Footwear sole structure with nested foam core

Abstract

A sole structure for footwear may include a sole component having a bottom wall and a peripheral wall extending upward from the bottom wall and partially surrounding a space above the bottom wall. The sole structure may have a midsole, which includes a foam core nested in the space. The peripheral wall of the sole component may be arranged on the outside of the side surface of the foam core. The sole component may be attached to a first portion of the side surface and separated from a second portion of the side surface. The second portion of the side surface may be arranged between the first portion and the bottom wall.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of priority to U.S. Provisional Application No. 63 / 006,286, filed on April 7, 2020, which is hereby incorporated by reference in its entirety. Technical Field

[0003] The present disclosure generally relates to a sole structure for an article of footwear that includes a foam core nested within a sole component.

[0004] background

[0005] Footwear sole structures are often constructed of multiple components of different materials in order to meet the goals of durability, stability, and cushioning. For example, some components may have high energy return and elastic rebound under compressive loading, while other components may have less elastic rebound but greater wear resistance. Footwear manufacturers work hard to design and assemble the various components so that each component can perform its function. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] The drawings described herein are for illustration purposes only, are schematic in nature and are intended to be exemplary rather than limiting the scope of the present disclosure.

[0008] Figure 1 is a perspective view illustrating a medial side of a sole structure for an article of footwear.

[0009] Figure 2 is a partial perspective view showing the lateral side of the sole structure.

[0010] Figure 3 is a partial exploded view showing the lateral side of the sole structure.

[0011] Figure 4 is a perspective top view showing components of the sole structure in a disassembled state.

[0012] Figure 5 is included in Figure 1 The line 5-5 in Figure 1 An article of footwear having a sole structure and showing a cross-sectional view of a footwear upper with the sole structure under steady-state loading.

[0013] Figure 6 yes Figure 5 Cross-sectional view of an article of footwear wherein the sole structure is under dynamic compressive loading.

[0014] Figure 7is a perspective view showing the lateral side of the sole structure with the outsole component removed.

[0015] Figure 8 is a perspective view showing the medial side of the sole structure with the outsole component removed.

[0016] Fig. 9 is a side view of the lateral side of a foam core included in the sole structure.

[0017] Fig.10 is a perspective view showing the inner side of the foam core.

[0018] Fig.11 is the rear view of the foam core.

[0019] Fig.12 is a bottom view of the foam core.

[0020] Fig.13 It is a bottom view of the outsole component of the shoe.

[0021] Fig.14 is a perspective view of a forward outsole component included in the sole structure.

[0022] Fig.15 yes Fig.13 A perspective view of an outsole component of a shoe.

[0023] Fig.16 This is a bottom-up perspective view of the midsole layer.

[0024] describe

[0025] The present disclosure generally relates to a sole structure for an article of footwear having a foam core with relatively high energy return and cushioning capabilities, and the sole structure is configured and constructed to protect the foam core from wear while minimizing the restraint of the foam core so that the cushioning benefits of the foam core can be more fully realized.

[0026] The sole structure can include a sole component, and the sole component has a bottom wall and a peripheral wall extending upward from the bottom wall and partially surrounding the space above the bottom wall. The sole structure can also include a midsole, which includes a foam core arranged in the space. The peripheral wall of the sole component can be arranged on the outside of the side surface of the foam core. The sole component can be attached to the first part of the side surface and separated from the second part of the side surface, and the second part is arranged between the first part and the bottom wall. For example, the second part of the side surface can be without any attachment in the space. By this configuration, the foam core is fully fixed to the sole component, to ensure the stability of the sole structure, while still allowing a part of the foam core to be elastically deformed at least in the initial stage of loading, without interference or constraint of the sole component.

[0027] In an embodiment, the foam core may have a first stiffness, and the sole component may have a second stiffness greater than the first stiffness. Thus, by nesting the foam core within the space defined by the sole component, the relatively compliant foam core may be protected by the stiffer sole component. As used herein, "stiffness" is the rate of change of load to displacement when the component is compressed (such as when the component is under a dynamic compressive load due to impact with the ground). The component may have a constant stiffness (i.e., a linear rate of change of load to displacement), a nonlinear stiffness (such as an exponentially increasing rate of change of load to displacement when compressed), or may have a ratio that is initially linear and changes to nonlinear (or initially nonlinear and changes to linear). When, for example, one component (e.g., a sole component) physically restricts another component (e.g., a foam core) from elastically deforming under compression, the stiffness of the sole structure described herein may have an effective stiffness in a portion of the displacement range, which is based on the stiffness values ​​of more than one component of the sole structure.

[0028] In one aspect, the sole structure may further include an adhesive layer disposed on a first portion of the side surface of the foam core and adhering the sole component to the first portion of the side surface of the foam core. The second portion may be free of adhesive because the second portion may not be secured to the sole component or any other component of the sole structure.

[0029] In another aspect, the second portion of the side surface of the foam core can be recessed inwardly from the first portion, thereby defining a gap between the inner side of the peripheral wall of the sole component and the second portion of the side surface of the foam core. The foam core can expand unconstrainedly in the gap under compression loading, thereby allowing its ideal cushioning properties to be achieved. For example, the second portion of the side surface of the foam core can be freely compressed outwardly under dynamic compression loading until the second portion contacts and compresses against the inner side of the peripheral wall of the sole component, thereby filling or substantially filling the gap. Because the second portion can be between the first portion and the bottom wall, for example, below the first portion, during wear, more dynamic movement of the foam core is closer to the ground, thereby increasing the stability of the sole structure.

[0030] In one aspect, the side surface of the foam core can extend along the medial side, lateral side and rear portion of the sole structure. The peripheral wall of the sole component can extend on the medial side, lateral side and rear portion of the sole structure adjacent to the side surface of the foam core and on the outside of the side surface of the foam core. Therefore, the peripheral wall effectively surrounds and protects the foam core at the medial side, lateral side and rear portion of the foam core. In an embodiment, the peripheral wall of the sole component can have a recess, which extends from the upper edge of the peripheral wall to the bottom wall of the sole component at the rear portion of the sole structure. The foam core can extend across the recess on the inner side of the peripheral wall. Compared with the embodiment without the recess, the recess can provide increased flexibility in the lateral direction of the sole structure (for example, the medial side of the sole structure can be more easily bent near the recess relative to the lateral side of the sole structure).

[0031] In various embodiments, the relative shapes and surface areas of the first portion and the second portion may be different. For example, in an embodiment, the first portion of the side surface of the foam core may include an elongated strip having a first leg extending from the bottom surface of the foam core toward the top edge of the foam core, a second leg extending from the first leg surrounding the foam core to the rear of the foam core, and a third leg at the rear of the foam core and extending from the second leg toward the bottom surface of the foam core. The second portion may extend from the first leg to the third leg between the second leg and the bottom surface of the foam core. For example, the second portion may extend between the first leg and the third leg with an uninterrupted span. In one configuration, the minimum height of the second portion may be greater than the maximum height of the second leg (e.g., in the vertical direction).

[0032] In some embodiments, the first portion may extend along the inner side, outer side, and rear of the foam core. For example, the elongated strip may be an inner side elongated strip at the inner side of the foam core, and the first portion of the side surface of the foam core may also include an outer side elongated strip at the outer side of the foam core. The outer side elongated strip may have a first leg at the outer side of the foam core and extending from the bottom surface of the foam core toward the top edge of the foam core, a second leg extending from the first leg around the foam core to the rear of the foam core, and a third leg at the rear of the foam core and extending from the second leg toward the bottom surface of the foam core. In such an embodiment, the second portion of the side surface of the foam core may further extend from the first leg to the third leg at the outer side of the foam core between the second leg of the outer side elongated strip and the bottom surface of the foam core.

[0033] In another aspect, the bottom wall of the sole component may have through holes, and the foam core may extend over the through holes. Thus, some freedom of movement of the foam core during compression is also provided at the bottom of the foam core.

[0034] In an embodiment, the sole component may be an outsole that includes a ground contacting surface of the sole structure. The outsole may be a durable material that is selected to withstand wear while protecting the foam core. For example, the outsole may be rubber and the foam core may be Thermoplastic elastomer foam and may be sold by Nike under the trade name ZoomX.

[0035] In one configuration, the sole structure may also include a mid-bottom layer extending between the top surface of the sole component and the bottom surface of the foam core. The bottom surface of the foam core may be fixed to the top surface of the mid-bottom layer, and the bottom surface of the mid-bottom layer may be fixed to the top surface of the sole component. In an embodiment, the foam core and the sole component may be arranged in a heel area of ​​the sole structure, and the mid-bottom layer may extend forward from between the foam core and the sole component in the heel area. For example, in addition to the heel area, the mid-bottom layer may also extend to the mid-shoe area and the forefoot area of ​​the sole structure.

[0036] In addition to being secured to the bottom surface of the foam core, the mid-bottom layer may also be secured to the side surface of the foam core. For example, the side surface of the foam core may have a third portion below the second portion. The third portion may be recessed inwardly relative to the second portion. The mid-bottom layer may be bonded to the third portion of the foam core. The side surface of the foam core may define a wavy edge between the second portion and the third portion. The mid-bottom layer may have a wavy upper edge that mates with the wavy edge of the side surface of the foam core.

[0037] In one configuration, a sole structure for an article of footwear may include an outsole having a bottom wall and a peripheral wall extending upward from the bottom wall and partially surrounding a space above the bottom wall, the peripheral wall forming a cup from the medial side of the sole structure around the rear of the heel region of the sole structure to the lateral side of the sole structure. The sole structure may also include a midsole, the midsole including a foam core nested in the space, the foam core having a side surface, the side surface having a first portion and a second portion, the second portion being recessed inwardly from the first portion at both the medial side and the lateral side of the foam core, thereby defining a gap between the inner side of the peripheral wall of the outsole and the second portion of the foam core at each of the lateral side and the medial side of the foam core. The midsole may include a mid-bottom layer disposed between the foam core and the bottom wall of the outsole, the mid-bottom layer being fixed to the bottom surface of the foam core and the top surface of the bottom wall of the outsole. The peripheral wall of the outsole may be disposed on the outside of the medial side of the foam core and the outside of the lateral side of the foam core. The peripheral wall of the outsole may be attached to a first portion of the side surface of the foam core at the medial side and the lateral side of the foam core and separated from a second portion of the side surface of the foam core at the medial side and the lateral side of the foam core.

[0038] When understood in conjunction with the accompanying drawings, the above features and advantages of this teaching and other features and advantages will become apparent from the detailed description of the following mode of implementing this teaching. It should be understood that even if an embodiment can be described separately in the following drawings, the individual features of the embodiment may also be combined in additional embodiments.

[0039] Referring to the drawings, wherein like reference numerals refer to like parts throughout the several views, Figure 1 A method for using an article of footwear such as Figure 5 and Figure 6 The sole structure 10 of the article of footwear 12 is shown in FIG. The sole structure 10 has a midsole 14, which includes a foam core 16 as described herein nested in a sole component 18. In the illustrated embodiment, the midsole 14 also includes a mid-layer 20 disposed between the foam core 16 and the sole component 18, such as Figure 5 and Figure 6 The sole component 18 is configured as an outsole component having a ground engaging surface 21 , and may be referred to herein as the outsole component 18 . Fig.14 An additional outsole component 94 is shown as being positioned underneath a forefoot portion of midsole layer 20. In some embodiments, outsole components 18, 94 may be integrated into a one-piece outsole.

[0040] The foam core 16 may be a softer (less stiff) material than the outsole component 18. For example, the foam core 16 may include a foamed polymer material and may be at least partially polyurethane (PU) foam, polyurethane ethylene-vinyl acetate (EVA) foam, and may include heat-expanded and molded EVA foam particles. The foam core 16 may include Thermoplastic elastomer foam, and can be sold by Nike under the trade name ZoomX. Mid-bottom layer 20 can be any of these foamed polymer materials, and can have a compression stiffness different from foam core 16. Outsole component 18 can be a material more durable than foam core 16. For example, outsole component 18 can include a rubber material, which can be natural rubber, or synthetic rubber, or a combination of the two. The example of rubber type includes butadiene rubber, styrene-butadiene (SBR) rubber, butyl rubber, isoprene rubber, urethane rubber, nitrile rubber, chloroprene rubber, ethylene propylene diene monomer (EPDM) rubber, ethylene propylene rubber, urethane rubber, polynorbornene rubber, methyl methacrylate butadiene styrene (MBS) rubber, styrene ethylene butylene (SEBS) rubber, silicone rubber and mixtures thereof. Rubber compound can be virgin material, regrind material and mixtures thereof.

[0041] Sole structure 10 includes a heel region 24, a midfoot region 26, and a forefoot region 28. When a human foot of a size corresponding to sole structure 10 is placed in foot-receiving cavity 30 of article of footwear 12 and supported on sole structure 10 (e.g., Figure 5 1 and 1 ), the heel region 24 generally includes a portion of the sole structure 10 that corresponds to the rear portion of the human foot 77, including the calcaneus. The forefoot region 28 of the sole structure 10 generally includes a portion of the sole structure 10 that corresponds to the toes and the joints connecting the metatarsal bones and phalanges of the human foot (interchangeably referred to herein as "metatarsal-phalangeal joints" or "MPJ" joints). The midfoot region 26 of the sole structure 10 is disposed between the heel region 24 and the forefoot region 28 and generally includes a portion of the sole structure 10 that corresponds to the arch area of ​​the human foot, including the navicular joint. The sole structure 10 has a medial side 32 (at Figure 1 ) and the outer side 34 (partially in Figure 2 2 ), both the medial side 32 and the lateral side 34 extend from the heel region 24 to the forefoot region 28 and are generally on opposite sides of a longitudinal axis LM (which may be a longitudinal centerline) of the sole structure 10. The medial side 32, lateral side 34, and rear portion 70 of the sole structure 10 described herein correspond to and may also be used to refer to the medial side, lateral side, and rear portion of the various components of the sole structure 10.

[0042] Reference Figure 3 and Figure 4 , outsole member 18 has a bottom wall 36 that includes ground engaging surface 21 at the bottom of sole structure 10. Outsole member 18 includes a perimeter wall 38 that extends upward from bottom wall 36 and partially surrounds a space 40 above bottom wall 36. A bottom surface 42 of midsole layer 20 is disposed in space 40 and is bonded to the bottom surface 42 of midsole layer 20, such as with an adhesive ( Figure 5 The adhesive layer 78 shown is bonded or otherwise secured to the top surface 44 of the outsole member 18 in the space 40. The through-holes 46 in the outsole member 18 are aligned with the through-holes 48 in the midsole layer 20. The midsole layer 20 has a wavy upper edge 50 that fits within a small recess 52 that has a wavy edge 54 at the inner side 49 of the peripheral wall 38 of the outsole member 18 (at the bottom of the midsole layer 20). Fig.15 ). Thus, the through-holes 46 and the wavy upper edge 50 serve as alignment features for the midsole layer 20 and the outsole component 18.

[0043] Foam core 16 is disposed in space 40 with a bottom surface 56 of foam core 16 secured to a top surface 58 of midsole layer 20. Thus, midsole layer 20 extends between outsole member 18 and bottom surface 56 of foam core 16. Small circular protrusions 60 in bottom surface 56 may align with through holes 46 and 48.

[0044] The foam core includes a side surface 62 having a first portion 62A, a second portion 62B disposed between the first portion 62A and the bottom wall 36 (e.g., directly below the first portion 62A), and a third portion 62C disposed between the second portion 62B and the bottom wall 36 (e.g., below the second portion 62B). The third portion 62C is recessed inwardly relative to the second portion 62B to define a corrugated edge 64 between the second portion 62B and the third portion 62C (e.g., a corrugated lower edge of the second portion 62B). The corrugated upper edge 50 of the mid-layer 20 also mates with the corrugated edge 64 so that the interior side 51 of the mid-layer 20 is in contact with the third portion 62C and adhered to the third portion 62C by applying adhesive to the interior side 51 and / or the third portion 62C.

[0045] The upper edge 66 of the peripheral wall 38 of the outsole member 18 mates with the foam core 16 at a small recess 68 of the foam core 16, which defines a top edge 69 of the first portion 62A of the side surface 62. The peripheral wall 38 of the outsole member 18 has a notch 61 extending from the upper edge 66 of the peripheral wall 38 to the bottom wall 36 of the outsole member 18, as shown in FIG. Figure 4 The recess 61 is provided at the rear portion 70 of the assembled sole structure 10. The peripheral wall 38 and the bottom wall 36 are unitary (one-piece) structures comprising the same material, and the peripheral wall 38 extends from the front medial edge 65 of the peripheral wall 38 (see FIG. Figure 1 and Fig.15 ) to the notch 61 at the medial side 32 of the sole component 18 and from the front lateral edge 67 of the peripheral wall 38 (see Figure 3 and Fig.15 ) is a continuous extension of the recess 61 at the lateral side 34 of the sole component 18. The side surface 62 of the foam core 16 extends across the recess 61 on the inner side of the peripheral wall 38 in the assembled sole structure 10.

[0046] The side surface 62 of the foam core 16 extends along the medial side 32, the lateral side 34, and the rear portion 70 of the sole structure 10. The peripheral wall 38 of the outsole component 18 is adjacent to the side surface 62 of the foam core 16 at the medial side 32, the lateral side 34, and the rear portion 70 of the sole structure 10 and extends outboard of the side surface 62 of the foam core 16. Therefore, the peripheral wall 38 effectively surrounds and protects the foam core 16 at the medial side 32, the lateral side 34, and the rear portion 70 of the foam core 16. Figure 3 and Figure 7-Figure 11As shown, the second portion 62B may have a textured surface, such as a plurality of circular protrusions 63 (some of which are Figure 3 , Figure 5 and Fig. 9 In other embodiments, there may be a different texture, or the second portion 62B may be smooth. The texture may be a circular protrusion 63 extending into the gap 76, such as Figure 5 The texture may be imparted to the foam core 16 by a mold into which the foam used to form the foam core 16 is injected or otherwise placed during the formation of the foam core 16 .

[0047] Reference Figure 3 Even with the circular protrusion 63 of the second portion 62B, the foam core 16 has a recess 72 at the second portion 62B. The recess 72 defines a top edge 74 of the second portion 62B of the side surface 62 and extends downward to the wave-shaped edge 64. Figure 5 As best shown in FIG. 1 , the recess 72 of the second portion 62B relative to the first portion 62A causes a gap 76 to exist between the inner side 49 of the peripheral wall 38 of the outsole member 18 and the second portion 62B of the side surface 62 of the foam core 16. Because the foam core 16 is elastically deformable, under a sufficiently large compressive load, the foam core 16 can deform laterally outward into the gap 76 (e.g., outward at the medial side 32 and the lateral side 34) to fill or substantially fill the gap 76, such as by contacting the inner side 49 of the outsole 18 across the gap 76. However, the sole structure 10 is configured such that the gap 76 exists (e.g., is not crossed or filled by the deformed foam core 16) during steady-state loading that is less than a predetermined amount. For example, steady-state loading of the sole structure 10 occurs when a wearer (represented by the foot 77 shown in phantom) stands on the sole structure 10 but does not dynamically impact the sole structure 10 against the ground G with at least a predetermined load.

[0048] exist Figure 5, the sole structure 10 is shown as being secured to a footwear upper 80 in an article of footwear 12. The footwear upper 80 may be a sock upper having sidewalls and a bottom, or may be secured to a strobel 82 at the lower periphery of the footwear upper 80. The footwear upper 80 and the strobel 82 are secured to the interior side 84 of the foam core 16, such as with an adhesive layer 78. The interior side 49 of the peripheral wall 38 is secured to the first portion 62A, such as with an adhesive layer 78. In other embodiments, the peripheral wall 38 may be thermally bonded or otherwise secured to the first portion 62A. The adhesive layer 78 may also be disposed at the interface between the bottom surface 56 of the foam core 16 and the top surface 58 of the mid-layer 20, and at the interface between the top surface 44 of the outsole component 18 and the bottom surface 42 of the mid-layer 20 to secure these respective surfaces to each other. No adhesive is disposed on the second portion 62B of the side surface 62, and no components are in contact with the second portion 62B during steady-state loading (e.g., Figure 5 As shown, the second portion 62B is spaced apart from the peripheral wall 38).

[0049] Reference Figure 6 , the dynamic compressive loading of the wearer's foot 77 on the sole structure 10 is represented by the load force L. Under such loading, the foam core 16 can resiliently compress to provide cushioning and energy return. The first portion 62A and the third portion 62C are adhered and thus fixed to the outsole member 18 during dynamic compression, but the second portion 62B is free to deform outwardly into the gap 76 without restraint, at least until the second portion 62B meets the inner side 49 of the peripheral wall 38, as shown in FIG. Figure 6 As shown. After the connection with the peripheral wall 38, the foam core 16 can continue to compress under dynamic loading. However, the compression of the foam core 16 at the second portion 62B is now affected by the stiffness of the peripheral wall 38, which generates a compressive reaction force acting on the foam core 16 at the second portion 62B. The foam core 16 can have a first stiffness, and the outsole component 18 can have a second stiffness greater than the first stiffness. Therefore, the relatively compliant foam core 16 is protected from wear by the stiffer outsole component 18 by nesting the foam core 16 within the outsole component 18, and during the first compressive loading stage before the connection with the peripheral wall 38, the relatively compliant foam core 16 is allowed to elastically deform laterally outward at the second portion 62B without being constrained by the peripheral wall 38, and then during the second compressive loading stage when the relatively compliant foam core 16 contacts the inner side 49 of the peripheral wall 38, the relatively compliant foam core 16 may be affected by the reaction force to the outsole component 18.

[0050] In embodiments that include a mid-layer 20 disposed between the bottom of the foam core 16 and the bottom wall 36 of the outsole component 18, the mid-layer 20 may have a greater stiffness than the foam core. Thus, the stiffness of the sole structure 10 under compressive loading may vary, as a lower stiffness may occur during a first loading phase, and a greater stiffness may occur during a second loading phase both laterally outward (due to the restraint of the peripheral wall 38) and in the vertical direction (due to the stiffer mid-layer 20).

[0051] With this configuration, the foam core 16 is sufficiently secured to the outsole component 18 to ensure stability of the sole structure 10 while still allowing the foam core 16 to elastically deform at the second portion 62B under load without interference or restraint from the outsole component 18. Because the second portion 62B is below the first portion 62A (which is limited by the peripheral wall 38) even during the first deformation stage, more dynamic movement of the foam core 16 (e.g., elastic deformation of the foam core 16 laterally outward into the gap 76) during wear is closer to the ground G, thereby increasing the stability of the sole structure 10.

[0052] In various embodiments, the relative shapes and surface areas of the first portion 62A, the second portion 62B, and the third portion 62C may be different. In the illustrated embodiment, the first portion 62A of the side surface 62 of the foam core 16 is configured as two elongated strips: an inner side elongated strip 62A1 on the inner side 32 starting from the front 73 of the foam core 16 and extending to the rear 70, and an outer side elongated strip 62A2 on the outer side 34 and extending from the front 73 of the foam core 16 to the rear 70. Fig. 9 and Fig.11 The outboard elongated strip 62A2 is shown together to include a first leg 86A extending upward in a direction from the bottom surface 56 of the foam core 16 toward the top edge 88 of the foam core 16, a second leg 86B extending from the first leg 86A around the foam core 16 to the rear portion 70 of the foam core 16, and a third leg 86C extending from the second leg 86B downward toward the bottom surface 56 along the rear portion 70 of the foam core 16. The second portion 62B at the inboard side 32 extends from the first leg 86A to the third leg 86C below the second leg 86B. The second portion 62B extends between the first leg 86A and the third leg 86C below the second leg 86B with an uninterrupted span. Furthermore, a minimum height H1 of the second portion 62B below the second leg 86B (e.g., a distance to the peak of the wave edge 64 and in a direction perpendicular to the length of the second leg 86B of the first portion 62A) may be greater than a maximum height H2 of the second leg 86B (e.g., a distance across the second leg 86B in a direction perpendicular to the length of the second leg 86B), as shown in FIG. Fig. 9 shown.

[0053] Fig.10 and Fig.11 The illustrated inboard elongated strip 62A1 also has a first leg 90A extending upward in a direction from the bottom surface 56 of the foam core 16 toward the top edge 88 of the foam core 16, a second leg 90B extending from the first leg 90A and around the foam core 16 to the rear 70 of the foam core 16 at the front 73 of the foam core 16, and a third leg 90C extending from the second leg 90B along the rear 70 of the foam core 16 downward toward the bottom surface 56. The second portion 62B at the outboard side 34 extends from the first leg 90A to the third leg 90C below the second leg 90B. The second portion 62B extends between the first leg 90A and the third leg 90C in an uninterrupted span. Furthermore, a minimum height H1 of the second portion 62B below the second leg 90B (e.g., a distance to the peak of the wave edge 64 and in a direction perpendicular to the length of the second leg 90B of the first portion 62A) may be greater than a maximum height H2 of the second leg 90B (e.g., a distance across the second leg 90B in a direction perpendicular to the length of the second leg 90B), as shown in FIG. Fig.10 As shown. Fig.11 As shown, the side surface 62 of the foam core 16 extends across the recess 61 (eg, Figure 4 The portion 62D shown in FIG. 6A is located between the third legs 86C, 90C.

[0054] Therefore, by configuring the first portion 62A as relatively narrow elongated strips 62A1, 62A2, the second portion 62B can have a relatively larger surface area than the first portion 62A to maximize the portion of the foam core 16 that can elastically deform without being constrained by the peripheral wall 38 during the initial dynamic loading stage before contact with the peripheral wall 38, after which the effective stiffness at the second portion 62B will be greater due to the peripheral wall 38.

[0055] Fig.12 1 is a bottom view of the foam core 16 showing the circular protrusion 60 at the bottom surface 56, which can be aligned with the through holes 46, 48 in the assembled sole structure 10, partially extending into the through hole 48, as shown in FIG. Figure 5 and Figure 6 shown.

[0056] Fig.13 is a bottom view of outsole member 18 showing a plurality of tread elements 92 at ground engaging surface 21 . Fig.142 is a perspective view of another outsole component 94 that may be included in sole structure 10. More specifically, outsole component 94 is configured as a forefoot outsole component, and inner surface 95 of outsole component 94 may be adhered to bottom surface 42 of midsole layer 20 in forefoot region 28 (see FIG. Figure 1 ). Forefoot outsole member 94 is disposed forward of outsole member 18, which may be referred to as heel outsole member 18. Alternatively, a single (one-piece) outsole may be used, such as if outsole members 94, 18 are formed together, with the front edge of outsole member 18 extending forwardly to outsole member 94 at a rearward extension of outsole member 94 and being integral with outsole member 94.

[0057] Fig.15 is a perspective view of outsole component 18 and best illustrates the space 40 within which foam core 16 (and the portion of midsole layer 20 in heel area 24) is nested in assembled sole structure 10. Fig.15 The best shown is the small depression 52, which has a corrugated edge 54 at the inner side 49 of the peripheral wall 38, and the corrugated upper edge 50 of the mid-layer 20 (at Fig.16 ) is mated to the wavy edge 54 in the assembled sole structure 10.

[0058] Thus, the foam core 16 is protected from wear and abrasion in the space 40 formed by the outsole component 18, but the second portion 62B of the side surface 62 of the foam core 16 is initially allowed to elastically deform laterally outward in an unrestricted manner due to the lack of attachment to any component and the gap 76. The attachment at the first portion 62A sufficiently secures the foam core 16 to the outsole component 18 to achieve stability. The foam core can have a first compression stage before the second portion 62B contacts the peripheral wall 38, and a second compression stage after the second portion 62B contacts the peripheral wall 38 and is restrained by the peripheral wall 38. In addition, if the mid-layer 20 is disposed between the foam core 16 and the outsole component 18, the mid-layer 20 can have a different compression stiffness than the foam core 16, thereby providing another compression stage in the vertical direction.

[0059] The following clauses provide example configurations of the articles of footwear disclosed herein.

[0060] Item 1. A sole structure for an article of footwear, the sole structure comprising: a sole component having a bottom wall and a peripheral wall extending upward from the bottom wall and partially surrounding a space above the bottom wall; and a midsole comprising a foam core nested in the space; wherein the peripheral wall of the sole component is disposed on the outside of a side surface of the foam core; and wherein the sole component is attached to a first portion of the side surface and is separated from a second portion of the side surface, the second portion of the side surface being disposed between the first portion and the bottom wall.

[0061] Item 2. The sole structure according to Item 1 also includes: an adhesive layer, which is arranged on the first part of the side surface of the foam core and adheres the sole component to the first part of the side surface of the foam core, and the second part of the side surface has no attachment within the space.

[0062] Clause 3. A sole structure according to any one of the preceding clauses, wherein: the second portion of the side surface of the foam core is recessed inwardly from the first portion, thereby defining a gap between the inner side of the peripheral wall of the sole component and the second portion of the side surface of the foam core.

[0063] Clause 4. The sole structure of Clause 3, wherein: the second portion of the side surface of the foam core elastically deforms outwardly into the gap toward the interior side of the peripheral wall of the sole component under compressive loading.

[0064] Clause 5. The sole structure of any of the preceding clauses, wherein the bottom wall of the sole component has through holes, and the foam core extends over the through holes.

[0065] Clause 6. A sole structure according to any of the preceding clauses, wherein: the peripheral wall of the sole component is adjacent to and extends outside of the side surface of the foam core at the medial side, lateral side and rear of the sole structure.

[0066] Clause 7. A sole structure according to any one of the preceding clauses, wherein: the peripheral wall of the sole component has a recess, the recess extending from the upper edge of the peripheral wall to the bottom wall of the sole component at the rear of the foam core; and the foam core extends across the recess on the inner side of the peripheral wall.

[0067] Clause 8. A sole structure according to Clause 7, wherein the peripheral wall and the bottom wall are an integral structure, and the peripheral wall is a continuous extension from the front medial side edge of the peripheral wall to the recess at the medial side of the sole component and from the front lateral side edge of the peripheral wall to the recess at the lateral side of the sole component.

[0068] Clause 9. A sole structure according to any one of the preceding clauses, wherein: the first portion of the side surface of the foam core comprises an elongated strip extending from the front of the foam core to the rear of the foam core in the longitudinal direction of the sole structure above the second portion.

[0069] Clause 10. A sole structure according to any one of the preceding clauses, wherein: the first portion of the side surface of the foam core includes an elongated strip having a first leg extending from the bottom surface of the foam core toward the top edge of the foam core, a second leg extending from the first leg around the foam core to the rear of the foam core, and a third leg at the rear of the foam core and extending from the second leg toward the bottom surface of the foam core; and the second portion extends from the first leg to the third leg between the second leg and the bottom surface of the foam core.

[0070] Clause 11. A sole structure according to Clause 10, wherein: the elongated strip is an inner side elongated strip at the inner side of the foam core, and the first part of the side surface of the foam core also includes an outer side elongated strip at the outer side of the foam core, the outer side elongated strip also having a first leg portion extending at the outer side of the foam core and from the bottom surface of the foam core toward the top edge of the foam core, a second leg portion extending from the first leg portion around the foam core to the rear of the foam core, and a third leg portion extending from the second leg portion toward the bottom surface of the foam core at the rear of the foam core; and the second part of the outer side elongated strip also extends from the first leg portion of the outer side elongated strip to the third leg of the outer side elongated strip between the second leg portion of the outer side elongated strip and the bottom surface of the foam core at the outer side of the foam core.

[0071] Clause 12. The sole structure of Clause 10, wherein a minimum height of the second portion is greater than a maximum height of the second leg portion.

[0072] Clause 13. The sole structure of any of the preceding clauses, wherein: the foam core has a first stiffness and the sole component has a second stiffness greater than the first stiffness.

[0073] Clause 14. A sole structure as recited in any preceding clause, wherein the sole component is an outsole and comprises a ground contacting surface of the sole structure.

[0074] Clause 15. The sole structure of Clause 14, further comprising: a midsole layer extending between a top surface of the sole component and a bottom surface of the foam core.

[0075] Clause 16. The sole structure of Clause 15, wherein: the bottom surface of the foam core is secured to a top surface of the midsole layer; and the bottom surface of the midsole layer is secured to the top surface of the sole component.

[0076] Item 17. A sole structure according to Item 15, wherein: the foam core is only arranged in the heel area of ​​the sole structure; and the midsole layer extends forward from between the foam core and the sole component in the heel area to the midshoe area and the forefoot area of ​​the sole structure.

[0077] Clause 18. The sole structure of Clause 17, wherein the sole component extends only in the heel region of the sole structure.

[0078] Clause 19. A sole structure according to Clause 15, wherein: the side surface of the foam core has a third portion below the second portion; the third portion is recessed inwardly from the second portion; and the midsole layer is bonded to the third portion of the side surface of the foam core.

[0079] Clause 20. A sole structure according to Clause 19, wherein: the side surface of the foam core defines a wavy edge between the second portion and the third portion; and the midsole layer has a wavy upper edge that cooperates with the wavy edge of the side surface of the foam core.

[0080] Item 21. A sole structure for an article of footwear, in particular a sole structure according to any one of the preceding items, the sole structure comprising: an outsole having a bottom wall and a peripheral wall extending upward from the bottom wall and partially surrounding a space above the bottom wall, the peripheral wall forming a cup from the inner side of the sole structure around the rear of the heel area of ​​the sole structure to the outer side of the sole structure; and a midsole comprising a foam core nested in the space, the foam core having a side surface, the side surface having a first portion and a second portion, the second portion being recessed inwardly from the first portion at both the inner side and the outer side of the foam core, so that at each of the outer side and the inner side of the foam core A gap is defined between the inner side of the peripheral wall of the outsole and the second portion of the foam core; wherein the midsole includes a mid-layer layer arranged between the foam core and the bottom wall of the outsole, and the mid-layer layer is fixed to the bottom surface of the foam core and the top surface of the bottom wall of the outsole; and wherein the peripheral wall of the outsole is arranged on the outside of the inner side of the foam core and on the outside of the outer side of the foam core; and wherein the peripheral wall of the outsole is attached to the first portion of the side surface of the foam core at the inner side and the outer side of the foam core, and is separated from the second portion of the side surface of the foam core at the inner side and the outer side of the foam core.

[0081] Clause 22. The sole structure of Clause 21, wherein the midsole layer is secured to a third portion of the side surface of the foam core between the second portion of the side surface of the foam core and the bottom wall of the outsole.

[0082] Clause 23. A sole structure according to any of the preceding clauses, wherein: the first portion of the side surface of the foam core includes an elongated inner side strip, which extends from the front of the foam core to the rear of the foam core at the inner side of the foam core in the longitudinal direction of the sole structure above the second portion; and the first portion of the side surface of the foam core also includes an elongated outer side strip, which extends from the front of the foam core to the rear of the foam core at the outer side of the foam core in the longitudinal direction of the sole structure above the second portion.

[0083] Item 24. A sole structure according to Item 23, wherein the medial side elongated strip and the lateral side elongated strip each include: a first leg extending from the bottom surface of the foam core toward the top edge of the foam core, a second leg extending from the first leg around the foam core to the rear of the foam core, and a third leg extending from the second leg toward the bottom surface of the foam core; and the second portion extends from the first leg to the third leg between the second leg and the bottom surface of the foam core.

[0084] Clause 25. The sole structure of Clause 24, wherein a minimum height of the second portion is greater than a maximum height of the second leg portion.

[0085] Clause 26. The sole structure according to any of the preceding clauses further includes: an adhesive layer, which is arranged on the first portion of the side surface of the foam core and adheres the outsole to the first portion of the side surface of the foam core, and the second portion of the side surface has no attachment within the space.

[0086] Clause 27. A sole structure according to any of the preceding clauses, wherein: the second portion of the side surface of the foam core is elastically deformed outwardly into the gap toward the inner side of the peripheral wall of the outsole at both the outer side and the inner side of the foam core under compressive loading.

[0087] Clause 28. The sole structure according to any of the preceding clauses, wherein the bottom wall of the outsole has through holes and the foam core extends over the through holes.

[0088] Clause 29. A sole structure according to any of the preceding clauses, wherein: the peripheral wall of the outsole has a recess, the recess extending from the upper edge of the peripheral wall to the bottom wall of the outsole at the rear of the foam core; and the foam core extends across the recess on the inner side of the peripheral wall.

[0089] Clause 30. The sole structure of any of the preceding clauses, wherein: the foam core has a first stiffness and the outsole has a second stiffness greater than the first stiffness.

[0090] Clause 31. A sole structure according to any one of the preceding clauses, wherein: the foam core is only arranged in the heel area of ​​the sole structure; and the midsole layer extends forward from between the foam core and the outsole in the heel area to the midshoe area and the forefoot area of ​​the sole structure.

[0091] Item 32. A sole structure according to Item 31, wherein the outsole is a heel outsole component and extends only in the heel area of ​​the sole structure; and the sole structure also includes a forefoot outsole component extending below the midsole layer in the forefoot area of ​​the sole structure.

[0092] Clause 33. A sole structure according to any of the preceding clauses, wherein: the side surface of the foam core has a third portion below the second portion; the third portion is recessed inwardly from the second portion; and the midsole layer is bonded to the third portion of the side surface of the foam core.

[0093] Clause 34. A sole structure according to Clause 33, wherein: the side surface of the foam core defines a wavy edge between the second portion and the third portion; and the midsole layer has a wavy upper edge that cooperates with the wavy edge of the side surface.

[0094] To assist and clarify the description of various embodiments, various terms are defined herein. Unless otherwise indicated, the following definitions apply throughout this specification (including claims). In addition, all references mentioned are incorporated herein in their entirety.

[0095] "Articles of footwear," "articles of footwear," and "footwear" may be considered both as machines and manufactured articles. Assembled, ready-to-wear articles of footwear (e.g., shoes, sandals, boots, etc.) and individual components of articles of footwear (such as midsoles, outsoles, upper components, etc.) prior to final assembly into ready-to-wear articles of footwear are considered and may be alternatively referred to herein in the singular or plural as "articles of footwear."

[0096] "A", "an", "the", "at least one" and "one or more" are used interchangeably to indicate that there is at least one of the items. Unless the context clearly indicates otherwise, there may be multiple such items. Unless otherwise explicitly or clearly indicated in view of the context, all numerical values ​​of parameters (e.g., amounts or conditions) in this specification (including the appended claims) should be understood to be modified by the term "approximately" in all cases, regardless of whether "approximately" actually appears before the numerical value. "Approximately" indicates that the numerical value described allows some slight imprecision (some approach to the accuracy of the value; approximately or moderately close to the value; almost). If the imprecision provided by "approximately" is not otherwise understood in this ordinary meaning in the art, then "approximately" as used herein at least indicates the changes that may be caused by the ordinary methods of measuring and using these parameters. In addition, the disclosure of a range should be understood to specifically disclose all values ​​within the range and further divided ranges.

[0097] The terms "comprising", "including" and "having" are inclusive and therefore specify the presence of the stated features, steps, operations, elements or components, but do not exclude the presence or addition of one or more other features, steps, operations, elements or components. The order of steps, processes and operations may be changed when possible, and additional or alternative steps may be adopted. As used in this specification, the term "or" includes any and all combinations of the relevant listed items. The term "any" is understood to include any possible combination of the referenced items, including "any" of the referenced items. The term "any" is understood to include any possible combination of the referenced claims of the appended claims, including "any" of the referenced claims.

[0098] For consistency and convenience, directional adjectives may be used throughout this detailed description corresponding to the illustrated embodiments. One of ordinary skill in the art will recognize that terms such as "above", "below", "upwardly", "downwardly", "top", "bottom", etc. may be used descriptively with respect to the drawings and do not represent limitations on the scope of the invention as defined by the claims.

[0099] The term "longitudinal" refers to a direction extending along the length of a component. For example, the longitudinal direction of a shoe extends between the forefoot region and the heel region of the shoe. The terms "forward" or "anterior" are used to refer to the general direction from the heel region toward the forefoot region, and the terms "rearward" or "posterior" are used to refer to the opposite direction, i.e., the direction from the forefoot region toward the heel region. In some cases, a component can be identified by a longitudinal axis and a forward longitudinal direction and a rearward longitudinal direction along the axis. The longitudinal direction or longitudinal axis may also be referred to as a front-rearward direction or a front-rearward axis.

[0100] The term "transverse" refers to a direction extending along the width of a component. For example, the transverse direction of a shoe extends between the lateral side and the medial side of the shoe. The transverse direction or transverse axis may also be referred to as the lateral direction or lateral axis or the medial direction or medial axis.

[0101] The term "vertical" refers to a direction that is generally perpendicular to both the lateral direction and the longitudinal direction. For example, in the case where the sole is laid flat on a ground surface, the vertical direction may extend upward from the ground surface. It should be understood that each of these directional adjectives may be applied to individual components of the sole. The term "upward" or "upwards" refers to a vertical direction pointing to the top of a component, which may include the instep, fastening area, and / or throat of an upper. The term "downward" or "downwards" refers to a vertical direction that is opposite to the upward direction, pointing to the bottom of a component and may generally point to the bottom of the sole structure of an article of footwear.

[0102] The "interior" of an article of footwear (such as a shoe) refers to the portion of the space occupied by the foot of the wearer when the shoe is worn. The "inner side" of a component refers to the side or surface of the component that is oriented toward (or will be oriented toward) the interior of the component or the article of footwear in the assembled article of footwear. The "outer side" or "exterior" of a component refers to the side or surface of the component that is oriented away from (or will be away from) the interior of the shoe in the assembled shoe. In some cases, other components may be located between the inner side of the component and the interior in the assembled article of footwear. Similarly, other components may be located between the outer side of the component and the space outside the assembled article of footwear. In addition, the terms "inward" and "inwardly" refer to the direction toward the interior of a component or an article of footwear (such as a shoe), and the terms "outward" and "outwardly" refer to the direction toward the exterior of a component or an article of footwear (such as a shoe). In addition, the term "proximal" refers to a direction closer to the center of the footwear component or closer to the foot when the foot is inserted into the footwear article when the footwear article is worn by the user. Similarly, the term "distal" refers to a relative position further away from the center of the footwear component or further away from the foot when the foot is inserted into the footwear article when the footwear article is worn by the user. Therefore, the terms proximal and distal can be understood to provide generally opposite terms to describe relative spatial positions.

[0103] Although multiple embodiments have been described, this description is intended to be exemplary rather than restrictive, and it will be apparent to those of ordinary skill in the art that more embodiments and implementations within the scope of the embodiments are possible. Any feature of any embodiment may be used in combination with or replace any other feature or element in any other embodiment, unless otherwise limited. Therefore, the embodiments are not limited except in accordance with the appended claims and their equivalents. Moreover, various modifications and variations may be made within the scope of the appended claims.

[0104] Although several modes for implementing many aspects of the present teachings have been described in detail, those skilled in the art to which these teachings relate will recognize a variety of alternative aspects of implementing the present teachings within the scope of the appended claims. It is intended that all content contained in the above description or shown in the accompanying drawings should be interpreted as an illustration and example of the overall range of alternative embodiments that will be recognized by ordinary technicians, such as implied by the included content, structurally and / or functionally equivalent to the included content, or otherwise obvious based on the included content, and not limited to only those explicitly depicted and / or described embodiments.

Claims

1. A sole structure for an article of footwear, the sole structure comprising: a sole component having a bottom wall and a peripheral wall extending upward from the bottom wall and partially surrounding a space above the bottom wall; as well as a midsole comprising a foam core nested in the space; wherein the perimeter wall of the sole component is disposed outside the side surface of the foam core; and wherein the sole component is attached to a first portion of the side surface and is separate from a second portion of the side surface, the second portion of the side surface being disposed between the first portion and the bottom wall, and a portion of the second portion of the side surface is higher than a top of a foot-supporting surface of the foam core, The second portion of the side surface of the foam core is recessed inwardly from the first portion, thereby defining a gap between an interior side of the peripheral wall of the sole component and the second portion of the side surface of the foam core.

2. The sole structure according to claim 1, further comprising: An adhesive layer is disposed on the first portion of the side surface of the foam core and adheres the sole component to the first portion of the side surface of the foam core, the second portion of the side surface being free of any attachment within the space.

3. The sole structure according to claim 2, wherein: The second portion of the side surface of the foam core elastically deforms outwardly into the gap toward the interior side of the perimeter wall of the sole component under compressive loading.

4. The sole structure according to any one of claims 1 to 3, wherein: The bottom wall of the sole component has a through hole, and the foam core extends over the through hole.

5. The sole structure according to any one of claims 1 to 4, wherein: The perimeter wall of the sole component is adjacent to and extends outboard of the side surface of the foam core at a medial side, a lateral side, and a rear portion of the sole structure.

6. The sole structure according to claim 5, wherein: The peripheral wall of the sole component has a recess extending from an upper edge of the peripheral wall to the bottom wall of the sole component at a rear portion of the foam core; and The foam core extends across the recess inside the perimeter wall.

7. The sole structure according to any one of claims 1 to 6, wherein: The first portion of the side surface of the foam core includes an elongated strip extending from a front portion of the foam core to a rear portion of the foam core in a longitudinal direction of the sole structure over the second portion.

8. The sole structure according to any one of claims 1 to 6, wherein: the first portion of the side surface of the foam core includes an elongated strip having a first leg extending from a bottom surface of the foam core toward a top edge of the foam core, a second leg extending from the first leg around the foam core to a rear portion of the foam core, and a third leg at the rear portion of the foam core and extending from the second leg toward the bottom surface of the foam core; and The second portion extends from the first leg to the third leg between the second leg and the bottom surface of the foam core.

9. The sole structure of claim 8, wherein a minimum height of the second portion is greater than a maximum height of the second leg portion.

10. The sole structure according to any one of claims 1 to 9, wherein: The foam core has a first stiffness, and the sole component has a second stiffness greater than the first stiffness.

11. The sole structure of any one of claims 1-10, wherein the sole component is an outsole and comprises a ground contacting surface of the sole structure.

12. The sole structure according to claim 11, further comprising: A midsole layer extends between a top surface of the sole component and a bottom surface of the foam core.

13. The sole structure according to claim 12, wherein: The bottom surface of the foam core is secured to the top surface of the mid-layer; and A bottom surface of the midsole layer is secured to the top surface of the sole component.

14. The sole structure according to claim 12, wherein: The foam core is disposed only in a heel region of the sole structure; and The midsole layer extends forwardly from between the foam core and the sole component in the heel area to the midfoot area and the forefoot area of ​​the sole structure.

15. The sole structure according to claim 12, wherein: the side surface of the foam core having a third portion below the second portion; The third portion is recessed inwardly from the second portion; and The mid-layer is bonded to the third portion of the side surface of the foam core.

16. The sole structure according to claim 15, wherein: The side surface of the foam core defines a corrugated edge between the second portion and the third portion; and The mid-bottom layer has a corrugated upper edge that mates with the corrugated edge of the side surface of the foam core.

17. A sole structure for an article of footwear, the sole structure comprising: an outsole having a bottom wall and a perimeter wall extending upward from the bottom wall and partially enclosing a space above the bottom wall, the perimeter wall forming a cup from a medial side of the sole structure around a rear portion of a heel region of the sole structure to a lateral side of the sole structure; as well as a midsole comprising a foam core nested in the space, the foam core having a side surface, the side surface having a first portion and a second portion, the second portion being recessed inwardly from the first portion at both a medial side and a lateral side of the foam core, thereby defining a gap between an inner side of the peripheral wall of the outsole and the second portion of the side surface of the foam core at each of the lateral side and the medial side of the foam core; wherein a portion of the second portion of the side surface of the foam core is higher than a top of a foot-supporting surface of the foam core; wherein the midsole comprises a mid-layer layer disposed between the foam core and the bottom wall of the outsole, the mid-layer layer being fixed to a bottom surface of the foam core and a top surface of the bottom wall of the outsole; and wherein the peripheral wall of the outsole is disposed on the outside of the medial side of the foam core and on the outside of the lateral side of the foam core; and wherein the peripheral wall of the outsole is attached to the first portion of the side surface of the foam core at the medial side and the lateral side of the foam core, and is separated from the second portion of the side surface of the foam core at the medial side and the lateral side of the foam core.

18. The sole structure of claim 17, wherein the midsole layer is secured to a third portion of the side surface of the foam core between the second portion of the side surface of the foam core and the bottom wall of the outsole.

19. The sole structure according to any one of claims 17-18, wherein: The foam core is disposed only in a heel region of the sole structure; and The midsole layer extends forwardly from between the foam core and the outsole in the heel area to the midfoot area and the forefoot area of ​​the sole structure.

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