Footwear having traction lugs incorporated into the midsole

Abstract

The present invention relates to footwear with traction protrusions bonded to a midsole. A footwear construction includes a sole assembly having a midsole of a first hardness and a plurality of separate, individually reactive protrusions bonded to the midsole having a second, greater hardness. On soft terrain, each protrusion can remain stretched and can engage the terrain to provide grip and traction. On hard terrain, each protrusion can be independently compressed into a deformed area of ​​the midsole to enhance traction, so that the midsole can also optionally contact the terrain with a portion of the protrusions. The sole assembly may include a fabric embedded in and encapsulated in the material of the protrusions and the midsole to mechanically bond the protrusions to the midsole and reduce delamination. Each protrusion may include a cap extending into the midsole, wherein the void is filled with midsole material to improve protrusion fixation. A related manufacturing method is also provided.

Description

Technical Field

[0001] The present invention relates to footwear, and more particularly, to footwear including a sole assembly having a plurality of traction lugs independently bonded to a midsole to provide dynamic traction on soft and hard underfoot terrain. Background Art

[0002] A variety of different sole assemblies are used in footwear. Many sole assemblies include a midsole composed of foam and a bottom outsole that is typically composed of a sheet of rubber for durability and ease of assembly. The foam provides underfoot cushioning, and the outsole provides traction. Many times, the outsole sheet includes a plurality of protrusions integrally formed with the sheet at various locations for traction and wear resistance. The outsole rubber sheet and the integral plurality of protrusions are typically composed of a single continuous material. The sheet spans between the protrusions so that the midsole is covered by the sheet. This protects the midsole from damage, but also has some problems.

[0003] For example, rubber sheets are usually heavy. Therefore, all the materials spanning between the various protrusions increase the total weight of the footwear. For performance and hiking footwear, when every gram is important, this may impair the wearer's performance and prematurely tire the wearer and / or slow down their pace. In addition, in the case where the material sheet spans between the various protrusions, the outsole is quite rigid. Therefore, the various protrusions that directly protrude from the sheet work as a large group rather than as discrete protrusions. Then, the various protrusions are prevented from reacting to the underside of the foot and engaging the underside of the foot, which may impair the traction on the underside of the foot. In the case of ordinary outsole sheet construction, the sole assembly may not be so flexible and is less able to conform to the contours and terrain under the foot. As a result, the sole assembly often cannot provide the user with acceptable body sensory feedback about the contours and terrain, which may be detrimental to the user's balance and movement.

[0004] The conventional sole assembly described above is generally unable to dynamically adapt to different terrains. Although the sole assembly reacts consistently on all terrains, this may compromise the overall traction on different terrains. For example, on soft terrain, the protrusions are static relative to the sheet and generally sink into the terrain material up to the sheet. Thus, the surface of the protrusions and the sheet engage the ground and provide adequate traction. However, on hard terrain, the individual protrusions protruding from the sheet will engage the ground. Due to the rigidity of the sheet, the protrusions also remain static relative to the sheet, protruding from the sheet, so that the hard terrain does not contact the sheet. As a result, the overall contact of the sole assembly with the terrain is limited to the surface of the protrusions that contact the terrain. Without the additional sheet contact, the total surface area contacting the terrain is significantly reduced, which may compromise the traction on this hard terrain.

[0005] With the conventional sole assembly described above, the user would have to be aware of the different traction characteristics of their footwear on different types of terrain. In order to achieve acceptable performance, the user should be able to understand the feedback from the terrain underfoot to determine whether it is hard or soft, and therefore what type of traction is available for their activities using that particular footwear and sole assembly. From this, the user can adjust their movements over the terrain and reactions to the terrain accordingly. If the user is inexperienced or unfamiliar with the terrain type, the user may inadvertently overestimate the amount of traction available, which may be detrimental to movement, balance, and performance.

[0006] Therefore, there is still room for improvement in the construction of sole components to improve traction and function on different types of terrain and to reduce the overall weight of the footwear to enhance performance. Summary of the invention

[0007] A footwear construction includes a sole assembly having a midsole and a plurality of separate, individually reactive protrusions bonded to the midsole. On soft terrain, each protrusion can remain extended and can contact the terrain to provide grip and traction. On hard terrain, each protrusion can dynamically and independently compress into a deformed area of ​​the midsole, allowing the midsole to contact the terrain, optionally with a portion of the protrusions, to enhance traction.

[0008] In one embodiment, the midsole may be composed of a first material having a first hardness. The plurality of protrusions may be composed of a second material different from the first material and may have a second hardness greater than the first hardness. Thus, the protrusions may be harder and more durable than the midsole. However, the midsole may be compliant and resilient such that the harder protrusions may individually and separately compress upward and retract into the softer material of the midsole, thereby acting similar to a piston upward into the midsole.

[0009] In another embodiment, the midsole may include a midsole lower surface facing the ground and may define a plurality of raised recesses. Each raised recess may be defined in the midsole lower surface and may be defined by a recess bottom and a recess boundary edge. Each projection may be disposed in a corresponding recess.

[0010] In yet another embodiment, the midsole may include a deformation zone above each protruding recess. The deformation zone may have the same structure and material as the rest of the midsole, but due to its positioning relative to the protrusions, may be configured to deform and / or change in shape, density or other characteristics so that a single protrusion may be actuated or may move upward and at least partially into the deformation zone above it. As a result, when the protrusion is retracted into the midsole deformation zone, the lower surface of the midsole surrounding or adjacent to the protrusion may contact or engage the ground or terrain under the foot.

[0011] In yet another embodiment, the sole assembly may include a plurality of discrete protrusions. Those protrusions may be disposed in corresponding protrusion recesses in the protrusion recesses. When the protrusions are in an unloaded state or soft traction mode, each outsole protrusion may protrude outwardly from the corresponding recess and / or below the lower surface of the midsole for a first distance, which may optionally be 0.1 mm to 20 mm (inclusive), 0.1 mm to 15 mm (inclusive), 0.1 mm to 10 mm (inclusive), 1 mm to 5 mm (inclusive) or other distances. When the protrusions are in a hard traction mode, wherein the protrusions may be individually retracted upwards into the deformation zone, these protrusions may be retracted to a second protrusion distance less than the first distance.

[0012] In yet another embodiment, the outsole projections may each include a base plate and a projection body. The projection body may include a projection wall that transitions downward from the base plate to the projection ground contacting surface. The base plate may include a flange extending laterally outward from the projection wall. The flange may include a flange lower surface and a raised flange edge.

[0013] In another embodiment, the substrate of each projection may be bonded to the midsole. In some cases, the substrate may include a contact wall that is directly mechanically and chemically bonded to the bottom of the recess of the midsole. The recess bottom and the contact wall may be connected at the midsole / projection interface located below the deformation zone. When a single projection is loaded, the interface, bottom and / or contact wall may bend convexly upward into the deformation zone.

[0014] In another embodiment, each discrete outsole protrusion can be operated in a soft traction mode and a hard traction mode independently of other discrete outsole protrusions. In the soft traction mode, even when the sole assembly is placed on a soft terrain surface under the load of the user, the protrusion can extend a first distance below the lower surface of the midsole. This first distance allows the protrusion to extend sufficiently to provide helpful and acceptable traction on soft terrain, thereby digging and biting into the terrain well. In the hard traction mode, when the sole assembly is under the load of the user, the protrusion is compressed upward into the deformation area of ​​the midsole, so that the outsole protrusion extends a second distance less than the first distance below the lower surface of the midsole. In some cases, this second distance allows the lower surface of the midsole to contact and engage the terrain under the foot with the protrusion simultaneously. As a result, the lower surface of the midsole and the protrusion can provide a combined ground contact surface, which has a larger surface area than the surface area of ​​the individual protrusions. This can enhance traction on hard terrain.

[0015] In yet another embodiment, the projections may be coupled to the midsole to impair delamination from the midsole. For example, each projection may include a cap coupled to the base plate opposite the body of the projection. A void may be formed between the cap and the base plate. The midsole material may extend into and fill the void. The material in the void may better interlock the projection with the midsole material and may provide a mechanical bond to secure the outsole projection to the midsole.

[0016] In further embodiments, the sole assembly may include a fabric embedded in and encapsulated in the material of the projection and the midsole to mechanically bond the projection to the midsole and reduce delamination. The fabric may include adjacent strands with interstitial spaces between the adjacent strands. The fabric may be coupled to the outsole projection so that a second material extends through the interstitial spaces coextensive with the projection. The second material may encapsulate corresponding strands of the adjacent strands coextensive with the outsole projection. The fabric may be coupled to the midsole so that the first material extends through the corresponding interstitial spaces in the interstitial spaces coextensive with the midsole. The first material may encapsulate corresponding strands of the adjacent strands coextensive with the midsole.

[0017] In another further embodiment, a method is provided, comprising: placing discrete and spaced-apart outsole protrusions into a mold, each outsole protrusion comprising a base plate that faces upward into a mold cavity of the mold and a protrusion body, the protrusion body comprising a protrusion wall that transitions downwardly from the base plate to a protrusion ground contacting surface, the base plate comprising a contact wall and a protrusion peripheral flange, the protrusion peripheral flange extending laterally outward from the protrusion wall and comprising a flange lower surface and a protrusion flange edge; introducing a midsole material into the mold cavity, the midsole material being bonded to the contact wall of each of the protrusions; curing the midsole material to form a midsole having a first hardness, the first hardness being less than a second hardness of each of the protrusions, the protrusions being collectively coupled to the midsole and to each other; and removing the midsole from the mold, the midsole having the protrusions coupled thereto.

[0018] In yet a further embodiment, the method may include embedding a fabric in each of the projections prior to the placing step such that each of the projections is co-coupled with the fabric and the fabric co-extends across a plurality of the projections.

[0019] In yet a further embodiment, the method may include allowing the midsole material to envelop the fabric during the introducing step such that the midsole material bonds to the fabric and the projections to enhance the securement of the projections to the midsole.

[0020] The present footwear construction provides previously unattainable benefits in terms of traction and weight reduction. The current sole assembly and its discrete, separate and independent outer sole projections eliminate the heavy connecting sheet connecting the projections. Instead, these projections can be independently connected to the midsole in an isolated manner. The midsole can be made of a compliant and / or elastic and compressible material. Therefore, these projections can dynamically react to different types of terrain. For example, when the projections engage a hard terrain surface, the projections can be individually compressed upward and / or retracted into the midsole. However, these projections can remain extended to fully engage the softer terrain under the foot to provide traction therein. Therefore, these projections and the midsole can dynamically engage the terrain under the foot, thereby providing a sufficient amount of traction regardless of whether the terrain is soft or hard.

[0021] These and other objects, advantages and features of the present invention will be more fully understood and appreciated by referring to the description of the current embodiments and the accompanying drawings.

[0022] Before explaining the embodiments of the present invention in detail, it should be understood that the present invention is not limited to the details of the operations set forth in the following description or illustrated in the accompanying drawings or the details of the construction and arrangement of the components. The present invention may be implemented in various other embodiments and practiced or executed in alternative ways not explicitly disclosed herein. In addition, it should also be understood that the wording and terminology used herein are for descriptive purposes and should not be considered restrictive. The use of "include" and "comprise" and its variations is intended to cover the items listed thereafter and their equivalents as well as additional items and their equivalents. In addition, enumeration may be used in the description of various embodiments. Unless otherwise expressly stated, the use of enumeration should not be interpreted as limiting the present invention to any specific order or quantity of components. The use of enumeration should also not be interpreted as excluding from the scope of the present invention any additional steps or components that may be combined with or incorporated into the steps or components listed. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 is a side perspective view of a footwear of the present embodiment, the footwear including a sole assembly having a plurality of discrete projections attached to a midsole;

[0024] Figure 2 is a bottom view of a plurality of discrete protrusions independently and separately secured to the midsole;

[0025] Figure 3 is a cutaway view of a single lug and midsole in uncompressed soft traction mode;

[0026] Figure 4 is a cross-sectional view of the lugs and midsole in a compressed, hard traction mode;

[0027] Figure 5is a cross-sectional view of a projection and midsole including a first alternative embodiment of a cap;

[0028] Figure 6 is a cross-sectional view of a projection and midsole of a second alternative embodiment including a cap and fabric embedded in the midsole for enhancing bonding of the projection to the midsole;

[0029] Figure 7 is a cross-sectional view of a projection and midsole of a third alternative embodiment including a cap and fabric, the fabric having holes for the cap;

[0030] Figure 8 is a perspective view of a fabric with holes applied to a protrusion before a midsole material is applied to the protrusion and the fabric;

[0031] Fig. 9 is a cross-sectional view of a protrusion of a fourth alternative embodiment in which the fabric is molded to the protrusion before the fabric and protrusion are coupled to the midsole;

[0032] Fig.10 is a cross-sectional view of a projection and its fabric coupled to a midsole material; and

[0033] Fig.11 is a cross-sectional view of a protrusion and midsole of a fifth alternative embodiment having fins that enhance the coupling of the protrusion to the midsole. DETAILED DESCRIPTION

[0034] Current embodiments of footwear are Figure 1-3 10. In this embodiment, the footwear includes a sole assembly 20, which includes a midsole 30 and a plurality of independent and separate protrusions 40, which are dispersed across the lower surface of the midsole, wherein each protrusion is separated from the midsole and dynamically connected at different positions. Although the current embodiment is described in the context of hiking shoes or performance shoes, its sole assembly can be incorporated into any type or style of footwear, including running shoes, off-road shoes and boots, work boots, all-terrain shoes, sneakers, sports shoes, traditional tennis shoes, walking shoes, multi-functional sports footwear, casual shoes, formal shoes or any other type of footwear or footwear parts. It should also be noted that directional terms such as "vertical", "horizontal", "top", "bottom", "up", "down", "inside", "inward", "outward" and "outward" are used to help describe the present invention based on the orientation of the embodiments shown in the diagrams. In addition, the terms "inside", "outside" and "longitudinal" are used in a manner commonly used for footwear. For example, when used to refer to a side of a shoe, the term "medial" refers to the inside (i.e., the side facing the other shoe), while "lateral" refers to the outside. When used to refer to directions, the term "longitudinal direction" refers to a direction extending generally along the length of the shoe between the toe and the heel, and the term "lateral direction" refers to a direction extending generally across the width of the shoe between the medial and lateral sides of the shoe.

[0035] The use of directional terminology should not be construed as limiting the invention to any particular orientation. Additionally, as used herein, the term "arch region" (or arch or midfoot) generally refers to a portion of a footwear or sole component that corresponds to the arch or midfoot of a wearer's foot; the term "forefoot region" (or forefoot) generally refers to a portion of the front portion of the arch region of a footwear that corresponds to the forefoot (e.g., including the ball and toes) of a wearer's foot; and the term "heel region" (or heel) generally refers to a portion of the rear portion of the arch region of a footwear that corresponds to the heel of a wearer. Forefoot region 12, arch region or midfoot region 14, and heel region 16 are generally located in Figure 1 however, the contours of these areas may vary depending on the construction of the sole component and / or footwear.

[0036] refer to Figure 1-4 , the footwear 10 may include a sole assembly 20. The sole assembly 20 may include a midsole 30 and a plurality of independent protrusions 40. In some embodiments, more or fewer elements of the sole assembly 20 may be included. The components of the sole assembly may individually and / or collectively provide a variety of properties to the article of footwear 10, such as energy return, pronation correction, supination correction, support, rigidity, flexibility, stability, cushioning, comfort, weight reduction, and / or other properties. Generally, regardless of which components are present, the sole assembly 20 may form the bottom-most portion of the footwear 10. The sole assembly 20 may include a side-to-side width W, a heel-to-toe longitudinal length L, and a longitudinal axis LA, which may be common to the sole assembly, the midsole, and the outer layer.

[0037] The footwear 10 may include a textile upper 17 coupled to a sole assembly 20. The upper 17 may be formed of a variety of material elements that are coupled together to cover at least a portion of a wearer's foot. These material elements may be selected based on the intended use of the article of footwear 10 and may include, for example, synthetic fabrics, mesh fabrics, polymers, or leather. The upper 17 may be configured to increase the stiffness of the sole assembly 20. For example, the upper may be constructed of leather, plastic, canvas, or other materials. The upper 17 may include one or more closure elements, such as laces (not shown). The upper 17 further includes an upper opening 19 for receiving a wearer's foot and a lower perimeter 13 for attaching to the sole assembly 20.

[0038] A footbed (not shown) may be located within the void defined by the upper and may be non-stretchable and lightweight and coupled to the upper to provide a void for receiving the wearer's foot. The footbed may be made of a piece of material, such as foam, EVA, polyurethane (PU), latex, gel or other material, and provide cushioning by virtue of its compressibility, and may also conform to the foot to provide comfort, support and stability. The lower peripheral allowance or edge of the upper may be sutured, glued or otherwise fastened to the footbed around the periphery of the footbed. The sole assembly 20 may be combined with any other type or style of upper construction that can be properly coupled thereto, such as a Strobel construction. For the Strobel construction, a Strobel plate or insole plate or insole 18 may be coupled to the lower peripheral allowance 13 of the upper to close the void 12 of the upper. The coupling of the sole assembly / outsole to the upper may be achieved using adhesives, cements, injection molding, casting molding or any other technology for coupling the upper and the sole assembly.

[0039] refer to Figure 1-3 , the sole assembly may include a midsole 30. The midsole 30 may include a midsole upper surface 30U, a ground-facing midsole lower surface 30LS, a midsole lateral sidewall 30L, and a midsole medial sidewall 30M. Along the length L of the midsole, the transition portion and the midsole upper surface may form a downward concave portion spanning a width W along different portions of the length of the midsole 30.

[0040] As shown, the midsole upper surface 30U can be coupled to the Strobel plate 18 and portions of the lower peripheral margin 13 of the upper. The attachment can be by glue, adhesive, heat bonding, stitching or other techniques and structures. The midsole lower surface 30LS can be contoured or flat depending on the footwear application and the expected interaction with the terrain G underfoot, which can be any surface, such as: ground; hard terrain, such as concrete, sidewalk, rock, rock surface, hard clay, floor, etc.; and / or soft terrain, such as soft ground, sand, soft clay, gravel, grass, tundra, forest floor, field mud, etc.

[0041] As mentioned above, the midsole may include midsole sidewalls 30M and 30L. These sidewalls may present various profiles leading from the upper surface to the lower surface. In some cases, these sidewalls may be concave or convex. The midsole 30 may be made of a variety of materials, such as ethyl vinyl acetate (EVA), polyurethane (PU), latex, gel, expanded thermoplastic polyurethane (eTPU) and / or polyether block amide (PEBA), such as plasticizer-free poly(ether-b-amide) provided by Arkema of France under the trade name Pebax (R). The midsole may be relatively soft, compliant and resilient. In some cases, the midsole may be comprised of a first material having a first hardness that is optionally less than 75 Shore D, less than 60 Shore D, less than 40 Shore D, less than 30 Shore D, less than 25 Shore D, between 25 Shore D and 50 Shore D, between 25 Shore D and 40 Shore D, or between 20 Shore D and 35 Shore D. In some cases, the material may have a tear strength that is optionally less than 170 kN / m, less than 150 kN / m, less than 125 kN / m, less than 100 kN / m, less than 75 kN / m, less than 50 kN / m, between 40 and 150 kN / m, between 50 and 125 kN / m, or between 60 and 100 kN / m.

[0042] Midsole 40 may include a midsole lower surface 30LS, which may also be referred to as a ground-facing midsole lower surface. This surface may be relatively flat in some applications, with each protrusion being bonded directly to the surface by molding the midsole material to each protrusion in a mold as described below. However, as Figure 3 As shown in , the lower surface 30LS of the midsole may define a plurality of raised recesses 31. Each raised recess 31 may be defined in the lower surface of the midsole and may be bounded by a recess bottom 32 and a recess boundary edge 33. The recess boundary edge may transition to the lower surface 30LS of the midsole at a transition portion or corner 34. The transition portion may be an angled corner or a rounded smooth transition portion. The recess bottom 32 may be mechanically and chemically bonded to the contact wall 42CW and / or the substrate 42 at an interface 40I. At this interface, the midsole material constituting the midsole 30 may be chemically and mechanically bonded to the contact wall and other portions of the base flange, depending on the application.

[0043] The midsole 30 may include a deformation region DR above each protrusion recess. The deformation region may be an area that is highly compressed or simply more compressed than an adjacent area AR of the midsole that is not higher than a single protrusion 41 of the sole assembly. The deformation region may have a volume sufficient to be compressed when the protrusion is at a certain height. Figure 4 In the hard traction mode shown Figure 4 The deformation region DR may have the same density and consistency as the other surrounding materials of the midsole. However, due to its proximity to the underlying single protrusion, it may be locally compressed. For example, when a user steps on the ground G, the user's weight applies a load L to the midsole and the individual protrusions. As a result, the reaction normal force NF from the ground pushes the individual protrusions upward and into a portion of the deformation region DR, as shown in FIG. Figure 4 as shown in .

[0044] As mentioned above, the sole assembly 20 may include a plurality of discrete outsole protrusions 40, which are located away from each other and independently arranged on the lower surface 30L of the midsole and / or in the corresponding protrusion recesses 31 as described above. Each protrusion 40 can be arranged as required, and can alternatively be arranged in a repeated pattern. These protrusions may include one or more geometric shapes. Each outsole protrusion 40 may be composed of one or more second materials, such as natural or synthetic rubber, thermoplastic polyurethane elastomer, nylon, polymer blends, wear-resistant polymers, elastomers and / or other materials. Other materials may be used, such as fiber-reinforced polymers, which may include epoxy resins, polyethylene or thermosetting plastics reinforced with carbon, glass and / or aramid fibers, so as to enhance protection. The second material may have a hardness greater than the first hardness of the first material of the midsole.

[0045] like Figure 3 As shown in , each individual protrusion 41 may protrude outwardly from a corresponding recess 31. The outsole protrusion may include a base plate 42 and a protrusion body 44. The protrusion body 44 may include one or more protrusion walls 44W that transition downwardly from the base plate to a protrusion ground contacting surface 45 that is configured to directly engage the terrain G below the protrusion when a load is placed on the sole assembly 20. The protrusion ground contacting surface may take a variety of shapes depending on the desired traction characteristics of the sole assembly. As shown in FIG. Figure 2 As shown in FIG. 4 , surface 45 may be V-shaped, but of course, the shape may be other geometric shapes, such as elliptical, circular, polygonal, etc. The raised body may present a shape similar to the surface, and wall 44W may reflect the contour of the shape. Optionally, wall 40W may taper outwardly from the raised axis TA as the wall progresses toward the midsole 30. Thus, the raised body may be thicker near the base plate than at the ground contacting surface 45.

[0046] The base plate 42 may include a raised peripheral flange 46 that extends laterally outward from one or more raised walls 44W and includes a flange lower surface 46U and a raised flange edge 47. The raised peripheral flange may extend laterally outward from each raised wall 40W by a distance DF that is optionally 0 mm to 5 mm (inclusive), 0.1 mm to 3 mm (inclusive), or 0.1 mm to 2 mm (inclusive). The base plate, the peripheral flange, and the raised flange edge may each have a base height HB extending between the contact wall 42CW and the flange lower surface 46U. The base height HB may be less than, equal to, or greater than the depth of the raised recess HR. When the base height is less than the depth HR, the lower surface 46U is above the midsole lower surface 30LS. When the base height is equal to the depth HR, the lower surface 46U is flush with the midsole lower surface 30LS. When the base height is greater than the depth HR, the lower surface is lower than the midsole lower surface.

[0047] The substrate 42 and the recess may be oriented so that there is a gap G1 around the flange edge 33. For example, the raised flange edge 33 may be adjacent to and facing the recess boundary edge 33. However, these elements may be separated by a gap G1 between them around the projection and the substrate. Optionally, the gap may be optionally 0 mm to 2 mm (inclusive), 0.1 mm to 2 mm (inclusive), or 0.1 mm to 0.5 mm (inclusive), and may vary around the substrate.

[0048] As mentioned above, the substrate may include contact walls 42CW that are chemically and physically bonded to the bottom of the recess below the deformation region DR. The contact walls 42CW may extend from the corresponding edges 47 on the opposite sides of the substrate 42. As shown, the contact walls 42W may be smooth and planar, or may have contours and / or protrusions extending upwardly therefrom to enhance the mechanical bonding of the midsole material thereto. For example, in Fig.11 In an alternative embodiment shown in , a protrusion 541 may include a contact wall 542CW having a plurality of spaced apart fins 548 extending upwardly from a base plate 542. These fins may be spaced apart from each other by a distance FD so that the midsole material of the midsole may enter and fill the spaces between the fins 549. This, in turn, may provide more surface area contact between the midsole and the fins of the protrusion. This may also provide more mechanical and chemical bonding between the midsole and the individual protrusions to reduce delamination of the protrusions from the midsole.

[0049] Return to Figure 1-4 In the embodiment of the present invention, each individual protrusion can be arranged in a corresponding protrusion recess in the protrusion recess. Figure 3As shown in , when the protrusion is in an unloaded state or soft traction mode, each individual protrusion 41 can protrude outward from the corresponding recess 31 and / or below the midsole lower surface 30LS accordingly by a first distance or first protrusion height HL1, which can be optionally 0.1 mm to 20 mm (inclusive), 0.1 mm to 15 mm (inclusive), 0.1 mm to 10 mm (inclusive), 1 mm to 5 mm (inclusive) or other distances. The distance can be selected according to the application to fully dig into the soft underfoot terrain or some other ground surface.

[0050] like Figure 4 As shown in , when the projection is in hard traction mode, the projection can be retracted to a second protruding distance HL2 that is less than the first distance HL1. In this hard traction mode, the projection and the sole assembly can generally contact a hard ground surface HG. When this happens, the projection can be retracted upwards into the deformation region DR of the midsole 30 alone. When this happens, the substrate can optionally be bent upwards, wherein the substrate 42 and / or the recess 31 and the recess bottom 32 are deformed along the upward convex CU direction as shown. Of course, depending on the shape and rigidity of the projection 41, these elements may not be deformed, but instead can maintain their shape when the projection is compressed upwards into the deformation region DR of the midsole. In some cases, the peripheral flange may be slightly deformed in a similar upward convex configuration in these cases. When the projection is compressed upwards into the deformation region, the height of the projection can be reduced to HL2 or HL3, which can also be less than HL1. In some cases where HL3 is 0 mm, the lower surface HL3 of the midsole contacts the terrain HG under the foot. This can allow the midsole itself to provide some traction on the hard terrain HG. The protrusions may be in the hard traction mode when the height of the protrusions is reduced to HL2, HL3, or some other height that is less than HL1 when the protrusions are in the soft traction mode.

[0051] The method of manufacturing the footwear 10 and the sole assembly 20 will now be described in detail. Generally, the method may include placing one of the projections 40 having a Figure 3 A plurality of protrusions of the features of the protrusion 41 shown in the figure are placed in a mold. Before this placement in the mold, each protrusion itself can be molded with various features and components. Each protrusion can be trimmed and shaped as needed for further processing.

[0052] The individual protrusions can be placed into the midsole mold according to their shape and designated position. For example, protrusions of different shapes and sizes can be placed in different positions according to their intended function and traction capabilities. The midsole mold can be in the shape of the midsole and generally the shape of the user's foot. The individual outsole protrusions can be placed in the midsole mold according to their shape and designated position. Figure 2 The construction shown in is spaced apart within a mold, with the substrate facing upward into the mold cavity of the mold.

[0053] With all the various protrusions properly placed, the mold cavity can be closed and the midsole material, i.e., the first material described above, can be introduced into the cavity, optionally under pressure, either by injection molding or some other means. The midsole material in its fluid form can be bonded to the contact wall 42CW and edge 47 at some locations of each protrusion.

[0054] With the midsole material filling the mold cavity and engaging each individual protrusion with spaces therebetween, the midsole material may be cured for a period of time. This curing allows the midsole material to form the midsole 30. The midsole may have a first hardness that is less than a second hardness of each of the plurality of protrusions that are collectively coupled to the midsole and to each other. After the midsole is cured, the midsole with the protrusions coupled thereto may be removed from the mold. Thus, the sole assembly may be bonded, glued, or otherwise coupled to the upper 17 as described above.

[0055] Figure 5 14. A first alternative embodiment of a sole assembly 120 and a particular projection 141 is shown in FIG. The assembly and projection may be similar to the sole assembly, midsole, and projection described above in structure, function, and operation, but with several exceptions. For example, the projection may include a substrate having a contact wall 142CW. However, the projection may also include a cap 150 that protrudes upward from the projection body and / or the substrate 142. The cap 150 may include a column 152 that extends upward from the substrate 142 into the midsole. The column may include a column axis PA. The cap may be coupled to the upper end of the column and may extend outward from the column axis PA so that a gap 153 is formed between the cap and the substrate. The gap may be continuous and may extend around the cap 150 and / or the column 152 all the way. In some cases, the gap 153 may completely fill the circular transition 152T between the cap and the column to provide a lot of surface contact between the midsole and the cap and the projection. Typically, a first material comprising the midsole is disposed in the void and mechanically interlocked with the cap such that mechanical removal of the outsole projections from the midsole, such as by delamination or tearing of individual projections from the midsole, is mitigated.

[0056] like Figure 5 As shown in , the cap 150 can extend radially outward from the column axis PA. The cap can extend above the raised peripheral flange 146. As shown, the cap outermost boundary or edge 157 can be disposed a distance DF inwardly from the raised peripheral flange 146 and the outer flange edge 147. Alternatively, in other configurations, the cap edge 157 can be flush with the flange 147 or its edge, or can extend beyond those elements.

[0057] The method for making the sole assembly 110 of this structure is almost the same as the method for making the sole assembly of the above-mentioned embodiment, but there are several exceptions. For example, in the molding of the protrusions, each of these protrusions can be molded to include a cap extending upward from the substrate, and the cap and the substrate form a gap between them. When these protrusions are placed in the midsole mold cavity, the caps of each protrusion extend upward into the cavity. When the midsole material is introduced, it flows into each gap adjacent to these caps and solidifies. In this way, the mechanical bonding between the midsole and each protrusion is enhanced. In this structure, similar to the above-mentioned structure, the substrate of each outsole protrusion can be away from the adjacent substrate of the adjacent outsole protrusion, so that the midsole is connected to the substrate in a separated partial relationship when solidifying.

[0058] Figure 6 2 shows a second alternative embodiment of a sole assembly 220 and a particular projection 241. The assembly and projection may be similar to the sole assembly, midsole and projection described above in structure, function and operation, but with several exceptions. For example, projection 241 may include a substrate 242 having a contact wall 242CW. The projection may also include a cap 250 protruding upward from the projection body and / or substrate 242, and there is usually a gap 253 between the cap and the substrate or projection. However, the construction may also include a fabric 260. Depending on the application, the fabric may be any textile material, and may be knitted, woven or loosely woven, or even non-woven. The fabric 250 may include a plurality of adjacent strands, and there are a plurality of gap spaces between these adjacent strands. The fabric may include an upper surface 260U and a lower surface 260L, which may be arranged on opposite sides of the fabric, and when included in the sole assembly, they are usually facing up or facing down, respectively.

[0059] The fabric 260 as shown can be embedded and encapsulated in the midsole material 230. As shown, the fabric can be connected to the midsole so that the first material or the midsole material extends through the corresponding gap space in the multiple gap spaces. The midsole material can encapsulate the corresponding strands in the multiple adjacent strands extending together with the midsole. The fabric can be embedded and hidden in the midsole and is not visible to the observer of the midsole from the bottom view of the midsole. For example, the fabric 260 can extend adjacent to the midsole lower surface 230LS and can be set at a sufficient distance DF below the surface so that the fabric is not visible in or at the lower surface. Optionally, in certain cases where an aesthetic design is desired, the fabric can be shown through the lower surface so that it is visible therein or on it. The fabric 260 can also be set in the gap 153 adjacent to the cap 150. The fabric can also extend adjacent to the substrate 243, and in particular, extend adjacent to the contact wall 242CW.

[0060] In addition, the fabric can extend into the void 253 along with the first material of the midsole. As an example, the fabric can extend into the void, extending a distance D1 from the peripheral plane P of the cap inward toward the column axis PA, and can be folded or wrinkled near the column 252. The fabric can optionally contact the column or cap in the void. In some cases, the fabric can be positioned a distance D2 from the column or cap so that the midsole material engages the cap or column, rather than the fabric. This can enhance the connection of the protrusion to the midsole. The fabric and the first material in the void can provide additional mechanical bonding to secure the outsole protrusion to the midsole to prevent the outsole protrusion from delaminating from the midsole.

[0061] The method of manufacturing the sole assembly 210 of this configuration is almost the same as the method of manufacturing the sole assembly of the above-mentioned embodiment, but with several exceptions. For example, in the molding of the protrusions, each of these protrusions can be molded to include a cap extending upward from the base plate, and the cap and the base plate form a gap between them. When these protrusions are placed in the midsole mold cavity, the cap of each protrusion extends upward into the cavity.

[0062] With the projections and caps thus placed in the mold, fabric 260 may be placed over the projections and caps. The fabric may be placed against contact wall 242CW, placed in void 253 and on top 251T of the cap. Alternatively, the fabric may be stuffed into the void 253 of the corresponding projection. When the midsole material is introduced, it flows into each void adjacent to the cap. In doing so, it can push and actuate the fabric further into the void at a distance D1. The midsole material may also be embedded in the fabric and may encapsulate the corresponding strands, thereby protruding through the gap space. When the midsole material is cured, additional caps and fabric combinations may be used to enhance the mechanical bond between the midsole and each projection.

[0063] Figure 7 and Figure 8 3 shows a third alternative embodiment of a sole assembly 320 and, in particular, a projection 341 and a fabric 360. The assembly and projection may be similar in structure, function and operation to the sole assembly, midsole and projection described above, but with several exceptions. For example, projection 341 may include a base plate 342 having a contact wall 342CW, and a cap 351 having a gap 353 defined between the cap and base plate 342. However, contact wall 342CW may be disposed proximate to the lower surface 330LS of the midsole. In this case, there is no raised recess in the midsole. Fabric 360 may also be configured to include a cap hole 360A through which the cap is assembled and extends. The cap hole may have a size D4 that is smaller than the size D3 of the cap, so that the edge 360E of the fabric is assembled in the gap 353. Therefore, the fabric may be placed consistently in the gap, and if desired for the application, excessive wrinkling of the fabric around the cap may be avoided.

[0064] Fig. 9 and Fig.10 A fourth alternative embodiment of a sole assembly 420 and in particular a projection 441 and a fabric 460 is shown in FIG. The assembly and projections may be similar in structure, function, and operation to the sole assembly, midsole, and projections described above, with several exceptions. For example, projection 441 may include a base plate 442 having a contact wall 442CW. However, in this configuration, the fabric 460 may be embedded and encapsulated in the projection itself, in a second material that constructs the projection. The fabric may include a raised area 460L that is embedded and encapsulated in the projection, for example, in the base plate 442 of the projection 441. The fabric 460 can also be embedded and encapsulated in the midsole material 430 in a manner similar to the above-described embodiments, and optionally spaced apart from the midsole lower surface 420LS so that it is hidden in the midsole.

[0065] The method of manufacturing the sole assembly 410 of this configuration is almost the same as the method of manufacturing the sole assembly of the above-mentioned embodiment, but with several exceptions. For example, in the molding of the protrusions, each of these protrusions can be molded with the second material of the protrusions to include its various features. However, before this molding, the fabric 460 can be placed in the mold 500, such as Fig. 9 . The second material may be introduced into the mold so that the second material extends through corresponding ones of the interstitial spaces of the raised portion 460L of the fabric. The second material may also encapsulate corresponding ones of the adjacent strands that extend coextensively with the outsole protrusions. The fabric may include an upper surface 460U and a lower surface 460B. The fabric may extend within the base plate 442. When the second material is molded in the mold 500, the second material may be disposed above the upper surface and below the lower surface.

[0066] In the case where the outsole projections are molded to the fabric, the projections and fabric may be placed into another mold 600, such as Fig.10 . The mold may be closed and the midsole material 430 may be introduced into the mold cavity. The midsole material may encapsulate the fabric during the introduction step so that the midsole material bonds with the fabric and the protrusions to enhance the fixation of the protrusions to the midsole. In doing so, the midsole material contacts and bonds with the base plate 442, but the non-fabric area 460L. The midsole material also encapsulates and embeds the remaining portion 460R of the fabric that is not within the protrusions. After the midsole material is cured, the sole assembly with the protrusions well secured to the midsole by the fabric may be removed for further assembly of the footwear.

[0067] Directional terms such as "vertical," "horizontal," "top," "bottom," "upper," "lower," "inner," "inwardly," "outerly," and "outwardly" are used to help describe the invention based on the orientation of the embodiments shown in the figures. The use of directional terms should not be construed to limit the invention to any particular orientation.

[0068] In addition, when a component, part or layer is referred to as being "connected to", "on", "engaged", "adhered to", "fixed to" or "coupled to" another component, part or layer, it may be directly connected to, on, engaged, adhered to, fixed to or coupled to another component, part or layer, or there may be any number of intermediate components, parts or layers. In contrast, when an element is referred to as being "directly connected to", "directly on", "directly engaged", "directly adhered to", "directly fixed to" or "directly coupled to" another element or layer, there may be no intermediate elements or layers. Other terms used to describe the relationship between components, layers and parts should be interpreted in a similar manner, such as "adjacent" versus "directly adjacent" and similar terms. As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items.

[0069] The above description is a description of the current embodiment of the present invention. Various changes and modifications may be made without departing from the spirit and broader aspects of the present invention as defined in the appended claims, which should be interpreted in accordance with the principles of patent law, including the doctrine of equivalents. The present disclosure is provided for illustrative purposes and should not be interpreted as an exhaustive description of all embodiments of the present invention or as limiting the scope of the claims to specific elements illustrated or described in conjunction with these embodiments. For example, but not limited to, any individual element of the described invention may be replaced by an alternative element that provides substantially similar functions or otherwise provides sufficient operation. For example, this includes: currently known alternative elements, such as those that may be currently known to those skilled in the art; and alternative elements that may be developed in the future, such as those that may be identified as alternatives by those skilled in the art when developing. In addition, the disclosed embodiments include multiple features that are consistently described and can provide many benefits in a collaborative manner. The present invention is not limited to those embodiments that include all of these features or provide all of the benefits described, unless otherwise explicitly stated in the claims announced. Any reference to a claim element in the singular form, such as using the articles "one", "a", "a kind" or "the" should not be interpreted as limiting the element to the singular. Any reference to claim elements such as “at least one of X, Y, and Z” is intended to include: any one of X, Y, or Z alone; any combination of X, Y, and Z, such as X, Y, Z; X, Y; X, Z; Y, Z; and / or any other possible combination of these elements together or alone, noting that they are open-ended and may include other elements.

Claims

1. A shoe structure comprising: A midsole composed of a first material having a first hardness, the midsole comprising a midsole upper surface, a midsole lower surface facing the ground, and a plurality of raised recesses, each of the raised recesses being defined in the midsole lower surface and bounded by a recess bottom and a recess boundary edge, the midsole comprising a deformation area above each of the raised recesses; as well as A plurality of outsole protrusions disposed in corresponding protrusion recesses among the plurality of protrusion recesses, each outsole protrusion being composed of a second material that is different from the first material and has a second hardness greater than the first hardness, the outsole protrusions protruding outwardly from the corresponding recesses, the outsole protrusions comprising: substrate; posts extending upwardly from the base plate into the midsole; and a cap coupled to an upper end of the post such that a gap is formed between the cap and the substrate; and a raised body including a raised wall transitioning downwardly from the base plate to a raised ground contacting surface, the base plate including a raised peripheral flange extending laterally outwardly from the raised wall and including a flange lower surface and a raised flange edge, the raised flange edge being adjacent to and facing the recess boundary edge, the base plate including a contact wall chemically and physically bonded to the recess bottom below the deformation region, wherein the outsole protrusion is operable in a soft traction mode and a hard traction mode, wherein in the soft traction mode, the protrusion extends a first distance between 0.1 mm and 15 mm below the lower surface of the midsole, and in the hard traction mode, the protrusion is compressed upward into the deformation region of the midsole such that the outsole protrusion extends a second distance below the lower surface of the midsole that is less than the first distance and such that at least a portion of the lower surface of the midsole is a midsole ground contacting surface, wherein the cap includes an outermost edge of the cap above the gap, wherein the cap includes an upper cap surface located above an outermost edge of the cap, wherein the first material having the first hardness is directly bonded to the cap upper surface and the cap outermost edge and is disposed in the gap below the cap outermost edge, wherein the outsole protrusion is molded and formed as a one-piece protrusion including the base plate, the post, the cap and the protrusion body, such that the base plate, the post, the cap and the protrusion body are collectively formed of the second material having the second hardness.

2. The footwear construction of claim 1, wherein: The post includes a post axis, wherein the cap extends radially outward from the post axis such that the gap is formed between the cap and the substrate.

3. The footwear structure according to claim 2, in, The first material mechanically interlocks with the cap such that mechanical removal of the outsole projections from the midsole is mitigated.

4. The footwear structure according to claim 1, in, said cap extending over said raised peripheral flange, wherein the cap includes an outermost edge of the cap extending outwardly from the column axis, Wherein, the outermost edge of the cap is arranged to be a certain distance inward from the raised peripheral flange, so as to be closer to the column axis than the raised peripheral flange.

5. The footwear construction of claim 1, comprising: A fabric is embedded and encapsulated in the outsole protrusions and in the midsole, the fabric being concealed in the outsole protrusions and the midsole, the fabric providing additional mechanical bonding to secure the outsole protrusions to the midsole to prevent delamination of the outsole protrusions from the midsole.

6. The footwear construction according to claim 5, in, The fabric comprises an upper surface and a lower surface, wherein the fabric extends within the substrate, wherein the second material is disposed above the upper surface and below the lower surface.

7. The footwear construction according to claim 6, in, The fabric extends within the recess, wherein the fabric extends adjacent to the midsole lower surface without being visible in the midsole lower surface.

8. The footwear construction of claim 1, comprising: a fabric disposed in the void adjacent the cap and extending adjacent the base plate and adjacent the midsole lower surface, wherein the fabric is embedded in and encapsulated in the first material of the midsole, wherein the first material of the midsole extends into the gap; The fabric and the first material in the voids provide additional mechanical bonding to secure the outsole projections to the midsole to prevent delamination of the outsole projections from the midsole.

9. The footwear construction of claim 1, comprising: A fabric comprising a plurality of adjacent strands with a plurality of interstitial spaces between the adjacent strands, wherein the fabric is coupled to the outsole projection such that the second material extends through respective ones of the plurality of interstitial spaces, the second material encapsulating respective ones of the plurality of adjacent strands extending coextensive with the outsole projection, wherein the fabric is coupled to the midsole such that the first material extends through respective ones of the plurality of interstitial spaces, the first material encapsulating respective ones of the plurality of adjacent strands coextensive with the midsole.

10. The footwear construction according to claim 9, in, The fabric is embedded and hidden within the outsole projections and the midsole and is not visible to an observer of the midsole from a bottom view of the midsole.

11. A footwear construction comprising: A midsole composed of a first material having a first hardness, the midsole comprising a midsole upper surface, a midsole lower surface facing the ground, and a plurality of raised recesses, each of the raised recesses being defined in the midsole lower surface and bounded by a recess bottom and a recess boundary edge, the midsole comprising a deformation area above each of the raised recesses; as well as a plurality of outsole projections disposed in corresponding ones of the plurality of raised recesses, each outsole projection being composed of a second material different from the first material and having a second hardness greater than the first hardness, the outsole projections projecting outwardly from the corresponding recess, the outsole projections comprising a base plate and a projection body, the projection body comprising a projection wall transitioning downwardly from the base plate to a raised ground contacting surface, the base plate comprising a raised peripheral flange extending laterally outwardly from the projection wall and comprising a flange lower surface and a raised flange edge, the base plate being bonded to the recess bottom below the deformation region; a post extending upwardly from the base plate into the midsole; as well as a cap coupled to the upper end of the post such that a gap is formed between the cap and the substrate, the cap including an outermost cap edge that transitions to an upper cap surface; wherein the outsole protrusion is operable in a soft traction mode and a hard traction mode, wherein in the soft traction mode the protrusion extends a first distance below the lower surface of the midsole, and in the hard traction mode the protrusion is compressed upward into the deformation region of the midsole such that the outsole protrusion extends a second distance below the lower surface of the midsole that is less than the first distance, wherein the first material having the first hardness extends into the void and is directly bonded to the cap upper surface and the cap outermost edge; The entire flange lower surface is higher than the lower surface of the midsole or flush with the lower surface of the midsole.

12. The footwear construction according to claim 11, in, The raised flange edge is separated from the recessed boundary edge by a gap.

13. The footwear construction according to claim 12, in, The first material of the midsole extends into the void and fills the void; wherein the first material in the voids provides a mechanical bond to secure the outsole projections to the midsole, thereby reducing delamination of the plurality of outsole projections from the midsole.

14. The footwear construction according to claim 11, in, The outsole projection in the soft traction mode extends below the midsole lower surface a first distance of 0.1 mm to 15 mm, inclusive, wherein the outsole protrusion is compressed upwardly into the deformation region of the midsole in the hard traction mode so that the outsole protrusion extends below the lower surface of the midsole by a second distance that is less than the first distance, The substrate bends upward in the hard pulling mode, wherein the recess is deformed convexly upward.

15. The footwear construction according to claim 11, in, The first hardness is less than 50 Shore D, Wherein, the second hardness is greater than the first hardness.

16. The footwear construction of claim 11, comprising: a fabric substrate extending through and embedded within the outsole projections and the second material, wherein the fabric substrate extends away from the outsole protrusion and is embedded in the midsole and the first material adjacent to the lower surface of the midsole, Therein, the textile substrate is initially embedded in the first material and the second material in different molds.

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