Footwear article

Abstract

This application relates to a footwear item including a strobel having an inner surface and an outer surface formed on the side opposite the inner surface, the strobel defining a footbed and a peripheral wall extending laterally from the footbed to a distal edge. The footwear item further includes a vamp attached to the distal edge of the strobel along a peripheral seam to define an internal cavity for receiving a foot, the peripheral seam being configured to extend along one side of the internal cavity.

Description

[0001] This application is a divisional application of the application with an application date of July 20, 2020, an application number of 202080053825.3, and an invention title of "Footwear article".

[0002] Cross-reference to related applications

[0003] This application claims priority to non-provisional U.S. Patent Application No. 16 / 933,496, filed on July 20, 2020, which claims priority to U.S. Provisional Application No. 62 / 878,682, filed on July 25, 2019, and U.S. Provisional Application No. 62 / 923,658, filed on October 21, 2019, under 35 U.S.C. § 119(e). The disclosures of these applications are hereby incorporated by reference in their entirety. Technical field

[0004] The present disclosure relates to a footwear article having a sole structure that includes particulate matter and an inner shoe attached to the sole structure. Background

[0005] This section provides background information on the present disclosure, which is not necessarily prior art.

[0006] Footwear articles conventionally include an upper and a sole structure. The upper can be formed of any suitable material to receive, secure, and support the foot on the sole structure. The upper can cooperate with laces, straps, or other fasteners to adjust the fit of the upper around the foot. A bottom portion of the bottom surface of the upper that is adjacent to the foot is attached to the sole structure.

[0007] The sole structure typically includes a layered arrangement that extends between the ground surface and the upper. One layer of the sole structure includes an outsole that provides abrasion resistance and frictional attachment to the ground surface. The outsole can be formed of rubber or other materials that impart durability and wear resistance and enhance frictional attachment to the ground surface. Another layer of the sole structure includes a midsole disposed between the outsole and the upper. The midsole provides cushioning for the foot and is typically at least partially formed of a polymeric foam material that elastically compresses under an applied load to cushion the foot by attenuating the ground reaction force. The midsole can define a bottom surface on a side opposite the outsole and a footbed on the opposite side, the contour of which can be set to conform to the contour of the bottom surface of the foot. The sole structure can also include an insole or sockliner that enhances comfort and is located within a void near the bottom portion of the upper.

[0008] Midsole structures using polymeric foams are typically configured as a single slab that elastically compresses under an applied load, such as during walking or running motions. Generally, the design focus of a single-piece polymeric foam is to balance cushioning characteristics related to the softness and responsiveness of the slab as it compresses under a gradient load. A polymeric foam that provides too soft of a cushion will reduce compressibility and the ability of the midsole to attenuate ground reaction forces after repeated compression. Conversely, a polymeric foam that is too hard and thus very responsive sacrifices softness, resulting in a loss of comfort. While different regions of the slab of polymeric foam can vary in density, hardness, energy return, and material selection to balance the overall softness and responsiveness of the slab, it is difficult to achieve a single slab of polymeric foam that is loaded in a gradient manner from soft to responsive. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The drawings described herein are for illustrative purposes only of selected configurations and are not intended to limit the scope of the present disclosure.

[0010] Figure 1 is a lateral view of an article of footwear in accordance with the principles of the present disclosure;

[0011] Figure 2 is Figure 1 a medial view of the article of footwear;

[0012] Figure 3 is Figure 1 an exploded perspective view of the article of footwear showing the sole structure and the inner liner of the article of footwear;

[0013] Figure 4 is Figure 1 an exploded bottom perspective view of the article of footwear showing the sole structure separated from the inner liner;

[0014] Figure 5 is Figure 1 an exploded top perspective view of the article of footwear showing the sole structure separated from the inner liner;

[0015] Figure 6 is Figure 1 a bottom plan view of the article of footwear;

[0016] Figure 7 is taken along Figure 6 line 7-7 of Figure 1 a cross-sectional view of a cushioning member of the article of footwear;

[0017] Figure 8 is taken along Figure 6 line 8-8 of Figure 1 a cross-sectional view of a cushioning member of the article of footwear;

[0018] Figure 9 Is Figure 1 A top perspective view of a cushioning element of a footwear item;

[0019] Figure 10 Is Figure 9 A bottom perspective view of the cushioning element;

[0020] Figure 11 Is Figure 9 A top plan view of the cushioning element;

[0021] Figure 12 Is Figure 9 A bottom plan view of the cushioning element;

[0022] Figure 13 Is Figure 1 An outer side view of an insole of a footwear item; and

[0023] Figure 14 Is Figure 13 An exploded top perspective view of the insole.

[0024] Throughout the drawings, corresponding reference numerals indicate corresponding parts. Detailed Description

[0025] Example configurations will now be described more fully with reference to the accompanying drawings. The example configurations are provided so that this disclosure will be thorough and will fully convey the scope of the disclosure to those of ordinary skill in the art. Specific details, such as examples of specific components, devices, and methods, are set forth to provide a thorough understanding of the configurations of this disclosure. It will be apparent to those of ordinary skill in the art that the example configurations may be implemented in many different forms and that the specific details and example configurations should not be construed as limiting the scope of this disclosure.

[0026] The terminology used herein is for the purpose of describing particular example configurations only and is not intended to be limiting. As used herein, unless the context clearly indicates otherwise, the singular articles "a", "an", and "the" may also be intended to include the plural forms. The terms "comprises", "comprising", "including", and "having" are inclusive and thus specify the presence of stated features, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and / or groups thereof. Unless specifically identified as the order of execution, the method steps, processes, and operations described herein should not be construed as necessarily requiring them to be performed in the particular order discussed or illustrated. Alternative or alternative steps may be employed.

[0027] When an element or layer is referred to as being “on,” “engaged to,” “connected to,” “attached to,” or “coupled to” another element or layer, it can be directly on, engaged, connected, attached, or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” “directly attached to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers. Other words used to describe the relationship between elements should be interpreted in a like manner (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and / or” includes any and all combinations of one or more of the associated listed items.

[0028] The terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers, and / or sections. These elements, components, regions, layers, and / or sections should not be limited by these terms. These terms may be used only to distinguish one element, component, region, layer, or section from another region, layer, or section. Terms such as “first,” “second,” and other numerical terms do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, first component, first region, first layer, or first section discussed below may be referred to as a second element, second component, second region, second layer, or second section without departing from the teachings of the exemplary configurations.

[0029] In one configuration, a footwear article is provided and the footwear article includes a strobel having an inner surface and an outer surface formed on an opposite side of the inner surface, the strobel defining a footbed and a peripheral wall extending laterally from the footbed to a distal edge. The footwear article further includes an upper attached to the distal edge of the strobel along a peripheral seam to define an internal cavity for receiving a foot, the peripheral seam being configured to extend along a side of the internal cavity.

[0030] The footwear article may further include one or more of the following optional features. A sole structure may be attached to the outer surface of the footbed and may have a sidewall that extends at least partially over the peripheral wall of the strobel, with the peripheral seam being exposed above the sidewall. The strobel may be formed of a first material and the upper may be formed of a second material different from the first material.

[0031] In one configuration, the perimeter seam can include a first portion having a first stitch and a second portion having a second stitch. The first stitch can be an overlock stitch and the second stitch can be a lock stitch.

[0032] At least one reinforcement member can be attached to the footbed of the strobel. The at least one reinforcement member can include an internal reinforcement member attached to the inner surface of the strobel. The internal reinforcement member can extend from the heel region of the strobel to the midfoot region of the strobel and from the lateral side of the strobel to the medial side of the strobel. Additionally, the at least one reinforcement member can include an external reinforcement member attached to the outer surface of the strobel. Further, the external reinforcement member can include a first segment extending along the lateral side of the footbed, a second segment spaced from the first segment and extending along the medial side of the footbed, and a third segment connecting the first segment and the second segment and extending around the heel region of the footbed.

[0033] In another configuration, there is provided an article of footwear including a sole structure, a strobel, and an upper, the strobel having (i) a footbed disposed on the sole structure and (ii) a perimeter wall extending laterally from the footbed to a distal edge above the sole structure, the upper being attached to the distal edge of the strobel along a perimeter seam.

[0034] The article of footwear can also include one or more of the following optional features. In one configuration, the perimeter seam can extend continuously around the article of footwear and can be at least partially exposed above the sole structure.

[0035] The strobel can be formed from a first material and the upper can be formed from a second material different from the first material.

[0036] The perimeter seam can include a first portion having a first stitch and a second portion having a second stitch. The first stitch can be an overlock stitch and the second stitch can be a lock stitch.

[0037] In one configuration, at least one reinforcement member can be attached to the footbed of the strobel. The at least one reinforcement member can include an internal reinforcement member attached to the inner surface of the strobel. The internal reinforcement member can extend from the heel region of the strobel to the midfoot region of the strobel and from the lateral side of the strobel to the medial side of the strobel. Additionally, the at least one reinforcement member can include an external reinforcement member attached to the outer surface of the strobel. Further, the external reinforcement member can include a first segment extending along the lateral side of the footbed, a second segment spaced from the first segment and extending along the medial side of the footbed, and a third segment connecting the first segment and the second segment and extending around the heel region of the footbed.

[0038] Reference Figure 1 , the footwear item 10 includes a sole structure 100 and an inner liner 200 attached to the sole structure 100. Generally, the sole structure 100 is configured to provide cushioning and responsive characteristics for the footwear item 10, while the inner liner 200 is configured to receive the wearer's foot to secure the wearer's foot to the sole structure 100.

[0039] The footwear 10 may further include a front end portion 12 associated with the foremost point of the footwear item 10, and a rear end portion 14 corresponding to the rearmost point of the footwear 10. As Figure 6 shown, the longitudinal axis A of the footwear 10 10 extends along the length of the footwear 10 from the front end portion 12 to the rear end portion 14, and generally divides the footwear 10 into an inner side 16 and an outer side 18. Thus, the inner side 16 and the outer side 18 respectively correspond to opposite sides of the footwear 10 and extend from the front end portion 12 to the rear end portion 14. As used herein, the longitudinal direction refers to the direction extending from the front end portion 12 to the rear end portion 14, while the lateral direction is the direction transverse to the longitudinal direction and extending from the inner side 16 to the outer side 18.

[0040] The footwear item 10 may be divided into one or more regions. These regions may include a forefoot region 20, a midfoot region 22, and a heel region 24. As Figure 6 and Figure 7 shown, the forefoot region 20 may be further subdivided into a toe portion 20 corresponding to the phalanges T and a ball portion 12 associated with the metatarsals of the foot B . The midfoot region 22 may correspond to the arch region of the foot, and the heel region 24 may correspond to the rear portion of the foot (including the calcaneus).

[0041] The footwear item 10 may be further described as including a perimeter region 26 and an interior region 28, as Figure 3 shown. The perimeter region 26 is generally described as the region located between the interior region 28 of the sole structure 100 and the outer perimeter. In particular, the perimeter region 26 extends along each of the inner side 16 and the outer side 18 from the forefoot region 20 to the heel region 24, and surrounds each of the front end portion 12 and the rear end portion 14. The interior region 28 is bounded by the perimeter region 26 and extends along the central portion of the sole structure 100 from the forefoot region 20 to the heel region 24. Thus, each of the forefoot region 20, the midfoot region 22, and the heel region 24 may be described as including a perimeter region 26 and an interior region 28.

[0042] The components of the footwear article 10 can be further defined according to the vertical position on the footwear article 10. For example, the footwear article 10 includes a plantar region 30 on the bottom of the footwear article 10, and the plantar region 30 is configured to oppose or support the plantar surface of the foot. A dorsal region 32 is formed on the side of the footwear 10 opposite the plantar region 30, extends along the top side of the footwear article 10, and receives the dorsal portion of the foot. Lateral regions 34 extend between the plantar region 30 and the dorsal region 32 along the medial side 16 and the lateral side 18, and surround the outer perimeter of the foot.

[0043] Reference Figure 4 , the sole structure 100 includes a midsole 102 configured to impart cushioning and responsive properties, and an outsole 104 configured to impart traction and wear-resistant properties. The midsole 102 and the outsole 104 can cooperate to define a ground-engaging surface 36 along the plantar region 30 of the footwear article 10. The sole structure 100 can also include one or more directional supports, such as a toe cap 106 disposed at the front end portion 12 of the midsole 102, a saddle 108 extending from the medial side 18 of the midsole 102, and a heel clip 110 extending from the rear end portion 14 of the midsole 102. As described in detail below, the midsole 102 includes a cushioning element 112, a plurality of cushioning particles 114 received by the cushioning element 112, and an upper barrier layer 116 attached to the top of the cushioning element 112 to encapsulate the cushioning particles 114 on a first side of the cushioning element 112. The outsole 104 can include a plurality of outsole elements 118a-118c that are attached to the side of the cushioning element 112 opposite the upper barrier layer 116 to encapsulate the cushioning particles 114 within the midsole 102.

[0044] Reference Figures 9 - 12 , the cushioning element 112 of the midsole 102 extends from a first end portion 120 disposed at the front end portion 12 of the footwear 10 to a second end portion 122 disposed at the rear end portion 14 of the footwear 10. The cushioning element 112 also includes a top surface 124 and a bottom surface 126, and the bottom surface 126 is formed on the opposite side of the top surface 124. The distance between the top surface 124 and the bottom surface 126 defines the thickness of the cushioning element 112. Outer side surfaces 128 extend from the top surface 124 to the bottom surface 126 and define the outer perimeter profile of the cushioning element 112.

[0045] The buffer element 112 further includes an inner side surface 130 that is spaced inwardly from the outer side surface 128 and extends continuously from the top surface 124 to the bottom surface 126 to form a channel 132 through the thickness of the buffer element 112. As shown, the inner side surface 130 is formed between the peripheral region 26 and the inner region 28 in the forefoot region 20, the midfoot region 22, and the heel region 24 of the shoe. Accordingly, the channel 132 is substantially formed within the inner region 28 of the buffer element 112 and extends continuously from a first end 134 in the forefoot region 20 to a second end 136 in the heel region 24. In the illustrated example, the first end 134 is disposed between the toe portion 20 T and the metatarsal ball portion 20 B of the forefoot region 20 such that the channel 132 extends through the metatarsal ball portion 20 B and the toe portion 20 T is supported by the top surface 124 of the buffer element 112. Accordingly, the top surface 124 of the buffer element 112 extends along the peripheral region 26 in the forefoot region 20, the midfoot region 22, and the heel region 24. In other examples, the channel 132 may extend through the entire forefoot region 20 such that when the sole structure 100 is assembled, the toe portion 20 T is also supported by the cushioning particles 114.

[0046] The buffer element 112 includes one or more ribs 138a, 138b that are configured to divide the channel 132 into a plurality of pockets 152a - 152c for receiving the cushioning particles 114. In the illustrated example, the one or more ribs 138a, 138b include a first rib 138a disposed between the forefoot region 20 and the midfoot region 22, and a second rib 138b disposed between the midfoot region 22 and the heel region 24. In other examples, the buffer element 112 may include a different number of ribs 138a, 138b. For example, in the case where the channel 132 extends along the entire inner region 28 of the buffer element 112, the buffer element 112 may include three or more ribs to divide the channel 132 into four or more pockets. Here, at least one pocket may be disposed within the toe portion 20 T of the shoe.

[0047] Each of the ribs 138a, 138b extends across the channel 132 from a first end 140a, 140b attached to the inner side surface 130 on the inner side 16 to a second end 142a, 142b attached to the inner side surface 130 on the outer side 18. As Figure 9 and Figure 10As shown, ribs 138a, 138b also include upper surfaces 144a, 144b formed at the top surface 124 of the buffer element 112 and lower surfaces 146a, 146b formed at the bottom surface 126 of the buffer element 112. The upper surfaces 144a, 144b of each rib 138a, 138b may be offset or recessed from the top surface 124 of the buffer element 112 by a distance. The lower surfaces 146a, 146b of each rib 138a, 138b may coincide with the bottom surface 126 of the buffer element 112 and may form part of the ground engaging surface 36 of the sole structure 100.

[0048] Reference Figure 7 , each rib 138a, 138b may also include front side surfaces 148a, 148b extending from the upper surfaces 144a, 144b toward the lower surfaces 146a, 146b and facing the front end portion 12. Each rib 138a, 138b may also include rear side surfaces 150a, 150b extending from the upper surfaces 144a, 144b toward the lower surfaces 146a, 146b and facing the rear end portion 14. The distance from the front side surfaces 148a, 148b to the rear side surfaces 150a, 150b defines the width W of each rib 138a, 138b 138a , W 138b . In the illustrated example, the width W of the ribs 138a, 138b 138 increases along the direction from the upper surfaces 144a, 144b to the lower surfaces 146a, 146b. Thus, each rib 138a, 138b is configured such that the stiffness gradually increases as the compression toward the lower surface 146 increases. The front side surface 148a of the first rib 138a and the rear side surface 150b of the second rib 138b may have a concave profile, while the rear side surface 150a of the first rib 138a and the front side surface 148b of the second rib 138b may be substantially straight.

[0049] Again referring to Figures 9 - 12 , the ribs 138a, 138b divide the channel 132 into a forefoot pocket 152a disposed on the front side of the first rib 138a, a midfoot pocket 152b disposed between the first rib 138a and the second rib 138b, and a heel pocket 152c disposed on the rear side of the second rib 138b. Each of the forefoot pocket 152a, midfoot pocket 152b, and heel pocket 152c extends from a respective top opening 154a - 154c formed through the top surface 124 to a bottom opening 156a - 156c formed through the bottom surface 126. As described above, the width W of the ribs 138a, 138b 138a , W 138bIt can gradually increase in the direction from the top surface 124 to the bottom surface 126. Accordingly, the cross-sectional area of one or more of the bags 152a - 152c can gradually decrease along the direction from the top surface 124 to the bottom surface 126.

[0050] Continuing to refer to Figures 9 - 12 , the top surface 124 and the bottom surface 126 of the cushioning element 112 include a plurality of recesses for receiving a covering or an enclosure of the bags 152a - 152c. As Figure 9 and Figure 11 shown, the top surface 124 includes a top recess 158 extending outward from the inner side surface 130 of the cushioning element 112. The peripheral contour of the top recess 158 corresponds to the outer peripheral contour of the upper barrier layer 116, and the depth of the top recess 158 corresponds to the thickness of the upper barrier layer 116. Accordingly, the top recess 158 is configured to receive the upper barrier layer 116 such that when the sole structure 100 is assembled, the top surface of the upper barrier layer 116 is flush with the top surface 124 of the cushioning element 112, as Figure 7 shown.

[0051] The bottom surface 126 of the cushioning element 112 further includes a plurality of outsole recesses 160a - 160c corresponding to the bottom openings 156a - 156c of each of the bags 152a - 152c. For example, each of the outsole recesses 160a - 160c can extend outward from one of the bottom openings 156a - 156c to provide a receptacle for receiving one of the outsole elements 118a - 118c. Accordingly, the outsole recesses 160a - 160c are configured to have a depth corresponding to the thickness of the respective outsole elements 118a - 118c, while the peripheral contour of each of the outsole recesses 160a - 160c corresponds to the peripheral contour of one of the outsole elements 118a - 118c.

[0052] Continuing to refer to Figure 10, the buffer element 112 may be provided with one or more windows 162a, 162b that are formed through the peripheral region 26 of the buffer element 112 and open into one of the bags 152a - 152c. For example, the buffer element 112 includes a first pair of windows 162a, 162b that are formed in the bottom surface 126 and extend from the outer side surface 128 through the peripheral region 26 to the inner side surface 130. As shown, the windows 162a, 162b include a first window 162a that extends into the midsole pocket 152b on the inner side 16, and a second window 162b that extends into the midsole pocket 152b on the outer side 18. When the sole structure 100 is assembled, each of the windows 162a, 162b provides a space through which the cushioning particles 114 can flow between the buffer element 112 and the outsole 104. Thus, the cushioning particles 114 can be disposed against the midsole outsole element 118b along the outer perimeter of the sole structure 100 and can be seen through the midsole outsole element 118b.

[0053] Still referring to Figure 10 , the heel region 24 of the buffer element 112 may include an inclined surface 164 formed around the bottom opening 156c of the heel pocket 152c. Generally, the inclined surface 164 is offset from and spaced apart from the bottom surface 126. As shown, the inclined surface 164 extends toward the top surface 124 such that the inclined surface 164 is spaced apart from the ground plane GP in the heel region. In one configuration, the inclined surface 164 is formed at an inclined angle θ with respect to the ground engaging surface 36 of the sole structure 100 such that the inclined surface 164 extends away from the ground plane GP at an angle θ along the direction from the midsole region 22 to the rear end 14.

[0054] The heel region 24 of the cushioning element also includes one or more struts 166a - 166c that project downward from the ramp 164. Accordingly, each of the struts 166a - 166c extends from a proximal end 168a - 168c attached at the ramp 164 to a distal end 170a - 170c that forms the terminus at the opposite end of the struts 166a - 166c. The distal ends 170a - 170c are configured to engage the heel outsole element 118c when the sole structure 100 is assembled, thereby providing support for the footwear item 10 in the heel region 24. Accordingly, the distal ends 170a - 170c can be understood to form part of the bottom surface 126 of the cushioning element 112. The cross - sectional area of one or more of the struts 166a - 166c can decrease along the direction from the proximal ends 168a - 168c to the distal ends 170a - 170c. For example, at least one of the width and / or length of one or more of the struts 166a - 166c can gradually decrease along the height direction from the proximal ends 168a - 168c to the distal ends 170a - 170c.

[0055] In the illustrated example, one or more of the struts 166a - 166c include a series of struts 166a - 166c arranged around the bottom opening 156c of the heel pocket 152c. Specifically, the series of struts 166a - 166c includes an inner strut 166a disposed on the inner side surface 16 of the bottom opening 156c, an outer strut 166b disposed on the outer side surface 18 of the bottom opening 156c, and a rear strut 166c disposed at the rear end of the bottom opening 156c. As Figure 12 shown, the struts 166a - 166c are arranged sequentially along the outer perimeter of the bottom opening 156c. Here, the struts 166a - 166c are arranged sequentially along a horseshoe - shaped arcuate path or axis A 166 corresponding to the curvature of the rear end portion 14 of the sole structure 100. The struts 166a - 166c can be spaced apart from each other along the axis A 166 to provide a series of gaps 172 disposed between adjacent ones of the struts 166a - 166c. These gaps 172 maximize the flow of the cushioning particles 114 within the heel region 24 since the cushioning particles 114 can flow freely between adjacent ones of the struts 166a - 166c.

[0056] In some examples, the heel region 24 of the cushioning element can include a relief 167 formed in the outer side surface 128. The relief 167 extends continuously around the heel region 24 from a first end on the inner side surface 16 to a second end on the outer side surface 18. The relief 167 is configured to allow the peripheral region 26 and particularly the outer side surface 128 to act as a spring or a living hinge, thereby allowing the cushioning element 112 to compress in the heel region 24.

[0057] The cushioning element 112 is formed of one or more elastomeric polymeric materials such as foam or rubber to impart to the wearer's foot the properties of cushioning, responsiveness, and energy distribution. In the illustrated example, the cushioning element 112 is formed as a composite material, whereby different components of the cushioning element 112 are formed of different materials to impart different properties to the sole structure 100. For example, the peripheral region 26 of the cushioning element 112 may be formed of a first polymeric material having a first hardness, while the ribs 138a - 138b or at least the top portions of the ribs 138a - 138b are formed of a second polymeric material having a lower hardness than the peripheral region 26. Thus, the ribs 138a - 138b can be more easily compressed and will provide a softer feel along the footbed to minimize point loading along the plantar surface of the foot.

[0058] Example elastomeric polymeric materials for the cushioning element 112 may include materials based on foaming or molding one or more polymers such as one or more elastomers (e.g., thermoplastic elastomers (TPE)). The one or more polymers may include aliphatic polymers, aromatic polymers, or mixtures of both; and may include homopolymers, copolymers (including terpolymers), or mixtures of both.

[0059] In some aspects, the one or more polymers may include olefinic homopolymers, olefinic copolymers, or blends thereof. Examples of olefinic polymers include polyethylene, polypropylene, and combinations thereof. In other aspects, the one or more polymers may include one or more ethylene copolymers such as ethylene - vinyl acetate (EVA) copolymer, EVOH copolymer, ethylene - ethyl acrylate copolymer, ethylene - unsaturated monocarboxylic acid copolymer, and combinations thereof.

[0060] In additional aspects, the one or more polymers may include one or more polyacrylates such as polyacrylic acid, esters of polyacrylic acid, polyacrylonitrile, polyacrylic acid acetate, polymethyl acrylate, polyethyl acrylate, polybutyl acrylate, polymethyl methacrylate, and polyvinyl acetate; including derivatives thereof, copolymers thereof, and any combinations thereof.

[0061] In still additional aspects, the one or more polymers may include one or more ionomer polymers. In these aspects, the ionomer polymers may include polymers having carboxylic acid functional groups, sulfonic acid functional groups, salts thereof (e.g., sodium salts, magnesium salts, potassium salts, etc.), and / or acid anhydrides thereof. For example, the ionomer polymers may include one or more fatty acid - modified ionomer polymers, polystyrene sulfonate, ethylene - methacrylic acid copolymer, and combinations thereof.

[0062] In other aspects, one or more polymers can include one or more styrene block copolymers, such as acrylonitrile butadiene styrene block copolymer, styrene acrylonitrile block copolymer, styrene ethylene butylene styrene block copolymer, styrene ethylene butadiene styrene block copolymer, styrene ethylene propylene styrene block copolymer, styrene butadiene styrene block copolymer, and combinations thereof.

[0063] In other aspects, one or more polymers can 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). As used herein, "polyurethane" refers to a copolymer (including oligomers) containing urethane groups (-N(C=O)O-). In addition to urethane groups, these polyurethanes can also contain additional groups such as esters, ethers, ureas, urethanes, biurets, carbodiimides, oxazolidines, isocyanurates, uretdiones, carbonates, and similar groups. In one aspect, one or more of the polyurethanes can be produced by polymerizing one or more isocyanates with one or more polyols to produce copolymer chains having (-N(C=O)O-) bonds. Alternatively, one or more polymers can include one or more natural rubbers and / or synthetic rubbers, such as butadiene and isoprene.

[0064] When the elastomeric polymer material is a foamed polymer material, the foamed material can be foamed using a physical blowing agent that changes phase into a gas based on changes in temperature and / or pressure, or using a chemical blowing agent that forms a gas when heated above its activation temperature. For example, the chemical blowing agent can be an azo compound, such as azodicarbonamide, sodium bicarbonate, and / or isocyanate.

[0065] In some embodiments, the foamed polymer material can be a crosslinked foamed material. In these embodiments, a peroxide-based crosslinking agent, such as dicumyl peroxide, can be used. Additionally, the foamed polymer material can include one or more fillers, such as pigments, modified clay or natural clay, modified or unmodified synthetic clay, talc, glass fiber, glass powder, modified silica or natural silica, calcium carbonate, mica, paper, wood chips, and the like.

[0066] The elastomeric polymer material can be formed using a molding process. In one example, when the elastomeric polymer material is a molded elastomer, the uncured elastomer (e.g., rubber) can be mixed in a Banbury mixer with optional fillers and a curing package (such as a sulfur-based or peroxide-based curing package), calendered, formed into shape, placed in a mold, and vulcanized.

[0067] In another example, when the elastomeric polymer material is a foamed material, the material can foam during a molding process such as an injection molding process. The thermoplastic polymer material can be melted in the barrel of an injection molding system, combined with a physical or chemical blowing agent and an optional crosslinking agent, and then injected into a mold under conditions that activate the blowing agent, thereby forming a molded foam.

[0068] Optionally, when the elastomeric polymer material is a foamed material, the foamed 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 pieces of foam, shaping the foam, etc.), or both.

[0069] The compression molding process ideally begins by forming one or more foam preforms (such as by injection molding a polymer material and foaming the polymer material, by forming foamed pellets or beads, by cutting a foamed sheet, and similar operations). Then, a compression molded foam can be manufactured by placing one or more preforms formed from the foamed polymer material in a compression mold and applying sufficient pressure to the one or more preforms to compress the one or more preforms in the closed mold. Once the mold is closed, sufficient heat and / or pressure is applied to the one or more preforms in the closed mold for a sufficient duration to change the preform by forming a skin on the outer surface of the compression molded foam, fuse separate foam particles to each other, permanently increase 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.

[0070] The outsole 104 can include one or more discrete outsole elements 118a - 118c that are separated from each other. The outsole elements 118a - 118c can be formed from a transparent or translucent material. The outsole elements 118a - 118c can be formed from a durable material such as, for example, rubber, and can be attached to the bottom surface 126 of the cushioning element 112 at the respective recesses 160a - 160c. Thus, the outsole elements 118a - 118c can be attached to the bottom surface 126 of the cushioning element 112 near the bottom openings 156a - 156c that are respectively associated with the first pocket 152a, the second pocket 152b, and the third pocket 152c. Optionally, one or more of the outsole elements 118a - 118c can include perforations formed therethrough to allow air to move through the outsole 104 into the channels 132 when the cushioning particles 114 within the sole structure 100 are compressed or decompressed.

[0071] The outsole elements 118a - 118c can be along the length of the sole structure 100 substantially parallel to the longitudinal axis L10 separated from each other in the direction of. Although the outsole 104 is described and shown as including separate portions spaced from each other, the outsole 104 may alternatively have an integral construction that generally extends across the entire bottom surface 126 of the cushioning element 112 such that the outsole 104 extends continuously between the front end portion 12 and the rear end portion 14 and between the inner side surface 16 and the outer side surface 18. Regardless of the specific construction of the outsole 104 (i.e., integral or discrete portions), the outsole 104 may include a tread extending from the outsole 104 to provide increased frictional attachment to the ground surface during use of the footwear item 10.

[0072] When the outsole 104 is attached to the cushioning element 112 at the bottom surface 126, forming the outsole 104 from a transparent or translucent material allows the pouches 152a - 152c to be observed through the outsole 104. Additionally, because the cushioning particles 114 substantially fill the corresponding pouches 152a - 152c, the interior of the pouches 152a - 152c and thus the cushioning particles 114 disposed therein are likewise visible through the material of the outsole 104 at the bottom openings 156a - 156c of the cushioning element 112. Accordingly, the cushioning particles 114 located within the respective pouches 152a - 152c of the cushioning element 112 are visible through the outsole 104 at the bottom openings 156a - 156c.

[0073] Reference Figure 5 and Figure 7 , the sole structure 100 includes a volume of cushioning particles 114 disposed directly within each of the pouches 152a - 152c. In other words, the cushioning particles 114 are not contained within an intermediate chamber or container but are loosely disposed within each of the pouches 152a - 152c. As Figure 7 shown, each of the pouches 152a - 152c is overfilled with a volume of cushioning particles 114 such that the volume of cushioning particles 114 within each of the pouches 152a - 152c extends above the upper surfaces 144a, 144b of the respective ribs 138a, 138b. Accordingly, the cushioning particles 114 will cooperate with the top surface 124 of the cushioning element 112 to support the plantar surface of the foot.

[0074] Regardless of the volume of the cushioning particles 114 disposed within the respective bags 152a - 152c, the cushioning particles 114 can be used to enhance the functionality and cushioning characteristics of the sole structure 100. The cushioning particles 114 contained within the bags 152a - 152c can include polymer beads. For example, the cushioning particles 114 can be formed from any of the elastomeric polymer materials discussed above with respect to the cushioning element 112. In some examples, the cushioning particles 114 are formed from a foamed polyurethane (TPU) material and have a substantially spherical shape. The foam beads defining the cushioning particles 114 can have generally the same size and shape, or alternatively can have at least one of different sizes and different shapes. Regardless of the specific size and shape of the cushioning particles 114, the cushioning particles 114 cooperate with the cushioning element 112 and the outsole 104 to provide cushioning and responsive performance for the footwear item 10 during use.

[0075] Reference Figure 7 , the upper barrier layer 116 is received within the top recess 158 of the cushioning element 112 to encapsulate the cushioning particles 114 within each of the respective bags 152a - 152c. Thus, the upper barrier layer 116 cooperates with the top surface 124 of the cushioning element 112 to form the support surface of the sole structure 100. The upper barrier layer 116 is formed from a breathable material so as to allow air to move in and out of the respective bags 152a - 152c as the cushioning particles 114 move between a compressed state and a relaxed state. In some examples, the upper barrier layer 116 is formed from a knitted fabric material having a relatively high elastic modulus to allow the upper barrier layer 116 to extend into the bags 152a - 152c when the sole structure 100 is compressed by the foot during use.

[0076] Integrating the cushioning particles 114 into the footwear item 10 provides a degree of comfort and cushioning for the user's foot during use. For example, when a force is applied by the wearer's foot on the upper barrier layer during use of the footwear item, the force causes the upper barrier layer 116 to bend and stretch, thereby allowing the wearer's foot to engage and move the cushioning particles 114 disposed within the bags 152a - 152c. Such movement of the upper barrier layer 116 also compresses the material of the cushioning element 112 that generally surrounds the bags 152a - 152c, which in turn absorbs the forces associated with walking or running motions.

[0077] The toe box 106, the saddle 108, and the heel clip 110 are each formed from a polymer material having a rigidity greater than that of the cushioning element 112 and extend upwardly from the outer side surface 128 to provide additional support regions for the shoe inner liner 200. As shown, the toe box 106 is attached at the front end portion 12 and surrounds the toe portion 20 Textends from the inner side 16 to the outer side 18. The saddle 108 is attached at the outer side 18 in the midfoot region 22 of the shoe. The heel clip 110 is attached at the rear end 14 and extends from the inner side 16 to the outer side 18 around the heel region 24.

[0078] With particular reference to Figure 13 and Figure 14 , a shoe inner liner 200 for a footwear item 10 is shown. As described in more detail below, the shoe inner liner 200 can be formed from one or more materials that are stitched or adhesively bonded together to form an internal cavity that is configured to receive and secure a foot for support on a sole structure 100. Suitable materials for the shoe inner liner 200 can include, but are not limited to, mesh, textile, foam, leather, and synthetic leather. The materials can be selected and positioned to impart properties of durability, breathability, abrasion resistance, flexibility, and comfort.

[0079] In some examples, the shoe inner liner 200 includes a strobel 202 and an upper 204, and the upper 204 is attached to the outer perimeter of the strobel 202 along a peripheral seam 206 to define the internal cavity. For example, stitching or an adhesive can secure the strobel 202 to the upper 204. An ankle opening is formed in the heel region 24 and can provide an entrance to the internal cavity. For example, the ankle opening can receive a foot to secure the foot within the cavity and facilitate entry of the foot into and removal of the foot from the internal cavity. In some examples, one or more fasteners extend along the upper 204 to adjust the fit of the internal cavity around the foot and accommodate entry of the foot into and removal of the foot from the internal cavity. The fasteners can include shoelaces, straps, cords, hook-and-loop, or any other suitable type of fastener.

[0080] As described in more detail below and as Figure 14 shown, the shoe inner liner 200 also includes an internal reinforcement member 208 that is configured to be attached to the inner surface of the strobel 202 within the internal cavity. An external reinforcement member 210 is disposed on the side of the strobel 202 opposite the internal reinforcement member 208 such that when the footwear item 10 is assembled, the external reinforcement member 210 faces the sole structure 100.

[0081] As Figure 14As shown, the Strumbehl 202 includes a footbed 212 and a peripheral wall 214 that extends laterally (i.e., non - parallelly) from the footbed 212. The footbed 212 is substantially flat, but may be contoured to conform to the contour of the bottom surface (e.g., plantar surface) of the foot. The footbed 212 includes an inner surface 216 and an outer surface 218, and the outer surface 218 is formed on the side of the footbed 212 opposite the inner surface 216. The inner surface 216 is configured to enclose the bottom portion of the internal cavity and support the plantar surface of the foot when the foot is placed within the internal cavity. The outer surface 218 is configured to face the sole structure 100 when the shoe inner liner 200 is assembled to the sole structure 100, and may be attached to the top surface 124 of the cushioning element 112 and the upper blocking layer 116. The outer perimeter of the footbed 212 is defined by a peripheral edge 220, which corresponds to the peripheral contour of the plantar surface of the foot.

[0082] The peripheral wall 214 of the Strumbehl 202 extends upwardly from a first end 222 attached to the peripheral edge 220 of the footbed 212 to a distal upper end edge 224 spaced apart from the footbed 212. The peripheral edge 220 of the footbed 212 and the first end 222 of the peripheral wall 214 may cooperate to provide an arcuate or concave transition between the substantially flat portion of the footbed 212 and the substantially upright portion of the peripheral wall 214. As shown, the footbed 212 and the peripheral wall 214 cooperate to define a cavity 226 for receiving the foot. In some examples, the peripheral wall 214 may only partially extend around the peripheral edge 220 of the footbed 212 such that at least a portion of the peripheral edge 220 is exposed.

[0083] In the illustrated example, the peripheral edge 220 of the footbed 212 and the first end 222 of the peripheral wall 214 are integral such that the footbed 212 and the peripheral wall 214 are formed as a substantially continuous piece without an obvious seam. In some examples, the Strumbehl 202 is formed from a single - piece flexible or elastic material. In other examples, the Strumbehl 202 may be composed of different materials having different properties, where these materials are joined to each other in a seamless manner to provide a substantially continuous and flush piece of material. By forming the Strumbehl 202 with a substantially continuous and seamless structure, the under - foot feel of the footwear item 10 is improved because the plantar surface of the foot will not be exposed to the obvious hard areas associated with traditional stitched seams.

[0084] The distance from the first end 222 of the peripheral wall 214 to the upper end edge 224 of the peripheral wall 214 defines the height H of the peripheral wall 214 around the footbed 212 214 . In some examples, the height H of the peripheral wall 214 214It can vary along the outer perimeter of the strobel 202. For example, the peripheral wall 214 can include one or more portions that have a greater height H than other portions 214 . In the illustrated example, the peripheral wall 214 is formed with a pair of wings 228 that extend from opposite sides of the insole 212. The first wing 228 extends from the inner side 16 of the insole 212, and the second wing 228 extends from the outer side 18 of the insole 212. Each wing 228 extends from a first end 230 in the midfoot region 22 of the shoe to a second end 232 in the heel region 24 of the shoe. As Figure 1 and Figure 2 shown, the height H of the peripheral wall 214 along the wings 228 214 is selected such that when the footwear item 10 is assembled, the wings 228 extend above the top edge of the sole structure 100. Accordingly, the portion of the peripheral seam 206 that extends along the wings 228 is exposed above the sole structure 100.

[0085] Continuing to refer to Figure 13 and Figure 14 , the upper 204 includes a sidewall 234 that is configured to surround the dorsal region of the foot when the wearer puts on the footwear item 10. The sidewall 234 extends from a lower end edge 236 along the bottom of the upper 204 to a collar 238 that defines an ankle opening at the top of the upper 204. As shown, the shape of the lower end edge 236 corresponds to the shape of the upper end edge 224 of the strobel 202 such that when the shoe inner liner 200 is assembled, the lower end edge 236 can mate with the upper end edge 224 to form the peripheral seam 206.

[0086] The peripheral seam 206 extends continuously around the outer perimeter of the shoe inner liner 200 to connect the strobel 202 to the upper 204. As described above, because the strobel 202 includes the peripheral wall 214, the peripheral seam 206 is positioned above the insole 212 and away from the plantar surface of the foot. More specifically, the peripheral seam 206 is disposed along the sides 16, 18 of the shoe inner liner 200 in the midfoot region 22 such that the vertical and lateral forces applied to the sole structure 100 during movement are not applied to the peripheral seam 206 and the foot. Accordingly, the underfoot feel of the shoe inner liner 200 is improved.

[0087] The perimeter seam 206 may include a first stitch 240a in a first portion and a second stitch 240b in a second portion. For example, in the illustrated configuration, the perimeter seam 206 includes a first stitch 240a that extends through the midfoot region 22 of the shoe and around the heel region 24, and includes a second stitch that extends from the midfoot region 22 and around the forefoot region 20 of the shoe. The first stitch may be a binding stitch (e.g., a multi-needle surge stitching), and the second stitch may be a hemming stitch (e.g., a straight stitching).

[0088] Reference Figure 14 , the inner shoe 200 includes an inner reinforcement member 208 and an outer reinforcement member 210, which are attached to opposite sides of the insole 212 relative to each other. Each of the reinforcement members 208, 210 is formed of a material having a greater stiffness than the material forming the insole 212 of the strobel 202. Accordingly, the reinforcement members 208, 210 provide a desired degree of support and stability to the insole 212. Each of the reinforcement members 208, 210 may be attached to the strobel 202 by adhesively bonding the reinforcement members 208, 210 to a respective one of the surfaces 216, 218 of the strobel 202.

[0089] The inner reinforcement member 208 is disposed on the inner surface 216 of the insole 212 and extends continuously from a first end 242 disposed in the midfoot region 22 of the shoe to a second end 244 disposed at the rear end 14. Similarly, the inner reinforcement member 208 extends continuously from the inner side 16 of the insole 212 to the outer side 18. Accordingly, the inner reinforcement member 208 is formed as a substantially continuous element covering the midfoot region 22 and the heel region 24 of the inner surface 216 of the insole 212.

[0090] The outer reinforcement member 210 is disposed on the outer surface 218 of the insole 212 and extends continuously from the forefoot region 20 of the shoe to the rear end 14. However, unlike the inner reinforcement member 208 that covers the perimeter region 26 and the inner region 28 of the insole 212, the outer reinforcement member 210 extends only along the perimeter region 26 of the outer surface 218. Here, the outer reinforcement member 210 is U-shaped or horseshoe-shaped and extends along the perimeter region 26 from a first end 245a disposed on the inner side 16 in the forefoot region 20 of the shoe to a second end 245b disposed on the outer side 18 in the forefoot region 20 of the shoe. Accordingly, the outer reinforcement member 210 includes an inner segment 246 that extends along the perimeter region 26 on the inner side 16, an outer segment 248 that extends along the perimeter region on the outer side 18, and a rear segment 250 that extends around the rear end 14 and connects the inner segment 246 and the outer segment 248.

[0091] As described above, the components 202, 204, 208, 210 of the inner shoe 200 can be formed of different materials to provide the desired properties. For example, the strobel 202 can be formed of a first material having a first material property, and the upper 204 can be formed of one or more second materials having a second material property. In some cases, the first material forming the strobel 202 has a higher modulus of elasticity than the second materials forming the upper 204. Additionally, the reinforcement members 208, 210 are formed of a third material that is stiffer than the material of the strobel 202.

[0092] The following articles provide exemplary configurations of the sole structure and footwear item described above.

[0093] Article 1. A footwear item including a strobel having an inner surface and an outer surface formed on a side opposite the inner surface, the strobel defining a footbed and a peripheral wall extending laterally from the footbed to a distal edge. The footwear item further includes an upper attached to the distal edge of the strobel along a peripheral seam to define an internal cavity for receiving a foot, the peripheral seam being configured to extend along a side of the internal cavity.

[0094] Article 2. The footwear item according to Article 1, further including a sole structure attached to the outer surface of the footbed and having a sidewall that extends at least partially over the peripheral wall of the strobel, the peripheral seam being exposed above the sidewall.

[0095] Article 3. The footwear item according to any of the preceding articles, wherein the strobel is formed of a first material and the upper is formed of a second material different from the first material.

[0096] Article 4. The footwear item according to any of the preceding articles, wherein the peripheral seam includes a first portion having a first stitch and a second portion having a second stitch.

[0097] Article 5. The footwear item according to Article 4, wherein the first stitch is a binding stitch and the second stitch is a lockstitch.

[0098] Article 6. The footwear item according to any of the preceding articles, further including at least one reinforcement member attached to the footbed of the strobel.

[0099] Article 7. The footwear item according to Article 6, wherein the at least one reinforcement member includes an internal reinforcement member attached to the inner surface of the strobel.

[0100] Clause 8. The footwear item according to Clause 7, wherein the internal reinforcement member extends from the heel region of the Ströbel to the midfoot region of the Ströbel and from the outer side of the Ströbel to the inner side of the Ströbel.

[0101] Clause 9. The footwear item according to any one of Clauses 6 to 8, wherein the at least one reinforcement member includes an external reinforcement member attached to the outer surface of the Ströbel.

[0102] Clause 10. The footwear item according to Clause 9, wherein the external reinforcement member includes a first segment extending along the outer side of the insole, a second segment spaced from the first segment and extending along the inner side of the insole, and a third segment connecting the first segment and the second segment and extending around the heel region of the insole.

[0103] Clause 11. A footwear item comprising a sole structure, a Ströbel, and a shoe upper, the Ströbel including (i) an insole disposed on the sole structure, and (ii) a peripheral wall extending laterally from the insole to an end edge above the sole structure, the shoe upper being attached to the end edge of the Ströbel along a peripheral seam.

[0104] Clause 12. The footwear item according to Clause 11, wherein the peripheral seam extends continuously around the footwear item and is at least partially exposed above the sole structure.

[0105] Clause 13. The footwear item according to any one of the preceding clauses, wherein the Ströbel is formed of a first material and the shoe upper is formed of a second material different from the first material.

[0106] Clause 14. The footwear item according to any one of the preceding clauses, wherein the peripheral seam includes a first portion having a first stitch and a second portion having a second stitch.

[0107] Clause 15. The footwear item according to Clause 14, wherein the first stitch is a binding stitch and the second stitch is a lockstitch.

[0108] Clause 16. The footwear item according to any one of the preceding clauses, further comprising at least one reinforcement member attached to the insole of the Ströbel.

[0109] Clause 17. The footwear item according to Clause 16, wherein the at least one reinforcement member includes an internal reinforcement member attached to the inner surface of the Ströbel.

[0110] Article 18. The footwear item according to Article 17, wherein the internal reinforcement member extends from the heel region of the Ströbel to the midfoot region of the Ströbel and from the outer side of the Ströbel to the inner side of the Ströbel.

[0111] Article 19. The footwear item according to any one of Articles 16 to 18, wherein the at least one reinforcement member includes an external reinforcement member attached to the outer surface of the Ströbel.

[0112] Article 20. The footwear item according to Article 19, wherein the external reinforcement member includes a first section extending along the outer side of the insole, a second section spaced apart from the first section and extending along the inner side of the insole, and a third section connecting the first section and the second section and extending around the heel region of the insole.

[0113] The foregoing description has been provided for purposes of illustration and description. The foregoing description is not intended to be exhaustive or to limit the disclosure. The individual elements or features of a particular configuration are generally not limited to that particular configuration but, where applicable, are interchangeable and can be used in the selected configuration even if not explicitly shown or described. The individual elements or features of a particular configuration can also vary in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.

Claims

1. A sole structure for a footwear item, the sole structure comprising: a cushioning element extending from a first end disposed at a front end portion of the footwear item to a second end disposed at a rear end portion of the footwear item and the cushioning element comprising: a top surface; a bottom surface formed on a side of the cushioning element opposite to the top surface; an outer side surface extending from the top surface to the bottom surface and defining an outer peripheral profile of the cushioning element; an inner side surface spaced inwardly from the outer side surface and continuously extending from the top surface to the bottom surface to form a channel through the thickness of the cushioning element; one or more ribs configured to divide the channel into a plurality of pockets for receiving cushioning particles, wherein the plurality of pockets includes a heel pocket; a bevel formed around a bottom opening of the heel pocket; and a plurality of struts projecting downwardly from the bevel and disposed around the bottom opening of the heel pocket; a plurality of cushioning particles disposed directly within each of the plurality of pockets, wherein each of the plurality of pockets is overfilled with a certain volume of cushioning particles such that the certain volume of cushioning particles within each of the plurality of pockets extends above an upper surface of a corresponding rib; an upper barrier layer received within a top recess of the cushioning element to encapsulate the cushioning particles within each of the corresponding pockets, wherein the upper barrier layer is formed of a breathable material; and an outsole comprising a plurality of outsole elements attached to a side of the cushioning element opposite to the upper barrier layer to encapsulate the cushioning particles within the cushioning element, wherein: each of the one or more ribs extends across the channel from a first end attached to the inner side surface on an inner side of the footwear item to a second end attached to the inner side surface on an outer side of the footwear item; each of the plurality of pockets extends from a corresponding top opening formed through the top surface to a bottom opening formed through the bottom surface; the top surface and the bottom surface of the cushioning element include a plurality of recesses for receiving a covering or encapsulation of the plurality of pockets; the top surface includes a top recess extending outwardly from the inner side surface of the cushioning element and configured to receive the upper barrier layer such that when the sole structure is assembled, a top surface of the upper barrier layer is flush with the top surface of the cushioning element; the bottom surface of the cushioning element further includes a plurality of outsole recesses corresponding to the bottom opening of each of the plurality of pockets; the cushioning element is formed of one or more elastic polymeric materials.

2. The sole structure according to claim 1, wherein the plurality of struts are sequentially arranged along a horseshoe-shaped arcuate path corresponding to a curvature of a rear end portion of the sole structure.

3. The sole structure according to any one of the preceding claims, wherein each of said struts extends from a proximal end attached at said bevel to a distal end of a tip formed at an opposite end of said strut.

4. The sole structure according to any one of the preceding claims, wherein a cross-sectional area of at least one of said struts gradually decreases in a direction away from said bevel.

5. The sole structure according to any one of the preceding claims, wherein said struts are spaced apart from each other.

6. The sole structure according to any one of the preceding claims, wherein said cushioning element further comprises a midfoot pocket and at least one forefoot pocket.

7. The sole structure according to claim 6, wherein said midfoot pocket and said forefoot pocket each comprise cushioning granules disposed therein.

8. The sole structure according to claim 6 or claim 7, wherein said upper barrier layer is attached to said top surface of said cushioning element to enclose each of said heel pocket, said midfoot pocket, and said forefoot pocket.

9. A sole structure for an article of footwear, said sole structure comprising: a midsole, said midsole comprising: a cushioning element extending from a first end disposed at a front end of said article of footwear to a second end disposed at a rear end of said article of footwear and said cushioning element comprising: a top surface; a bottom surface formed on a side of said cushioning element opposite to said top surface; an outer side surface extending from said top surface to said bottom surface and defining an outer peripheral profile of said cushioning element; an inner side surface spaced inwardly from said outer side surface and continuously extending from said top surface to said bottom surface to form a channel through a thickness of said cushioning element; one or more ribs configured to divide said channel into a plurality of pockets for receiving cushioning granules, wherein said plurality of pockets includes a heel pocket; a bevel formed around a bottom opening of said heel pocket; and one or more struts projecting downward from said bevel and disposed around said bottom opening; a plurality of cushioning granules disposed directly within each of said plurality of pockets, wherein each of said plurality of pockets is overfilled with a certain volume of cushioning granules such that said certain volume of cushioning granules within each of said plurality of pockets extends above an upper surface of a corresponding rib, and wherein said cushioning granules are capable of freely flowing between adjacent ones of said struts; and an upper barrier layer received within a top recess of said cushioning element to enclose said cushioning granules within each of the corresponding pockets, wherein said upper barrier layer is formed of a breathable material; and an outsole comprising a plurality of outsole elements attached to a side of said cushioning element opposite to said upper barrier layer to enclose said cushioning granules within said midsole, wherein: Each of the one or more ribs extends across the channel from a first end attached to the inner side surface on the inner side of the footwear item to a second end attached to the inner side surface on the outer side of the footwear item; Each of the plurality of bags extends from a respective top opening formed through the top surface to a bottom opening formed through the bottom surface; The top surface and the bottom surface of the cushioning element include a plurality of recesses for receiving a covering or encapsulation of the plurality of bags; The top surface includes a top recess extending outwardly from the inner side surface of the cushioning element, the top recess being configured to receive the upper barrier layer such that when the sole structure is assembled, the top surface of the upper barrier layer is flush with the top surface of the cushioning element; the bottom surface of the cushioning element further includes a plurality of outsole recesses corresponding to the bottom opening of each of the plurality of bags; The cushioning element is formed of one or more elastomeric polymer materials.

10. The sole structure according to claim 9, wherein the one or more struts include a plurality of struts arranged sequentially along a horseshoe-shaped arcuate path corresponding to the curvature of the rear end portion of the sole structure.

11. The sole structure according to any one of claims 9-10, wherein each of the struts extends from a proximal end attached at the bevel to a distal end of a tip formed at an opposite end of the strut.

12. The sole structure according to any one of claims 9-11, wherein the cross-sectional area of at least one of the struts gradually decreases in a direction away from the bevel.

13. The sole structure according to any one of claims 9-12, wherein the struts are spaced apart from each other.

14. The sole structure according to any one of claims 9-13, wherein the channel includes at least one of a forefoot pocket, a midfoot pocket, and a heel pocket.

15. The sole structure according to claim 14, wherein the forefoot pocket, the midfoot pocket, and the heel pocket each include cushioning particles disposed therein.

16. The sole structure according to claim 14 or claim 15, wherein the upper barrier layer is attached to the top surface of the cushioning element to encapsulate the heel pocket, the midfoot pocket, and the forefoot pocket.

Images