal edge at the rear end of the sac 106. A middle portion of the web region 120 extends and connects adjacent conduits and pads 130 in the conduit 132. Thus, the middle portion of the web region 120 can be completely surrounded by the chamber 118. In the illustrated example, the web region 120 is vertically positioned in the middle relative to the total thickness T118 of the fluid-filled chamber 118.

[0046] In the illustrated example, the ventral region 120 of chamber 118 and pad 130 cooperate to define an upper pouch 140 on a first side of pouch 106 associated with the upper blocking layer 114. Here, a conduit 132 may be disposed within the upper pouch 140 to form an alternating series of protrusions and recesses along the length of the upper pouch 140. As described in more detail below, base 108 may include one or more features configured to mate with the upper pouch 140 when the sole structure 100 is assembled. For example, base 108 may include notches and protrusions configured to engage the protrusions and recesses formed by the conduit 132 of pouch 106.

[0047] As used herein, the term "barrier layer" (e.g., barrier layers 114, 116) includes single-layer or multi-layer films. In some embodiments, one or both of barrier layers 114, 116 are made of a single-layer film (monolayer) (e.g., thermoformed or blow-molded). In other embodiments, one or both of barrier layers 114, 116 are made of a multi-layer film (multiple sublayers) (e.g., thermoformed or blow-molded). In any aspect, the film thickness of each layer or sublayer can range from about 0.2 micrometers to about 1 millimeter. In a further embodiment, the film thickness of each layer or sublayer can range from about 0.5 micrometers to about 500 micrometers. In yet another embodiment, the film thickness of each layer or sublayer can range from about 1 micrometer to about 100 micrometers.

[0048] One or both of the barrier layers 114 and 116 may be independently transparent, translucent, and / or opaque. For example, the upper barrier layer 114 may be transparent, while the lower barrier layer 116 may be opaque. As used herein, for barrier layers and / or fluid-filled chambers, the term "transparent" means that light passes through the barrier layer in a substantially straight line and that an observer can see through the barrier layer. In contrast, for an opaque barrier layer, light does not pass through the barrier layer and it is not clearly visible at all. A translucent barrier layer falls between a transparent barrier layer and an opaque barrier layer because light passes through the translucent layer, but some light is scattered, making it not clearly visible to the viewer.

[0049] Each of the barrier layers 114 and 116 may be made of an elastomeric material comprising one or more thermoplastic polymers and / or one or more crosslinkable polymers. In one aspect, the elastomeric material may include one or more thermoplastic elastomer materials, such as one or more thermoplastic polyurethane (TPU) copolymers, one or more ethylene-vinyl alcohol (EVOH) copolymers, etc.

[0050] As used herein, “polyurethane” refers to copolymers (including oligomers) containing urethane groups (-N(C=O)O-). These polyurethanes may also contain other groups besides urethane groups, such as esters, ethers, ureas, urethane esters, biuret, carbodiimides, oxazolyl alkyl groups, isocyanates, diuretics, carbonates, etc. In one aspect, one or more polyurethanes can be prepared by polymerizing one or more isocyanates with one or more polyols to produce copolymer chains having (-N(C=O)O-) bonds.

[0051] Examples of suitable isocyanates for producing polyurethane copolymer chains include diisocyanates, such as aromatic diisocyanates, aliphatic diisocyanates, and combinations thereof. Examples of suitable aromatic diisocyanates include toluene diisocyanate (TDI), adducts of TDI and triformylpropane (TMP), methylene diphenyl diisocyanate (MDI), xylene diisocyanate (XDI), tetramethylxylene diisocyanate (TMXDI), hydrogenated xylene diisocyanate (HXDI), naphthalene 1,5-diisocyanate (NDI), 1,5-tetrahydronaphthalene diisocyanate, p-phenylene diisocyanate (PPDI), 3,3'-dimethyldiphenyl 1,4,4'-diisocyanate (DDDI), 4,4'-dibenzyl diisocyanate (DBDI), 4-chloro-1,3-phenylene diisocyanate, and combinations thereof. In some embodiments, the copolymer chain is substantially free of aromatic groups.

[0052] In one aspect, the polyurethane polymer chain is generated from diisocyanates including HMDI, TDI, MDI, H12 aliphatic compounds, and combinations thereof. In another aspect, thermoplastic TPUs may include polyester-based TPUs, polyether-based TPUs, polycaprolactone-based TPUs, polycarbonate-based TPUs, polysiloxane-based TPUs, or combinations thereof.

[0053] On the other hand, the polymer layer can be formed from one or more of the following: EVOH copolymers, polyvinyl chloride, polyvinylidene ethylene polymers and copolymers (e.g., polyvinylidene chloride), polyamides (e.g., amorphous polyamides), amide copolymers, acrylonitrile polymers (e.g., acrylonitrile-methyl acrylate copolymers), polyethylene terephthalate, polyetherimide, polyacrylamide, and other polymeric materials known to have relatively low gas transport rates. Blends of these materials, as well as blends with the TPU copolymers described herein and optionally combinations including polyimides and crystalline polymers, are also suitable.

[0054] Barrier layers 114, 116 may include two or more sublayers (multilayer films), such as those shown in U.S. Patents 5,713,141 and 5,952,065 to Mitchell et al., the disclosures of which are incorporated herein by reference in their entirety. In embodiments where barrier layers 114, 116 include two or more sublayers, examples of suitable multilayer films include microlayer films, such as those disclosed in U.S. Patent 6,582,786 to Bonk et al., which is incorporated herein 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, wherein the total number of sublayers in each of 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.

[0055] The chamber 118 can be generated from the barrier layers 114, 116 using any suitable technique, such as thermoforming (e.g., vacuum thermoforming), blow molding, extrusion, injection molding, vacuum forming, rotational molding, transfer molding, pressure forming, heat sealing, casting, low-pressure casting, spin casting, reaction injection molding, radio frequency (RF) welding, etc. In one aspect, the barrier layers 114, 116 can be generated by co-extrusion followed by vacuum thermoforming to produce an inflatable chamber 118, which may optionally include one or more valves (e.g., one-way valves) that allow the chamber 118 to be filled with a fluid (e.g., gas).

[0056] Chamber 118 may be provided in a fluid-filled (e.g., as provided in footwear 10) or unfilled state. Chamber 118 may be filled to include any suitable fluid, such as gas or liquid. In one aspect, the gas may include air, nitrogen (N2), or any other suitable gas. In other aspects, chamber 118 may alternatively include other media, such as granules, beads, ground recycled materials, etc. (e.g., foam beads and / or rubber beads). The fluid supplied to chamber 118 may cause chamber 118 to be pressurized. Alternatively, the fluid supplied to chamber 118 may be at atmospheric pressure, such that chamber 118 is not pressurized, but only contains a certain volume of fluid at atmospheric pressure.

[0057] Chamber 118 ideally has a low gas transport rate to maintain the gas pressure it retains. In some embodiments, the nitrogen transport rate of chamber 118 is at least about ten (10) times lower than the nitrogen transport rate of a butyl rubber layer of substantially the same size. In one aspect, for an average film thickness of 500 micrometers (based on the thickness of barrier layers 114, 116), chamber 118 has a nitrogen transport rate of 15 cubic centimeters per square meter atm per day (cm³ / m²·atm·day) or less. In other aspects, the transport rate is 10 cm³ / m²·atm·day or less, 5 cm³ / m²·atm·day or less, or 1 cm³ / m²·atm·day or less.

[0058] In some embodiments, the upper barrier layer 114 and the lower barrier layer 116 are formed by respective mold portions, each mold portion defining various surfaces for forming recesses and extrusion surfaces, the extrusion surfaces corresponding to locations where a web region 120 and / or a peripheral seam 122 are formed when the upper barrier layer 114 and the lower barrier layer 116 are joined and bonded together. In some embodiments, an adhesive bond connects the upper barrier layer 114 and the lower barrier layer 116 to form the web region 120 and the peripheral seam 122. In other embodiments, the upper barrier layer 114 and the lower barrier layer 116 are joined by thermal bonding to form the web region 120 and the peripheral seam 122. In some examples, one or both of the upper barrier layer 114 and the lower barrier layer 116 are heated to a temperature conducive to forming and melting. In some examples, the barrier layers 114, 116 are heated before being placed between their respective molds. In other examples, the molds may be heated to increase the temperature of the barrier layers 114, 116. In some embodiments, the molding process for forming the fluid-filled chamber 118 incorporates a vacuum port within the mold portion to remove air, causing the upper barrier layer 114 and the lower barrier layer 116 to be drawn into contact with their respective mold portions. In other embodiments, a fluid such as air may be injected into the region between the upper barrier layer 114 and the lower barrier layer 116, causing an increase in pressure that leads to the barrier layers 114, 116 engaging with the surfaces of their respective mold portions.

[0059] In the illustrated example, the base 108 extends continuously from the front end 18 to the rear end 20 and is configured to receive and support the bladder 106 therein. As shown, the base 108 is formed as a composite structure including a cushioning element 110 and a support 112 at least partially housed within the cushioning element 110. As described below, the support 112 is configured to receive and support the bladder 106 within the heel region 16 of the cushioning element 110. Although the cushioning element 110 and the support 112 in the illustrated example are shown as separate components cooperating to form the base 108, in some examples, the base 108 may be formed as a single unit.

[0060] The cushioning element 110 is formed of a first material and extends continuously from a first end 142 at the front end 18 of the sole structure 100 to a second end 144 at the rear end 20 of the sole structure 100. The cushioning element 110 includes a top surface 146 extending continuously from the first end 142 to the second end 144, which defines the footbed of the base 108. The cushioning element 110 also includes a bottom surface 148 formed on the side of the cushioning element 110 opposite to the top surface 146. The distance from the top surface 146 to the bottom surface 148 defines the total thickness T110 of the cushioning element 110. Figure 7 ).like Figure 5 and 6As shown, the buffer element 110 also includes a recessed surface 150 offset from the bottom surface 148 to the top surface 146.

[0061] As shown, the aforementioned surfaces 146, 148, and 150 of the cushioning element 110 cooperate to define the support member 152 in the forefoot region 12 and the recess 154 in the heel region 16. In the example shown, the cushioning element 110 also includes an upper rear lip 156 hanging from the recessed surface 150 at the second end 144 of the cushioning element 110, which cooperates with a corresponding portion of the outsole 104 to close the support 112 at the rear end 20 of the sole structure 100, as described in more detail below.

[0062] A support member 152 of the cushioning element 110 is formed between a top surface 146 and a bottom surface 148, and extends continuously from a first end 142 of the cushioning element 110 to an end wall 158 in the midfoot region 14. Thus, the support member 152 provides cushioning and support characteristics of a base 108 in the forefoot region below the metatarsal bones and ball of the foot. Optionally, the support member 152 may include one or more bends 160 to increase the flexibility of the support member 152. In the example shown, the bends 160 are embodied as a series of grooves 160 formed in the top surface 146, wherein each groove 160 extends across the forefoot region 12 in a direction from the outer side 22 to the inner side 24.

[0063] Continue to refer to Figure 5 The recess 154 is defined by the recessed surface 150. In the illustrated example, the recess 154 is defined at its opposite ends by an end wall 158 in the midfoot region 14 and a lip 156 at the rear end 20 of the sole structure 100. Thus, the recess 154 extends from the midfoot region 14 to the rear end 20. The depth of the recess 154, defined by the offset distance from the bottom surface 148 to the recessed surface 150, corresponds to the height of the support 112. Therefore, when the support 112 is received within the recess 154, the bottom portion of the support 112 is flush with the bottom surface 148 of the cushioning element 110 to provide a continuous support surface along the bottom of the base 108.

[0064] As described above, the cushioning element 110 is formed of an elastic polymeric material, such as foam or rubber, to impart cushioning, responsiveness, and energy distribution properties to the wearer's feet. Exemplary elastic polymeric materials used for the cushioning element 110 may include those based on foaming or molding one or more polymers (e.g., one or more elastomers, such as thermoplastic elastomers (TPEs)). The one or more polymers may include aliphatic polymers, aromatic polymers, or mixtures thereof; or may include homopolymers, copolymers (including terpolymers), or mixtures thereof.

[0065] In some aspects, one or more polymers may include olefin homopolymers, olefin copolymers, or blends thereof. Examples of olefin polymers include polyethylene, polypropylene, and combinations thereof. In other aspects, 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 monofatty acid copolymers, and combinations thereof.

[0066] In another aspect, one or more polymers may include one or more polyacrylates, such as polyacrylic acid, esters of polyacrylic acid, polyacrylonitrile, polyacrylate, polymethyl acrylate, ethyl acrylate, butyl acrylate, polymethyl methacrylate, and polyvinyl acetate; including derivatives thereof, copolymers thereof, and any combination thereof.

[0067] In another aspect, one or more polymers may include one or more ionomer polymers. In these aspects, ionomer polymers may include polymers having carboxylic acid functional groups, sulfonic acid functional groups, their salts (e.g., sodium, magnesium, potassium, etc.), and / or their anhydrides. For example, one or more ionomer polymers may include one or more fatty acid-modified ionomer polymers, polystyrene sulfonates, ethylene-methacrylic acid copolymers, and combinations thereof.

[0068] In other respects, one or more polymers may include one or more styrene block copolymers, such as acrylonitrile butadiene styrene block copolymers, styrene acrylonitrile block copolymers, styrene ethylene butene styrene block copolymers, styrene ethylene butadiene styrene block copolymers, styrene ethylene propylene propylene styrene block copolymers, styrene butadiene styrene block copolymers, and combinations thereof.

[0069] In other respects, one or more polymers may include one or more polyamide copolymers (e.g., polyamide-polyether copolymers) and / or one or more polyurethanes (e.g., crosslinked polyurethanes and / or thermoplastic polyurethanes). Alternatively, one or more polymers may include one or more natural and / or synthetic rubbers, such as butadiene and isoprene.

[0070] When the elastic polymer material is a foam polymer material, it can be foamed using a physical blowing agent that transforms into a gas based on temperature and / or pressure changes, or a chemical blowing agent that forms a gas when heated above its activation temperature. For example, a chemical blowing agent can be an azo compound, such as hexamethylenetetramine, sodium bicarbonate, and / or isocyanate.

[0071] In some embodiments, the foam polymer material may be a cross-linked foam material. In these embodiments, a peroxide-based cross-linking agent, such as dicumyl peroxide, may be used. Furthermore, the foam polymer material may include one or more fillers, such as pigments, modified or natural clay, modified or unmodified synthetic clay, talc glass fiber, powdered glass, modified or natural silica, calcium carbonate, mica, paper, wood chips, and the like.

[0072] Molding processes can be used to form elastic polymer materials. In one example, when the elastic polymer material is a molded elastomer, an uncured elastomer (e.g., rubber) can be mixed with optional fillers and curing agents (e.g., sulfur-based or peroxide-based curing agents) in a Banbury mixer, calendered, shaped, placed in a mold, and vulcanized.

[0073] In another example, when the elastic polymer material is a foam material, it can be foamed in a molding process such as injection molding. Thermoplastic polymer material can be melted in the barrel of an injection molding system and mixed with a physical or chemical foaming agent and optionally a crosslinking agent, then injected into a mold under conditions of activated foaming agent to form molded foam.

[0074] Optionally, when the elastic polymer material is a foam material, the foam material can be a compression-molded foam. Compression molding can be used to change the physical properties of the foam (e.g., density, stiffness, and / or hardness), or to change the physical appearance of the foam (e.g., fusing two or more foam pieces to form a foam, etc.), or both.

[0075] The compression molding process is intended to begin by forming one or more foam preforms, for example, by injection molding and foaming a polymer material, by forming foam particles or beads, by cutting sheet-like foam material, etc. The compression-molded foam can then be manufactured by placing one or more preforms formed from one or more foam polymer materials into a compression mold and applying sufficient pressure to the preforms to compress them within a closed mold. Once the mold is closed, sufficient heat and / or pressure are applied to the preforms within the closed mold for a sufficient time to alter the preforms by forming a skin on the outer surface of the compression-molded foam, fusing individual foam particles together, permanently increasing the density of the foam, or any combination thereof. After heating and / or applying pressure, the mold is opened and the molded foam article is removed from the mold.

[0076] Continue to refer to Figure 1-5The support 112 is received within the recess 154 of the cushioning element 110 and cooperates with the cushioning element 110 and the outsole 104 to support the bladder 106. In the illustrated example, the support 112 includes a top plate 162 and a bottom plate 164, which are interconnected at opposite ends of the support 112 by a first end support 166 and a second end support 168. When the sole structure 100 is assembled, the top plate 162 is received abutting against the recessed surface 150 of the cushioning element 110. Here, the first end support 166 of the support 112 is positioned adjacent to and facing the end wall 158 of the recess 154, while the second end support 168 is adjacent to and facing the lip 156 of the cushioning element 110 at the rear end 20 of the sole structure 100. Figure 3 As shown, the support 112 extends beyond the upper 200 at the rear end 20, such that the second end support 168 is located behind the rear end of the upper 200, thereby providing a cantilever structure at the rear end 20 of the footwear article 10. Plates 162, 164 and end supports 166, 168 cooperate to define an internal receiving portion 170, which is configured to receive the pouch 106 therein when the sole structure 100 is assembled.

[0077] As shown, a top plate 162 extends from a first end support 166 to a second end support 168 and defines the upper portion of a receiving portion 170. The top plate 162 includes a protrusion 172 extending from an inner surface of the top plate 162 into the receiving portion 170. Typically, the protrusion 172 is configured to at least partially mate with a pouch 140 formed by the upper barrier layer 114 of the bladder 106. As shown, the protrusion 172 includes a plurality of ribs 174 arranged in a series along a direction from the first end support 166 to the second end support 168. Each rib 174 extends from the protrusion 172 to a distal end 176 facing the bottom plate 164. Here, the ribs 174 are configured to be received between adjacent conduits 132 of the bladder 106. Therefore, the side surfaces of the ribs 174 may be concave to receive corresponding convex portions of the conduits 132. Figure 7 As best shown in the sectional view, the rib 174 may not extend completely between the conduits 132, such that when the sole structure 100 is assembled, the distal end 176 is spaced apart from the ventral region 120.

[0078] The base plate 164 also extends from the first end support 166 to the second end support 168, defining the lower portion of the container 170. However, as Figure 5 and 6 As best shown, the base plate 164 includes an aperture 178 formed therethrough, which provides an opening to the receiving portion 170 for receiving the bladder 106. The aperture 178 has a peripheral profile corresponding to the peripheral profile of the bladder 106. Figure 7 and 9As shown, when the sole structure 100 is assembled, the bladder 106 can be located inside the opening portion 178, such that the periphery of the opening portion 178 surrounds the periphery of the bladder 106.

[0079] like Figure 5 and 6 As shown, the top plate 162 and the bottom plate 164 are interconnected at opposite ends of the bracket 112 by end supports 166 and 168. Each end support 166 and 168 has an arcuate cross-sectional shape and forms a semi-cylindrical shape at each end of the bracket 112. The arcuate shape of each end support 166 and 168 forms an elastic structure at each end of the bracket 112, which allows the plates 162 and 164 to compress towards each other. The end supports 166 and 168 may have different radii to provide different spring stiffnesses at each end of the bracket 112.

[0080] The total height H112 of bracket 112 ( Figure 7 The distance (h112) is defined as the distance from the top plate 162 to the bottom plate 164. In the illustrated example, the height H112 of the bracket 112 at each end support 166, 168 corresponds to the radius of the respective end support 166, 168. As shown, the first end support 166 has a smaller radius than the second end support 168, such that the height H112 of the bracket increases along the direction from the first end support 166 to the second end support 168. Therefore, the height H112 of the bracket 112 at the first end support 166 can be less than the height h112 at the second end support 168 to form a wedge-shaped bracket 112 in the heel region 16.

[0081] Optionally, the first end support 166 may include a plurality of struts 180 for providing longitudinal stability and stiffness to the support 112. In the illustrated example, the struts 180 are formed as a series of teeth 180 projecting from the lower portion of the first end support 166. Each tooth includes a front side extending tangentially from the foremost point of the first end support 166 and a bottom side formed flush with the base plate 162. Thus, the sides of the struts 180 intersect each other adjacent to the outer bottom 104, thereby providing increased thickness to the lower portion of the first end support 166. In use, the struts 180 provide longitudinal stiffness to the end support 166. Therefore, when a force is applied to the top plate 162 in the direction toward the front end 18, such as when stopping or landing during forward movement, the struts 180 can minimize deformation.

[0082] As described above, plates 162, 164 and end supports 166, 168 cooperate to define a container 170 of the support 112 for receiving the bladder 106 therein. As shown, the respective edges of the supports 166, 168 and plates 162, 164 can cooperate to define openings 182 on opposite sides of the support 112 leading to the receiving portion 170. In other words, the receiving portion 170 extends continuously through the support 112 from the outer side 22 to the inner side 24. In some examples, each opening 182 can be defined by a flange 184 extending outward (i.e., away from the opening 182) from the edges of the plates 162, 164 and end supports 166, 168. Thus, the flange 184 extends outward around each side of the support 112 and can receive the cushioning element 110 and the outsole 104 therebetween to ensure the lateral position of the support 112 in the sole structure 100.

[0083] refer to Figure 5 and 6 The outsole 104 includes an inner surface 186 facing the midsole 102 and an outer surface 188 defining the ground contact surface of the sole structure 100. The outsole 104 may include a recess 190 formed on the inner surface 186, the recess 190 being configured to receive the lower portion of the pouch 106 (e.g., the lower barrier layer 116) when the sole structure 100 is assembled. Figure 6 As shown, the receiving socket 190 includes a pair of channels 192 formed on opposite sides of the elongated central protrusion 194. Each channel 192 is configured as a lower portion of one of the receiving pads 130. Thus, the channels 192 have a profile and arrangement corresponding to the shape (e.g., elongated shape with rounded ends) and arrangement (e.g., converging) of the pads 130.

[0084] The protrusion 194 of the socket 190 is configured to be received between the lower portions of the pad 130, adjacent to the web region 120. For example... Figure 9 As shown, the protrusion 194 contacts the lower blocking layer 116 along the ventral region 120 and is formed along the inner surface 186 between the recessed channels 192 of the outsole 104. Thus, the protrusion 194 can form a recess in the outer surface 188 of the outsole 104 between the pads 130 of the bladder 106. In use, when the heel region 16 is compressed by the heel of the foot, the ventral region 120 and the protrusion 194 can provide a trampoline-like response between the pads 130 of the bladder 106.

[0085] The outsole 104 also includes a lower lip 196 configured to cooperate with the upper lip 156 of the cushioning element 110 to surround the second end support 168 of the bracket 112. (As in...) Figure 7As best shown in the cross-sectional view, the lower lip 196 extends upward from the outsole 104 and surrounds the lower portion of the second end support 168 of the bracket 112. In the illustrated example, the distal end of the upper lip 156 partially overlaps with the distal end of the lower lip 196 to form an overlap between the lips 156 and 196. Alternatively, the lower lip 196 may include a plurality of bends 198 formed in the inner surface 186 of the outsole 104. The bends 198 of the lower lip 196 are configured as grooves extending across the width of the outsole 104, which allows the lower lip 196 to conform to the outer surface of the second end support 168.

[0086] As described above, the components of the sole structure 100 cooperate to form a pressure-responsive vibration absorber in the heel region 16 of the sole structure 100. Here, the bladder 106 is confined between the top plate 162 and the socket 190 of the outsole 104. Therefore, the bladder 106 provides cushioning and support along the middle portion of the support 112. Figure 3 As shown, the ends 136, 138 of the pad 130 are spaced apart from the end supports 166, 168 of the bracket 112. As described above, the end supports 166, 168 are arcuate and are thus configured to bend or flex when the top plate 162 and the bottom plate 164 are compressed toward each other. Therefore, the end supports 166, 168 provide auxiliary support and cushioning for the pouch 106 in the heel region 16. In some examples, the end supports 166, 168 may be a spring-like elastic structure that provides a responsive reaction to the foot upon compression.

[0087] While the base 108 and bladder 106 provide cushioning in the heel region 16, the support member 152 provides cushioning and support in the forefoot region 12. In some cases, the material of the cushioning element 110 can provide different performance characteristics than the base 108 and bladder 106. For example, the support member 152 can provide localized, microscopic cushioning along the forefoot region 12, which includes more joints, while the support provides more holistic, macroscopic cushioning in the heel region 16 where the calcaneus is located.

[0088] The upper 200 is attached to the sole structure 100 and includes an inner surface defining a cavity configured to receive and secure the foot for support on the sole structure 100. The upper 200 may be formed of one or more materials stitched or adhesively bonded together to form the cavity. Suitable materials for the upper may include, but are not limited to, mesh, textiles, foam, leather, and synthetic leather. Materials can be selected and positioned to impart durability, breathability, abrasion resistance, flexibility, and comfort.

[0089] The following terms provide exemplary constructions of footwear articles, footwear article pouches, or sole structures of the aforementioned footwear articles.

[0090] Clause 1: A sole structure for footwear articles, the sole structure comprising: a cushioning element comprising a first material; a support comprising a second material, the support being attached to the cushioning element and comprising a first plate disposed against the cushioning element and a second plate spaced apart from the cushioning element, the second plate comprising an opening; and a pouch disposed within the support and comprising a first portion contacting the first plate and a second portion extending through the opening of the second plate.

[0091] Clause 2: The sole structure according to Clause 1 further includes an outsole disposed adjacent to the second plate on the side of the support opposite to the cushioning element.

[0092] Clause 3: The sole structure according to Clause 2, wherein the second portion of the bladder contacts the outsole.

[0093] Clause 4: The sole structure according to any one of the preceding clauses, wherein the second plate surrounds the second portion of the bladder.

[0094] Clause 5: The sole structure according to any one of the preceding clauses, wherein the first plate and the second plate partially define a receiving portion extending continuously from the first side to the second side through the support.

[0095] Clause 6: The sole structure according to Clause 5, wherein the support includes an arcuate first end support connecting the first plate and the second plate at a first end of the support.

[0096] Clause 7: The sole structure according to Clause 6, wherein the first end support is spaced apart from the bladder.

[0097] Clause 8: The sole structure according to Clause 6, wherein the support includes an arcuate second end support connecting the first plate and the second plate at a second end of the support.

[0098] Clause 9: The sole structure according to Clause 8, wherein the first end support and the second end support are spaced apart from the bladder.

[0099] Clause 10: The sole structure according to Clause 8, wherein the first end support has a different size than the second end support.

[0100] Clause 11: A sole structure for footwear articles, the sole structure comprising: a cushioning element; a support received by the cushioning element and defining a receiving portion extending continuously through the support from a first side of the sole structure to a second side of the sole structure; and a pouch comprising a first portion disposed within the receiving portion and a second portion extending through the support.

[0101] Clause 12: The sole structure according to Clause 11 further includes an outsole disposed on the side of the support opposite to the cushioning element.

[0102] Clause 13: The sole structure according to Clause 12, wherein the second portion of the bladder contacts the outsole via the support.

[0103] Clause 14: The sole structure according to any one of the preceding clauses, wherein the support includes a first plate surrounding a second portion of the bladder.

[0104] Clause 15: The sole structure according to Clause 14, wherein the support includes a second plate spaced apart from the first plate, and a first portion of the bladder contacts the second plate.

[0105] Clause 16: The sole structure according to Clause 15, wherein the support includes an arcuate first end support connecting the first plate and the second plate at a first end of the support.

[0106] Clause 17: The sole structure according to Clause 16, wherein the first end support is spaced apart from the bladder.

[0107] Clause 18: The sole structure according to Clause 16, wherein the support includes an arcuate second end support connecting the first plate and the second plate at a second end of the support.

[0108] Clause 19: The sole structure according to Clause 18, wherein the first end support and the second end support are spaced apart from the bladder.

[0109] Clause 20: The sole structure according to Clause 18, wherein the first end support has a different size than the second end support.

[0110] The foregoing description has been provided for illustrative purposes. It is not intended to be exhaustive or limiting of this disclosure. Elements or features of a particular construction are generally not limited to that particular construction, but are interchangeable where applicable, and may be used in the chosen construction even if not specifically shown or described. It can also be varied in many ways. Such variations should not be considered a departure from this disclosure, and all such modifications are intended to be included within the scope of this disclosure.

Claims

1. A sole structure for footwear articles, the sole structure comprising: A cushioning element, comprising a first material; A support, comprising a second material, is attached to the cushioning element and includes: (i) a first plate disposed abutting against the cushioning element; (ii) a second plate disposed opposite to the first plate and including an opening; (iii) a first end support connecting the first plate and the second plate at a first end of the support; (iv) a second end support connecting the first plate and the second plate at a second end of the support; (v) a first opening defined by a first edge of the first plate and the second plate, the first end support, and the second end support, the first opening being disposed on the outer side of the sole structure; (vi) a second opening defined by a second edge of the first plate and the second plate, the first end support, and the second end support, the second opening being disposed on the inner side of the sole structure; (vii) a first flange disposed along the first edge, the first flange defining the first opening and extending outwardly away from the first opening; and (viii) a second flange disposed along the second edge, the second flange defining the second opening and extending outwardly away from the second opening. Outsole, including the inner surface facing the cushioning element; and The bladder, disposed within the support, includes a first portion, a second portion, and a series of elongated conduits. The first portion contacts the first plate, and the second portion extends through the orifice and contacts the inner surface of the outsole. Each conduit extends transversely to the longitudinal axis of the sole structure and fluidly connects a first pad extending along the inner side of the sole structure to a second pad extending along the outer side of the sole structure.

2. The sole structure according to claim 1, wherein, The outsole includes a ground contact surface.

3. The sole structure according to claim 2, wherein, The ground contact surface is formed on the side of the outsole opposite to the inner surface.

4. The sole structure according to claim 1, wherein, The outsole includes a recess on the inner surface, the recess receiving the bladder.

5. The sole structure according to claim 1, wherein, The first plate partially defines a receiving portion that extends continuously from the first side to the second side through the support.

6. The sole structure according to claim 5, wherein, The bracket includes an arc-shaped first end support at a first end of the bracket.

7. The sole structure according to claim 6, wherein, The first end support is spaced apart from the bladder.

8. The sole structure according to claim 6, wherein, The bracket includes an arc-shaped second end support at the second end of the bracket.

9. The sole structure according to claim 8, wherein, The first end support and the second end support are spaced apart from the bladder.

10. The sole structure according to claim 8, wherein, The first end support has a different size than the second end support.

11. A sole structure for footwear articles, the sole structure comprising: Buffer element; A support includes: (i) a first plate disposed abutting against the cushioning element; (ii) a second plate disposed opposite to the first plate and including an opening; (iii) a first end support connecting the first plate and the second plate at a first end of the support; (iv) a second end support connecting the first plate and the second plate at a second end of the support; (v) a first opening defined by a first edge of the first plate and the second plate, the first end support, and the second end support, the first opening being disposed on the outer side of the sole structure; (vi) a second opening defined by a second edge of the first plate and the second plate, the first end support, and the second end support, the second opening being disposed on the inner side of the sole structure; (vii) a first flange disposed along the first edge, the first flange defining the first opening and extending outwardly away from the first opening; and (viii) a second flange disposed along the second edge, the second flange defining the first opening and extending outwardly away from the first opening; the support is received by the cushioning element and defines a receiving portion extending continuously through the support from the outer side of the sole structure to the inner side of the sole structure between the first opening and the second opening; and The bladder includes a first portion disposed within the receiving portion, a second portion extending through the support, and a series of elongated conduits, each conduit extending transversely to the longitudinal axis of the sole structure and fluidly connecting a first pad extending along the inner side of the sole structure to a second pad extending along the outer side of the sole structure.

12. The sole structure according to claim 11 further includes an outsole disposed on the side of the support opposite to the cushioning element.

13. The sole structure according to claim 12, wherein, The second part of the bladder contacts the outer bottom via the support.

14. The sole structure according to claim 11, wherein, The stent includes a first plate surrounding a second portion of the bladder.

15. The sole structure according to claim 14, wherein, The support includes a second plate spaced apart from the first plate, and a first portion of the bladder contacts the second plate.

16. The sole structure according to claim 15, wherein, The bracket includes an arc-shaped first end support that connects the first plate and the second plate at a first end of the bracket.

17. The sole structure according to claim 16, wherein, The first end support is spaced apart from the bladder.

18. The sole structure according to claim 16, wherein, The bracket includes an arc-shaped second end support that connects the first plate and the second plate at the second end of the bracket.

19. The sole structure according to claim 18, wherein, The first end support and the second end support are spaced apart from the bladder.

20. The sole structure according to claim 18, wherein, The first end support has a different size than the second end support.

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