Footwear sole structure with bladder

Abstract

A sole structure includes a midsole having a lower surface with a first recess having an outer perimeter spaced medially from an outer perimeter of the midsole and a perimeter junction area between the outer perimeter of the midsole and the outer perimeter of the first recess. A sole plate has an upper surface with a second recess forming a cavity between the sole plate and the midsole with the first recess. The upper surface of the sole plate has a perimeter junction area between an outer perimeter of the sole plate and an outer perimeter of the second recess. A bladder is nested in the cavity by a contoured upper surface medially within the perimeter junction area of the midsole and a contoured lower surface medially within the perimeter junction area of the sole plate. Methods of manufacturing the sole structure are disclosed.

Description

[0001] This application is a Divisional Application of Application No. 201980029953.1, titled "FOOTWEAR SOLE STRUCTURE WITH BLADDER," filed on May 22, 2019.

[0002] Cross Reference to Related Applications

[0003] This application claims priority to U.S. Provisional Patent Application No. 62 / 678,251, filed on May 30, 2018, the contents of which are incorporated by reference in their entirety. TECHNICAL FIELD

[0004] The present teachings relate generally to sole structures for articles of footwear. BACKGROUND

[0005] Shoes typically include a sole structure configured to be located under a wearer's foot to space the foot from the ground. The sole structure can typically be configured to provide one or more of cushioning, motion control, and resiliency. BRIEF DESCRIPTION OF DRAWINGS

[0006] Figure 1 is a schematic side view of a sole structure;

[0007] Figure 2 is a schematic top view of the sole structure of Figure 1

[0008] Figure 3 is a schematic bottom view of the sole structure of Figure 1

[0009] Figure 4 is a schematic exploded perspective view of the sole structure of Figure 1

[0010] is a schematic top view of a polymer bladder included in the sole structure of Figure 5 Figure 1

[0011] Figure 6 is a schematic bottom view of the polymer bladder of Figure 5

[0012] Figure 7 is a schematic cross-sectional view of the polymer bladder of taken along line 7-7 in Figure 5 Figure 5

[0013] Figure 8 is a schematic view of the medial side of the polymer bladder of Figure 5

[0014] Figure 9 is a schematic view of the forefoot region of the sole structure of taken along line 8-8 in Figure 2 Figure 2 ​​​​​​​​​schematic cross-sectional view taken along line 9-9 in

[0015] Figure 10 is a schematic cross-sectional view of a forefoot region of the sole structure of Figure 2 Figure 2 is a schematic cross-sectional view taken along line 10-10 in

[0016] Figure 11 is a schematic cross-sectional view of a forefoot region of the sole structure of

[0017] Figure 12 is a schematic cross-sectional view of a forefoot region of the sole structure of Figure 11 DETAILED DESCRIPTION

[0018] An inflation bladder can have contoured surfaces near its outer periphery to provide desired cushioning characteristics, responsiveness, and / or motion control. Bonding to contoured surfaces presents greater manufacturing challenges than bonding to relatively flat surfaces. The sole structure for an article of footwear provided herein has cooperating bladders, midsoles, and outsoles that are stacked together to capture the bladders between the midsoles and the outsoles, achieving secure bonding at the periphery of the sole structure while accommodating contoured surfaces of the bladders near their outer periphery. In addition, the sole structure can provide graded cushioning with different cushioning characteristics in different regions of the sole structure.

[0019] A sole structure for an article of footwear can include a midsole, an outsole, and a polymer bladder. The midsole can have a lower surface with first recesses and a peripheral bonding region between an outer periphery of the outsole and an outer periphery of the first recesses. The outer periphery of the first recesses can be spaced inward of the outer periphery of the midsole. The outsole can have an upper surface with second recesses disposed between the first recesses of the midsole. The first recesses and the second recesses can together form a cavity between the outsole and the midsole. The upper surface of the outsole can have a peripheral bonding region between an outer periphery of the outsole and an outer periphery of the second recesses. The polymer bladder can be nested in the cavity between the midsole and the outsole with a contoured upper surface of the polymer bladder inward of the peripheral bonding region of the midsole and a contoured lower surface of the polymer bladder inward of the peripheral bonding region of the outsole. Because the midsole and the outsole are configured to allow the bladder to be nested in the recesses with bonding regions outward of the contoured upper and lower surfaces, secure bonding near the bonding regions and desired cushioning characteristics of the contoured surfaces can both be achieved.

[0020] ​​In one or more embodiments, the bond can be at a peripheral flange of the polymer bladder. For example, the polymer bladder can have a peripheral flange that establishes at least a portion of an outer periphery of the polymer bladder and at least partially surrounds the fluid-filled interior cavity. The peripheral flange can be disposed between a peripheral bonding region of the midsole and a peripheral bonding region of the sole plate. The peripheral bonding region of the midsole can be bonded to an upper side of the peripheral flange, and the peripheral bonding region of the sole plate can be bonded to a lower side of the peripheral flange.

[0021] Alternatively, in one or more other embodiments, the peripheral bonding region of the midsole can be bonded to the peripheral bonding region of the sole plate. For example, the entire polymer bladder can be inboard of the peripheral bonding regions, while the midsole and the sole plate contact each other at the bonding regions outboard of the polymer bladder.

[0022] In one or more embodiments, the midsole and the sole plate can be configured to respectively mate with an upper surface and a lower surface of the polymer bladder. The contoured upper surface of the polymer bladder can mate with a lower surface of the midsole in a first recess. Similarly, the contoured lower surface of the polymer bladder can mate with an upper surface of the sole plate in a second recess. Thus, in such embodiments, and within dimensional tolerances of a manufacturing process for the components used to form the sole structure, a surface profile of the contoured upper surface of the polymer bladder is configured to be the same as a surface profile of the lower surface of the midsole in the first recess, such that the surfaces coincide. Similarly, a surface profile of the contoured lower surface of the polymer bladder can be configured to be the same as a surface profile of the upper surface of the sole plate in the second recess, such that the surfaces coincide.

[0023] In one or more embodiments, the contoured upper surface of the polymer bladder can include a plurality of circular protrusions, and the lower surface of the midsole can include a plurality of circular cavities corresponding to the plurality of circular protrusions. In the same or in one or more different embodiments, the contoured lower surface of the polymer bladder can include a plurality of domed portions, and the upper surface of the sole plate can include a plurality of circular cavities corresponding to the plurality of domed portions.

[0024] The polymer bladder can include an upper polymer sheet and a lower polymer sheet that are bonded to one another and enclose a fluid-filled interior cavity. A tensile member can be disposed in the fluid-filled interior cavity. For example, the tensile member can include a first tensile layer secured to the upper polymer sheet, a second tensile layer, and a plurality of tethers connecting the first tensile layer to the second tensile layer. The lower polymer sheet can be joined to the second tensile layer at a plurality of lower bonds, and the lower polymer sheet can be displaced from the second tensile layer between at least some of the lower bonds by fluid in the fluid-filled interior cavity. For example, if the lower bonds are arranged to form a closed shape, the portion of the lower polymer sheet surrounded by the closed shape is unbonded (i.e., unbonded to the second tensile layer) and thus can be displaced from the second tensile layer by fluid, forming a domed surface. In such embodiments, a majority of the profile at an upper surface of the polymer bladder can extend along the medial side and the lateral side. Due to the domed portion, a majority of a lower surface of the polymer bladder can have a profile. For example, the lower surface of the polymer bladder can have a domed surface across its entirety.

[0025] In one or more embodiments, a plurality of upper bonds join the upper polymer sheet to the first tensile layer. The upper polymer sheet can be displaced from the first tensile layer between the upper bonds along the medial side of the polymer bladder by fluid in the fluid-filled interior cavity, forming a plurality of circular protrusions extending along the medial side. The upper polymer sheet can also be displaced from the first tensile layer between the upper bonds along the lateral side of the polymer bladder by fluid in the fluid-filled interior cavity, forming a plurality of circular protrusions extending along the lateral side. The upper polymer sheet can be secured to the first tensile layer between the circular protrusions along the lateral side and the circular protrusions along the medial side, and thus does not form protrusions or a domed surface in the regions where it is secured to the first tensile layer. Between the circular protrusions along the lateral side and the medial side, the polymer bladder can be relatively flat.

[0026] The midsole can be configured in a complementary manner (i.e., have a complementary geometry) to interfit with the particular profiled shape of the upper polymer sheet, and the plate can be configured to interfit with the particular profiled shape of the lower polymer sheet. For example, a lower surface of the midsole can include a plurality of circular recesses corresponding to the plurality of circular protrusions of the upper polymer sheet along the medial side and the lateral side of the polymer bladder, such that the lower surface of the midsole lies flush against the profiled upper surface of the polymer bladder. A profiled lower surface of the polymer bladder can include a plurality of domed portions at which the lower polymer sheet is displaced from the second tensile layer by fluid in the fluid-filled interior cavity, and an upper surface of the plate can include a plurality of circular recesses corresponding to the plurality of domed portions, such that the upper surface of the plate lies flush against the profiled lower surface of the polymer bladder.

[0027] In one or more embodiments, the midsole can define a through-hole extending through the midsole over the polymer bladder. This can allow the polymer bladder to be seen through the through-hole. The cushioning received by the portion of the wearer's foot resting on the sole structure at the through-hole will be primarily provided by the polymer bladder. The cushioning received by the portion of the wearer's foot resting on the sole structure away from the through-hole can be provided by the combination of the midsole and the polymer bladder underneath the midsole as both components are vertically stacked underneath that portion of the wearer's foot.

[0028] The sole plate can provide a variety of properties and features. For example, the sole plate can be stiffer than the midsole and bladder in both compressive stiffness and bending stiffness. The sole plate can have integral cleat mounting features that can extend away from the bladder on the outer surface of the sole plate. For example, the cleat mounting features can be downwardly extending protrusions with central apertures each configured to receive and retain a cleat.

[0029] Additionally, the sole plate can have a forefoot region, a midfoot region, and a heel region, and the sole structure can include a forked reinforcement plate that is secured to or integrally formed as part of the sole plate. The forked reinforcement plate can have a central portion. The central portion can be in the midfoot region of the sole plate. The forked reinforcement plate can have a front medial arm and a front lateral arm each extending forward from the central portion. The forked reinforcement plate can have a rear medial arm and a rear lateral arm each extending rearward from the central portion. The front medial arm and the rear medial arm can abut the medial side of the sole plate, and the front lateral arm and the rear lateral arm can abut the lateral side of the sole plate. The forked reinforcement plate increases the thickness of the sole structure and the bending stiffness of the sole structure in the areas where the forked reinforcement plate extends. By extending along the lateral and medial sides, increased support is provided to react forces in these areas, such as due to side-to-side motion.

[0030] Furthermore, the arms of the forked reinforcement plate generally correspond to and are located underneath the portions of the polymer bladder that have domed portions at the medial and lateral sides of the bladder lower surface. The additional cushioning of the domed portions and the additional support of the forked reinforcement plate provide comfort and support during side-to-side motion.

[0031] The arms of the forked reinforcement plate can also extend along those portions of the sole plate that have cleat mounting features. Thus, the sole plate is reinforced in areas that can experience higher stresses due to forces transmitted to the sole plate on cleats.

[0032] A method for manufacturing a sole structure for an article of footwear includes stacking a sole plate, a polymer bladder, and a midsole such that the polymer bladder is nested in a cavity formed by a first recess in a lower surface of the midsole and a second recess in an upper surface of the sole plate. As stacked, a contoured upper surface of the polymer bladder is inboard of a peripheral bonding region of the midsole, and a contoured lower surface of the polymer bladder is inboard of a peripheral bonding region of the sole plate. The polymer bladder defines a sealed, fluid-filled interior cavity. The method further includes securing the midsole relative to the sole plate at the peripheral bonding region of the midsole.

[0033] In one or more embodiments, the midsole is secured directly to the sole plate. More particularly, securing the midsole relative to the sole plate can include bonding a peripheral bonding region of the midsole to a peripheral bonding region of the sole plate. In such embodiments, the polymer bladder is entirely inboard of the peripheral bonding region.

[0034] In other embodiments, the midsole is secured to a peripheral flange of the polymer bladder. More particularly, in such embodiments, the polymer bladder has a peripheral flange that establishes at least a portion of an outer periphery of the polymer bladder and at least partially surrounds the fluid-filled interior cavity. Securing the midsole relative to the sole plate includes bonding a peripheral bonding region of the midsole to an upper side of the peripheral flange, and bonding a peripheral bonding region of the sole plate to a lower side of the peripheral flange.

[0035] The method can further include inflating the fluid-filled interior cavity of the polymer bladder prior to stacking the sole plate, the polymer bladder, and the midsole. Accordingly, the lower surface of the midsole and the upper surface of the sole plate are configured to conform to the contoured surfaces of the inflated polymer bladder.

[0036] The method can further include securing a forked reinforcement plate to the sole plate. The forked reinforcement plate can be secured to the upper surface of the sole plate, in which case it is positioned between the sole plate and the polymer bladder. In other embodiments, the forked reinforcement plate can be secured to the lower surface of the sole plate. Alternatively, the forked reinforcement plate can be integrally formed with the sole plate.

[0037] The midsole, the polymer bladder, and the sole plate can be provided in a formed state, ready to be stacked. In other embodiments, the method can include forming one or more of the midsole, the polymer bladder, or the sole plate.

[0038] For example, the method can include, prior to stacking the sole plate, the polymer bladder, and the midsole, forming the lower surface of the midsole to have a first recess and a plurality of concavities, the midsole being configured to cooperate with a plurality of rounded protrusions of the contoured upper surface of the polymer bladder at the plurality of concavities.

[0039] For example, the method can include, prior to stacking the sole plate, the polymer bladder, and the midsole, forming an upper surface of the sole plate having the second recess and the plurality of concavities, the sole plate being configured to mate with the plurality of domed portions of the contoured lower surface of the polymer bladder at the plurality of concavities.

[0040] The method can include, prior to stacking the sole plate, the polymer bladder, and the midsole, forming the polymer bladder by disposing a stretch component between the upper polymer sheet and the lower polymer sheet, the stretch component including a first stretch layer, a second stretch layer, and a plurality of tethers connecting the first stretch layer to the second stretch layer. Forming the polymer bladder can further include bonding the lower polymer sheet to the upper polymer sheet around the stretch component and to the second stretch layer at a plurality of bonds. The lower polymer sheet can be unbonded to the second stretch layer adjacent to at least some of the bonds and displaced from the second stretch layer by fluid in the fluid-filled internal cavity when the fluid-filled internal cavity is inflated.

[0041] The above features and advantages and other features and advantages of the present teachings are readily apparent from the following detailed description of modes for carrying out the present teachings, taken in connection with the accompanying drawings.

[0042] Referring to the drawings, wherein like reference numerals refer to like elements throughout the several views, Figure 1 A sole structure 10 for an article of footwear 11 is shown. The sole structure 10 includes a midsole 12, a polymer bladder 14 (also referred to as bladder 14), such as shown in Figure 7 , and a sole plate 16 that cooperate with one another and are stacked together to capture the polymer bladder 14 between the midsole 12 and the sole plate 16, as Figures 9-12 best shown and described herein. The sole structure 10 can also include a cleat plate 19 that is secured to or integrally formed as part of the sole plate 16. The midsole 12 has an upper surface 18 that serves as a foot-receiving surface on which a foot is supported when the sole structure 10 is secured to a lower extent of an upper 23 (indicated by dashed lines in Figure 1 ) with the sole structure 10 disposed between the foot and the ground.

[0043] The sole structure 10 has a forefoot portion 22, a midfoot portion 24, and a heel portion 26. The forefoot region 22 can be generally associated with the toes and the joints connecting the metatarsal bones with the phalangeal bones. The midfoot region 24 can be generally associated with the arch. The heel region 26 can be generally associated with the heel, including the calcaneus bone. The sole structure 10 has a lateral side 28 and a medial side 30. In particular, the lateral side 28 and the medial side 30 can be opposite sides of the sole structure 10 and can extend along the forefoot region 22, the midfoot region 24, and the heel region 26. As shown, the sole structure 10 is for an athletic shoe, such as, but not limited to, for athletic activities, such as baseball. In other embodiments, the article of footwear 11 can be a dress shoe, a work shoe, a sandal, a slipper, a boot, or any other category of shoe.

[0044] The midsole 12 can be a layer of resilient foam that provides cushioning and that is elastically deformable to provide energy return. As non-limiting examples, the midsole 12 can include any of polyurethane foam, polyurethane ethylene-vinyl acetate (EVA) foam, and thermally expanded and molded EVA foam particles. In Figure 2 Only a portion of the upper surface 32 of the polymer bladder 14 is visible in FIG. 1 through a through-hole 34 that extends through the midsole 12 in the forefoot region 22 of the midsole 12.

[0045] Referring to Figure 7 The polymer bladder 14 includes an upper polymer sheet 36 and a lower polymer sheet 38 that are joined to one another along a peripheral flange 41 at a peripheral junction 40 to enclose an interior cavity 42. The peripheral flange 41 establishes an outer periphery 43 of the polymer bladder 14 and surrounds the fluid-filled interior cavity 42 peripherally. When the sheets 36, 38 are joined together and sealed together at the peripheral junction 40, for example, by a sealant Figure 5 and 6 The upper polymer sheet 36 and the lower polymer sheet 38 retain the fluid in the interior cavity 42 as shown, for example, through an inflation port 44. As used herein, the "fluid" that fills the interior cavity 42 can be a gas, such as air, nitrogen, another gas, or a combination thereof.

[0046] The upper and lower polymer sheets 36, 38 can be various polymeric materials capable of elastically retaining a fluid such as nitrogen, air, or another gas. Examples of polymeric materials for the upper and lower polymer sheets 36, 38 include thermoplastic polyurethane, polyurethane, polyester, polyester polyurethane, and polyether polyurethane. In addition, the upper and lower polymer sheets 36, 38 can each be formed from different layers of material including polymeric materials. In one embodiment, each of the upper and lower polymer sheets 36, 38 is formed from a film having one or more layers of thermoplastic polyurethane with one or more barrier layers of ethylene and vinyl alcohol copolymer (EVOH) that are impermeable to the pressurized fluid contained therein, such as a flexible microlayer film including alternating layers of a gas barrier material and an elastomeric material, as disclosed in U.S. Patent Nos. 6,082,025 and 6,127,026 to Bonk et al., which are incorporated herein by reference in their entirety. Alternatively, the layers can include ethylene-vinyl alcohol copolymer, thermoplastic polyurethane, and regrind of ethylene-vinyl alcohol copolymer and thermoplastic polyurethane. Other suitable materials for the upper and lower polymer sheets 36, 38 are disclosed in U.S. Patent Nos. 4,183,156 and 4,219,945 to Rudy, which are incorporated herein by reference in their entirety. Other suitable materials for the upper and lower polymer sheets 36, 38 include thermoplastic films containing crystalline materials, as described in U.S. Patent Nos. 4,936,029 and 5,042,176 to Rudy, and polyurethanes including polyester polyols, as described in U.S. Patent Nos. 6,013,340, 6,203,868, and 6,321,465 to Bonk et al., which are incorporated herein by reference in their entirety. In selecting materials for the bladder 14, engineering properties such as tensile strength, tensile properties, fatigue properties, dynamic modulus, and tangent delta can be considered. For example, the thickness of the upper and lower polymer sheets 36, 38 used to form the bladder 14 can be selected to provide these properties.

[0047] As Figure 7 As best shown, the bladder 14 includes a stretch member 46 disposed in the interior cavity 42. The stretch member 46 includes a first stretch layer 48, a second stretch layer 50, and a plurality of tethering strands 52 spanning the interior cavity 42 from the first stretch layer 48 to the second stretch layer 50. The tethering strands 52 connect the first stretch layer 48 to the second stretch layer 50. In the embodiment shown, the first stretch layer 48 is a first sheet of thermoplastic polyurethane, and the second stretch layer 50 is a second sheet of thermoplastic polyurethane. The tethering strands 52 are formed from a thermoplastic polyurethane material that is the same as the first and second stretch layers 48, 50. In other embodiments, the tethering strands 52 can be formed from a different material than the first and second stretch layers 48, 50. In one embodiment, the tethering strands 52 are formed from a material that is more elastic than the first and second stretch layers 48, 50. In another embodiment, the tethering strands 52 are formed from a material that is less elastic than the first and second stretch layers 48, 50. Figure 7In the middle, only some of the tether 52 are indicated with reference numerals. The tether 52 can also be referred to as a fabric stretch member or thread, and can be in the form of a drop thread connecting the first stretch layer 48 and the second stretch layer 50. The stretch component 46 can be formed as a unitary one-piece fabric element having a spacer knit fabric. It should be appreciated that the first stretch layer 48 and the second stretch layer 50 are permeable to gas in the interior cavity 42. In this way, the interior cavity 42 extends through the first stretch layer 48 and the second stretch layer 50 between and around the tether 52 from the inner surface of the upper polymer sheet 36 to the inner surface of the lower polymer sheet 38.

[0048] With reference to Figure 5 and 7 The upper polymer sheet 36 is bonded to the upper surface of the first stretch layer 48 at a plurality of bonds 54 that can be formed by a projection of a molding tool used during radio frequency welding, thermoforming or other forming process and force the upper polymer sheet 36 against the first stretch layer 48. The bonds 54 project inwardly into the interior cavity 42 and slightly deform the upper polymer sheet 36, creating a groove 56. The tether 52 that is aligned with (i.e., directly below) the inwardly projecting bond 54 is deformed by heat, by compression of the overlying material of the first stretch layer 48 and / or by the overlying material of the first stretch layer 48 overlying the tether 52, such that the tether 52 is shorter, thicker, or both shorter and thicker at the inwardly projecting bond 54 than elsewhere. Such a tether is indicated in Figure 7 by reference numeral 52A and can be referred to as a modified tether. However, reference herein to the tether 52 includes both the tether 52 and the modified tether 52A, unless otherwise indicated.

[0049] The modified tether 52A results in a recessed groove 56 in the upper surface 32 of the bladder 14 when the interior cavity 42 is inflated. The bonds 54 and the resulting grooves 56 are arranged to define a closed shape, which can be polygonal, as best shown in Figure 5 or alternatively can be circular, oval, etc. The grooves 56 facilitate articulation of the bladder 14 because the overall thickness of the bladder 14 is reduced at the grooves 56, reducing the bending stiffness. The pattern of bonds 54 and resulting grooves 56 can be arranged such that the grooves 56 present an articulation axis at locations where articulation is desired, for example, under the metatarsal phalangeal joints.

[0050] In Figure 5 for clarity in the drawings, only some of the bonds 54 are indicated. A non-weld material is applied to selected areas of the outer surface of the first stretch layer 48 and / or the inner surface of the upper polymer sheet 36 where it is not desired to bond the first stretch layer 48 to the upper polymer sheet 36. In Figure 5The circular protrusions 60 are provided in the illustrated position, and the solder resist material is applied only along the periphery of the first stretch layer 48 and / or the upper polymer sheet 36, where it covers the periphery along the medial side, the lateral side, and around the posterior portion of the heel region 26 between the portions of the outermost closed shapes at the junctions 54. The upper polymer sheet 36 is not bonded to the first stretch layer at those portions, and is displaced from the first stretch layer 48 along the medial side 28 of the polymer bladder 14 due to the fluid in the fluid-filled interior cavity 42, forming a plurality of circular protrusions 60 along the medial side 30 where the upper polymer sheet 36 is displaced from the first stretch layer 48, along the lateral side 28 of the polymer bladder 14, and around the posterior portion of the heel region 26.

[0051] As Figure 5 illustrated, the portions of the upper polymer sheet 36 between the forwardmost closed shapes formed by the junctions 54 are bonded to the first stretch layer 48 at surface junctions 55, as are the portions between the closed shapes formed by the junctions 54, and the portions falling between the circular protrusions 60 along the lateral side 30 and the circular protrusions 60 along the medial side 28 (i.e., laterally across Figure 5 the upper surface 32 in FIG. 1). Only some of the surface junctions 55 are labeled in Figure 5 FIG. 1, but the portions not labeled as circular protrusions 60 have surface junctions 55 at all of the closed shapes. Thus, the upper polymer sheet 36 is not displaced from the first stretch layer 48 in these areas, and thus does not form protrusions or domed surfaces in these areas. In other words, the upper polymer sheet 36 has a contoured upper surface 32 with circular protrusions 60 along the lateral side 30 and the medial side 28, and around the posterior portion of the heel region 26. The upper polymer sheet 36 extends relatively flat across the circular protrusions 60 of the upper surface 32, due to the absence of solder resist material.

[0052] Referring to Figure 6 and 7 , solder resist material is also applied to the outer surface of the second stretch layer 50 and / or the inner surface of the lower polymer sheet 38 at selected areas where bonding is not desired. The solder resist material is applied not only at the portions between the junctions 54 in the same areas as the upper polymer sheet 36 (i.e., at the outermost closed shapes along the medial side 30, the lateral side 28, and around the periphery of the posterior portion of the heel region 26), but also at the portions between the junctions 54 at the more inwardly disposed closed shapes in the heel region 26, and at the posterior extensions of the midfoot region 24. This results in domed portions 61 similar to the circular protrusions 60 when the bladder 14 is inflated. As used herein, "domed" means rounded, and is not necessarily hemispherical.

[0053] The portions of the lower polymer sheet 38 between the forward-most rows of closed shapes formed by the bonds 54 are bonded to the second stretch layer 50 at surface bonds 55, as between the closed shapes formed by the bonds 54 between the domed protrusions 61 along the lateral side 28 and the domed protrusions 61 along the medial side 30 (i.e., transversely across the Figure 6 lower surface 62 of the bladder 14 in the forefoot region 22 and the forward extent of the midfoot region 24). Only some of the surface bonds 55 are labeled in Figure 6 but the surface bonds 55 are not labeled as domed portions 61 at all of the closed shapes. Thus, the lower polymer sheet 38 is not displaced from the second stretch layer 50 in these regions having the surface bonds 55, and thus does not form protrusions or domed surfaces in these regions. In other words, the lower polymer sheet 40 has a contoured lower surface 62 with domed portions 61 everywhere but the forward extent of the midfoot region 24 between the domed portions 61 at the lateral side 30 and the medial side 28 and the relatively flat extent in the forefoot region 22. In the portions of the lower polymer sheet 38 having the surface bonds 55, a slight concave can be formed at the upper polymer sheet 36 across from the inwardly protruding bonds 54 due to the tensioning force caused by the shortened and thickened tether 52A. Positioning the rounded protrusions 60 and domed portions 61 along the lateral and medial sides 28, 30 provides cushioning that reacts to at least some lateral (i.e., laterally toward the medial side 30 or toward the lateral side 28) forces that can be caused by transverse cutting motions of the wearer's foot.

[0054] The midsole 12 and bladder 14, including the rounded protrusions 60 and domed portions 61, provide staged cushioning under compressive forces experienced during dynamic loading of the sole structure 10. For example, if the midsole 12 has a lower compressive stiffness than the pneumatic bladder 14, a first stage of cushioning can occur as the midsole 12 begins to compress, while a second stage of cushioning occurs as the harder bladder 14 subsequently begins to compress, the rounded protrusions 60 and / or domed portions 61 at least partially flattening under the dynamic load. The sole plate 16 and cleat 19 can be stiffer than the midsole 12 and bladder 14. For example, the sole plate 16 and cleat 19 can be carbon fiber, carbon fiber composite (e.g., carbon fiber filled nylon, glass fiber reinforced nylon, which can be injection molded fiber reinforced nylon), fiber twisted composite, thermoplastic elastomer, steel, or other materials or combinations of these materials, but are not limited to these materials. As the bladder 14 is compressed, it reacts against the conformal surface of the sole plate 16. Both the midsole 12 and the polymer bladder 14 are elastic, and return at least some of their deformation energy when the dynamic compressive load is removed.

[0055] The contoured upper surface 32 and the contoured lower surface 62 of the polymer bladder 14 present challenges for securely bonding, particularly at the lateral and medial sides 28, 30, to adjacent components of the sole structure 10. This can be due to the bonding process, which typically involves the application of pressure in the vertical direction (i.e., normal to the Figure 5 and 6 top and bottom views) relative to the bladder 14, which can be less effective when bonding with surfaces having a large profile with normal vectors at a large angle to the vertical direction.

[0056] To address this issue, the polymer bladder 14, the midsole 12, and the sole plate 16 are configured to stack together to capture the bladder 14 between the midsole 12 and the sole plate 16, so that the bonding occurs laterally of the contoured surfaces. More particularly, as Figure 4 and 9 -12 best shown, the midsole 12 has a lower surface 70 with a first recess 72. The first recess 72 has an outer periphery 74 that is spaced apart from an outer periphery 76 of the midsole 12 at the medial side. A perimeter bonding region 78 of the lower surface 70 is disposed between the outer periphery 76 of the midsole 12 and the outer periphery 74 of the first recess 72. Similarly, the sole plate 16 includes an upper surface 80 with a second recess 82 that is aligned with the first recess 72 of the midsole 12 to define a cavity 84 between the sole plate 16 and the midsole 12. The upper surface 80 of the sole plate 16 has a perimeter bonding region 86 between an outer periphery 88 of the sole plate 16 and an outer periphery 90 of the second recess 82.

[0057] The polymer bladder 14 is nested in the cavity 84 between the midsole 12 and the sole plate 16 with the contoured upper surface 32 of the polymer bladder 14 laterally of the perimeter bonding region 78 of the midsole 12 and the contoured lower surface 62 of the polymer bladder laterally of the perimeter bonding region 86 of the sole plate 16. The midsole 12 and the sole plate 16 can be configured to cooperate with the polymer bladder 14 at its upper and lower surfaces 32, 62. As Figures 9-12 shown, the contoured upper surface 32 of the polymer bladder 14 cooperates with the lower surface 70 of the midsole 12 in the first recess 72. As Figure 4 and 9 -12 shown, the lower surface 70 of the midsole 12 can include a plurality of circular cavities 92 that correspond to the plurality of circular protrusions 60 of the contoured upper surface 32 of the polymer bladder 14 along the medial and lateral sides 30, 28 of the polymer bladder 14, so that the lower surface 70 of the midsole 12 lies flush against the contoured upper surface 32 of the polymer bladder 14. Only some of the circular cavities 92 and circular protrusions 60 are labeled in Figure 4 .

[0058] Similarly, the contoured lower surface 62 of the polymer bladder 14 mates with the upper surface 80 of the sole plate 16 in the second recess 82. The upper surface 80 of the sole plate 16 includes a plurality of circular cavities 94 that correspond to the plurality of domed portions 61 of the bottom surface 62 of the polymer bladder 14, such that the upper surface 80 of the sole plate 16 lies flush against the contoured lower surface 62 of the polymer bladder 14. The sole plate 16 can be of a transparent material, such that the polymer bladder 14 can be seen through the sole plate at the bottom and sides of the sole structure, such as Figure 3 is transparent at least in those portions not covered by the forked reinforcing plate 19. If the forked reinforcing plate 19 is not transparent, or if the forked reinforcing plate 19 is transparent, it is not transparent in all portions.

[0059] The midsole 12 is thus configured in a geometrically complementary manner to intermate with the particular contoured shape of the upper polymer sheet 36, and the sole plate 16 is configured to intermate with the particular contoured shape of the lower polymer sheet 38 of the pneumatic polymer bladder 14.

[0060] Thus, within the dimensional tolerances of the manufacturing process for the components used to form the sole structure 10, the surface profile of the contoured upper surface 32 of the polymer bladder 14 is configured to be identical to the surface profile of the lower surface 70 of the midsole 12 in the first recess 72, such that these surfaces 32, 70 coincide. The surface profile of the contoured lower surface 62 of the polymer bladder 14 is configured to be identical to the surface profile of the upper surface 80 of the sole plate 16 in the second recess 82, such that the surfaces 62, 80 can coincide at least in embodiments where any forked reinforcing plate 19 is located at the lower surface 102 of the sole plate 16. As Figure 4 shown, the bladder 14 is shorter in length than the midsole 12 and the sole plate 16. In front of the forward edge 81 of the bladder 14, the joining region 78 of the midsole 12 contacts and directly joins to the joining region 86 of the sole plate 16. For clarity of the drawing, Figure 4 The closed shape of the upper surface 32 of the bladder 14 with the surface joint 55 to the first tensile layer 48 and without the formation of the circular protrusion 60 is not shown.

[0061] Because the midsole 12 and the sole plate 16 are configured to allow the bladder 14 to nest in the cavity 84 that is specifically configured to accommodate the contoured upper and lower surfaces 32, 62 of the bladder 14 with the joining regions 78, 86 located outside of the contoured upper and lower surfaces 32, 62 (i.e., outside of the circular protrusion 60 and the domed portions 61), both a secure joint and the desired cushioning properties of the contoured surfaces 32, 62 near the joining regions 78, 86 can be achieved.

[0062] In Figure 9 and 10In embodiments of the sole structure 10, the perimeter bonding region 78 of the midsole 12 is bonded directly to the perimeter bonding region 86 of the sole plate 16. For example, the entire polymer bladder 14 can be inboard of the perimeter bonding region, and the perimeter flange 41 of the bladder 14 is formed very narrow or trimmed very narrow, such that the midsole 12 and the sole plate 16 contact each other at the bonding region 78, 86 outboard of the polymer bladder 14. The bonding at the bonding region 78, 86 can occur by heat bonding of the midsole 12 to the sole plate 16 and / or by adhesive disposed on one or both of the bonding regions 78, 86.

[0063] In Figure 11 and 12 embodiments of the sole structure 110, the sole structure 110 is identical to the sole structure 10, with the bladder 14 nested in the cavity formed by the recess 72, but the perimeter flange 41 of the polymer bladder 14 is wider than the Figure 9 and 10 perimeter bonding region 86 of the sole plate 16. The perimeter flange 41 is disposed between the perimeter bonding region 78 of the midsole 12 and the perimeter bonding region 86 of the sole plate 16. The perimeter bonding region 86 of the midsole 12 is bonded to the upper side 87 of the perimeter flange 41, and the perimeter bonding region 86 of the sole plate 16 is bonded to the lower side of the perimeter flange.

[0064] The sole plate 16 can provide a variety of properties and features. For example, the sole plate 16 can be stiffer than the midsole 12 and the bladder 14 in both compressive stiffness and bending stiffness. The sole plate 16 also has integral cleat mounting features 100 that extend from the lower surface 102 of the sole plate away from the bladder 14, as best shown in Figure 1 , 3 and 4. The cleat mounting features 100 are downwardly extending projections with central apertures 104. The central apertures 104 are each configured to receive and retain a cleat 106.

[0065] Referring to Figures 3-4 and 9-10, the forked reinforcement plate 19 is secured to the upper surface 80 of the sole plate 16 between the sole plate 16 and the bladder 14. Alternatively, in the sole structure 110 shown in Figures 11-12 , the forked reinforcement plate 19 is secured to the lower surface 102 of the sole plate 16. In either embodiment, the forked reinforcement plate 19 can be integrally formed as part of the sole plate 16, such as if the sole plate 16 and the forked reinforcement plate 19 are co-molded together in the same mold. The forked reinforcement plate 19 has a central portion 108 that is disposed between the sole plate 16 and the bladder 14. Figure 3The central portion 108 is arranged at a posterior portion of the midfoot region 24 and an anterior portion of the heel region 26. Both the anterior medial arm 110A and the anterior lateral arm 110B extend forward from the central portion 108. Both the posterior medial arm 112A and the posterior lateral arm 112B extend rearward from the central portion 108. The anterior medial arm 110A and the posterior medial arm 112A abut the medial side 30 of the sole plate 16, and the anterior lateral arm 110B and the posterior lateral arm 112B abut the lateral side 28 of the sole plate 16. The cleat reinforcement plate 19 increases the thickness of the sole structure 10 and the bending stiffness of the sole structure 10 in the areas where the cleat reinforcement plate 19 extends. By extending along the lateral side 28 and the medial side 30, increased support is provided to react forces in those areas, for example due to lateral (i.e., side) movement.

[0066] The arms of the cleat reinforcement plate 19 generally correspond to the portions of the polymer bladder 14 having the domed portions 61 at the medial and lateral sides of the lower surface 62 of the bladder 14 and are located thereunder. The additional cushioning of the domed portions 61 and the additional support of the cleat reinforcement plate 19 provide comfort and support during lateral movement. The arms 110A, 110B, 112A, 112B of the cleat reinforcement plate 19 also extend along those portions of the sole plate 16 having the cleat mounting features 100. Thus, the sole plate 16 is reinforced at areas that can be subjected to higher stresses due to forces on the cleats 106.

[0067] Figures 1-12 The sole structure 10 or 110 of FIGS. 1-2 can be manufactured according to the method 200, the steps of which are listed in Table 1 below.

[0068] Table 1

[0069] Step Action 202 Forming a midsole 204 Forming a chassis 206 Forming a polymer bladder 208 Inflating a polymer bladder 210 Securing a cleat to a chassis 212 Stacking a chassis, a polymer bladder, and a midsole 214 Securing a midsole to a chassis at a perimeter bond region

[0070] In some embodiments, the method 200 can include forming the components of the sole structure 10 or 110 (e.g., steps 202-208). In other embodiments, the method can begin with preformed components, for example at step 210. For completeness, the steps of forming the components are described. For example, the method 200 can begin with step 202— forming the midsole 12, which includes forming a lower surface 70 of the midsole 12 having a first recess 72 and a plurality of rounded concavities 92 configured to cooperate with the plurality of domed protrusions 60 of the contoured upper surface 32 of the polymer bladder 14 at the plurality of rounded concavities.

[0071] The method 200 can include a step 204 of forming the sole plate 16, including forming the upper surface 80 of the sole plate 16 with the second recess 82 and the plurality of circular cavities 94, the sole plate 16 being configured to mate with the plurality of domed portions 61 of the contoured lower surface 62 of the polymer bladder 14 at the plurality of circular cavities.

[0072] The method 200 can further include a step 206 of forming the polymer bladder 14. Step 206 can include disposing the tensile member 46 between the upper polymer sheet 36 and the lower polymer sheet 38, joining the upper and lower polymer sheets to one another about the tensile member 46 at the peripheral flange 41, and joining the sheets 36, 38 to the tensile member 46 at the plurality of joints 54, as described herein.

[0073] The method 200 can further include a step 208 of inflating the interior cavity 42 of the polymer bladder 14. Thus, with the components formed as in steps 202-206, the lower surface 70 of the midsole 12 and the upper surface 80 of the sole plate 16 are configured to conform to the inflated polymer bladder 14.

[0074] The method 200 can further include a step 210 of securing the cleat plate 19 to the sole plate 16, in some embodiments at the upper surface 80 or in other embodiments at the lower surface 102, as described herein. Alternatively, in step 204, the cleat plate 19 can be co-molded with the sole plate 16.

[0075] After the components are formed and the cleat plate 19 is secured to or co-molded with the sole plate 16, as in steps 202-210, the method 200 includes a step 212 of stacking the sole plate 16, the polymer bladder 14, and the midsole 12, such that the polymer bladder 14 is nested in the cavity 84 formed by the first recess 72 and the second recess 82. As stacked, the contoured upper surface 32 of the polymer bladder 14 is inside the peripheral joint region 78 of the midsole 12, and the contoured lower surface 62 of the polymer bladder 14 is inside the peripheral joint region 86 of the sole plate 16.

[0076] The method 200 then includes a step 214 of securing the midsole 12 relative to the sole plate 16. In embodiments in which the midsole 12 is directly secured to the sole plate 16, as in the sole structure 10 shown in Figures 9-10 step 214 includes joining the peripheral joint region 78 of the midsole 12 to the peripheral joint region 86 of the sole plate 16. In such embodiments, the polymer bladder 14, including its relatively narrow peripheral flange 41, is entirely inside the peripheral joint regions 78, 86.

[0077] In other embodiments, such as in the sole structure 10 shown in Figures 11-12In the sole architecture 110, the midsole 12 and the chassis 16 are secured to the peripheral flange 41 of the polymer bladder 14. More particularly, in such embodiments, the step 214 includes bonding the peripheral bonding region 78 of the midsole 12 to the upper side 87 of the peripheral flange 41, and bonding the peripheral bonding region 86 of the chassis 16 to the lower side 89 of the peripheral flange 41. The method 200 can also include securing the cleats 106 to the cleat mounting features 100, and securing the sole structure 10 or 110 to the upper 23.

[0078] Thus, the components of both sole structures 10 and 110 are configured in a geometrically complementary manner to accommodate the contoured outer surface of the bladder 14 on the medial and lateral sides, to allow each sole structure 10, 110 to be manufactured by vertically stacking and bonding the components to one another.

[0079] The following clauses provide example constructions of sole structures for articles of footwear disclosed herein.

[0080] Clause 1 : A sole structure for an article of footwear, the sole structure comprising: a midsole, a chassis, and a polymer bladder; wherein the midsole has a lower surface having first recesses and a peripheral bonding region between an outer periphery of the chassis and an outer periphery of the first recesses; the chassis has an upper surface having second recesses arranged between the first recesses of the midsole, the first recesses and the second recesses together forming a cavity between the chassis and the midsole, the upper surface of the chassis having a peripheral bonding region between an outer periphery of the chassis and an outer periphery of the second recesses; and the polymer bladder nested in the cavity between the midsole and the chassis, a contoured upper surface of the polymer bladder being inward of the peripheral bonding region of the midsole, and a contoured lower surface of the polymer bladder being inward of the peripheral bonding region of the chassis.

[0081] Clause 2: The sole structure of clause 1, wherein the polymer bladder has a fluid-filled interior cavity and a peripheral flange establishing at least a portion of an outer periphery of the polymer bladder and at least partially surrounding the fluid-filled interior cavity; and the peripheral flange is arranged between the peripheral bonding region of the midsole and the peripheral bonding region of the chassis, the peripheral bonding region of the midsole being bonded to an upper side of the peripheral flange, and the peripheral bonding region of the chassis being bonded to a lower side of the peripheral flange.

[0082] Clause 3: The sole structure of any of clauses 1-2, wherein the peripheral bonding region of the midsole is bonded to the peripheral bonding region of the chassis.

[0083] Clause 4: The sole structure of any of clauses 1-3, wherein the contoured upper surface of the polymer bladder mates with the lower surface of the midsole in the first recesses.

[0084] Clause 5: The sole structure of Clause 4, wherein the contoured upper surface of the polymer bladder includes a plurality of rounded protrusions, and the lower surface of the midsole includes a plurality of rounded cavities corresponding to the plurality of rounded protrusions.

[0085] Clause 6: The sole structure of any of Clauses 1-5, wherein the contoured lower surface of the polymer bladder mates with the upper surface of the sole plate in the second recess.

[0086] Clause 7: The sole structure of Clause 6, wherein the contoured lower surface of the polymer bladder includes a plurality of domed portions, and the upper surface of the sole plate includes a plurality of rounded cavities corresponding to the plurality of domed portions.

[0087] Clause 8: The sole structure of any of Clauses 1-7, wherein the polymer bladder includes an upper polymer sheet and a lower polymer sheet bonded to one another and enclosing a fluid-filled interior cavity; the sole structure further comprising: a tensile member disposed in the fluid-filled interior cavity, the tensile member including a first tensile layer secured to the upper polymer sheet, a second tensile layer, and a plurality of tethers connecting the first tensile layer to the second tensile layer; and wherein a plurality of lower bonds join the lower polymer sheet to the second tensile layer, and the lower polymer sheet is displaced from the second tensile layer by fluid in the fluid-filled interior cavity between at least some of the lower bonds.

[0088] Clause 9: The sole structure of Clause 8, wherein a plurality of upper bonds join the upper polymer sheet to the first tensile layer; the upper polymer sheet is displaced from the first tensile layer by fluid in the fluid-filled interior cavity between at least some of the upper bonds along a medial side of the polymer bladder and along a lateral side of the polymer bladder, a plurality of rounded protrusions along the medial side and along the lateral side being formed where the upper polymer sheet is displaced from the first tensile layer; and the upper polymer sheet is secured to the first tensile layer between the rounded protrusions along the lateral side and between the rounded protrusions along the medial side.

[0089] Clause 10: The sole structure of Clause 8, wherein the lower surface of the midsole includes a plurality of rounded cavities corresponding to the plurality of rounded protrusions of the upper polymer sheet and extending along a medial side of the polymer bladder and along a lateral side of the polymer bladder; and the contoured lower surface of the polymer bladder includes a plurality of domed portions where the lower polymer sheet is displaced from the second tensile layer by fluid in the fluid-filled interior cavity, and the upper surface of the sole plate includes a plurality of rounded cavities corresponding to the plurality of domed portions.

[0090] Clause 11: The sole structure of any of Clauses 1-10, wherein the midsole defines a through-hole extending through the midsole over the polymer bladder.

[0091] Clause 12: The sole structure of any of clauses 1-11, wherein the sole plate has integral cleat mounting features.

[0092] Clause 13: The sole structure of any of clauses 1-12, wherein the sole plate has a forefoot region, a midfoot region, and a heel region, and further comprising: a forked reinforcement plate secured to the sole plate; wherein the forked reinforcement plate has a central portion, an anterior medial arm, and an anterior lateral arm; wherein both the anterior medial arm and the anterior lateral arm extend forward from the central portion; wherein the forked reinforcement plate has a posterior medial arm and a posterior lateral arm that both extend rearward from the central portion; wherein the anterior medial arm and the posterior medial arm abut the medial side of the sole plate; and wherein the anterior lateral arm and the posterior lateral arm abut the lateral side of the sole plate.

[0093] Clause 14: A method of manufacturing a sole structure for an article of footwear, the method comprising: stacking a sole plate, a polymer bladder, and a midsole such that the polymer bladder is nested in a cavity formed by a first recess in a lower surface of the midsole and a second recess in an upper surface of the sole plate, and a contoured upper surface of the polymer bladder is inboard of a peripheral bonding region of the midsole, and a contoured lower surface of the polymer bladder is inboard of a peripheral bonding region of the sole plate; wherein the polymer bladder defines a sealed, fluid-filled interior cavity; and securing the midsole relative to the sole plate at the peripheral bonding regions of the midsole.

[0094] Clause 15: The method of clause 14, wherein the polymer bladder has a peripheral flange that establishes an outer periphery of the polymer bladder and at least partially surrounds the fluid-filled interior cavity; and securing the midsole relative to the sole plate comprises bonding the peripheral bonding region of the midsole to an upper side of the peripheral flange, and bonding the peripheral bonding region of the sole plate to a lower side of the peripheral flange.

[0095] Clause 16: The method of clause 14, wherein securing the midsole relative to the sole plate comprises bonding the peripheral bonding region of the midsole to the peripheral bonding region of the sole plate.

[0096] Clause 17: The method of clause 14, further comprising: inflating the fluid-filled interior cavity of the polymer bladder prior to stacking the sole plate, the polymer bladder, and the midsole.

[0097] Clause 18: The method of clause 14, further comprising: securing a forked reinforcement plate to the sole plate.

[0098] Clause 19: The method of clause 14, further comprising: prior to stacking the sole plate, the polymer bladder, and the midsole, forming a lower surface of the midsole having a first recess and a plurality of concavities, the midsole being configured to mate with the plurality of rounded protrusions of the contoured upper surface of the polymer bladder at the plurality of concavities; and prior to stacking the sole plate, the polymer bladder, and the midsole, forming an upper surface of the sole plate having a second recess and a plurality of concavities, the sole plate being configured to mate with the plurality of domed portions of the contoured lower surface of the polymer bladder at the plurality of concavities.

[0099] Clause 20: The method of any of clauses 14-19, further comprising: prior to stacking the sole plate, the polymer bladder, and the midsole, forming the polymer bladder by: disposing a stretch component between the upper polymer sheet and the lower polymer sheet, the stretch component comprising a first stretch layer, a second stretch layer, and a plurality of tethers connecting the first stretch layer to the second stretch layer; and bonding the lower polymer sheet to the upper polymer sheet around the stretch component and to the second stretch layer at a plurality of bonds; wherein, when the fluid-filled internal cavity is inflated, the lower polymer sheet is not bonded to the second stretch layer adjacent to at least some of the bonds and is displaced from the second stretch layer by the fluid in the fluid-filled internal cavity.

[0100] To aid and illustrate the description of the various embodiments, various terms are defined herein. The following definitions apply to the entire description (including the claims) unless otherwise indicated. In addition, all references cited herein are incorporated by reference in their entirety.

[0101] “Article of footwear,”“article of footwear,” and“shoe” can be considered machines and manufactures. Assembled articles of footwear to be worn (e.g., shoes, sandals, boots, etc.) and individual components of articles of footwear (e.g., midsoles, outsoles, upper components, etc.) are considered and alternatively referred to herein as“articles of footwear” or“footwear” in the singular or plural form prior to final assembly into a finished product to be worn in the footwear.

[0102] "one," "an," and "the" are used interchangeably and mean that there is at least one of the referenced object. Plural objects can be present if the context so indicates. All numerical values should be understood to be modified in all instances by the term "about," whether or not "about" is actually expressed by the term, unless expressly indicated otherwise in the specification. "About" means that slight inaccuracies (in a manner to achieve the accuracy of the value; about or reasonably close to the value; close to) are permitted in the value. If the inaccuracy provided by "about" is not understood in the art to have the ordinary meaning, then "about" as used herein means at least the variation that can be caused by the ordinary methods of measurement and use of such a parameter. As used in the specification and the appended claims, unless otherwise indicated, a value is considered to be "approximately" equal to a specified value if it is neither more than 5% greater than the specified value nor more than 5% less than the specified value. Additionally, a disclosure of a range is understood to disclose all values and further subdivided ranges within the range.

[0103] The terms "comprising," "including," and "having" are inclusive and therefore 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, or components. The order of steps, methods, and operations can be changed when possible, and additional or alternative steps can be employed. As used in this specification, the term "or" includes any one and all combinations of the associated stated items. The term "any" should be understood to include any possible combination of the objects referenced by the term, including "any one" of the objects referenced by the term. The term "any" should be understood to include any possible combination of the referenced claims of the application, including "any one" of the referenced claims.

[0104] For consistency and convenience, directional adjectives can be used throughout this corresponding DETAILED DESCRIPTION of the specific embodiments illustrated. One skilled in the art will recognize that terms such as "above," "below," "up," "down," "top," "bottom," and the like are used as descriptive phrases only and are not intended to limit the scope of the invention as defined by the claims.

[0105] The term "longitudinal" refers to a direction extending along a length of a component. For example, a longitudinal direction of an article of footwear extends between a forefoot region and a heel region of the article of footwear. The term "forward" or "anterior" is used to refer to the general direction from the heel region to the forefoot region, and the term "rearward" or "posterior" is used to refer to the opposite direction, i.e., from the forefoot region toward the heel region. In some cases, a component can be identified with a longitudinal axis and forward and rearward longitudinal directions along the axis. The longitudinal direction or axis can also be referred to as an anterior-posterior direction or axis.

[0106] The term "lateral" refers to a direction extending along a width of a component. For example, a lateral direction of an article of footwear extends between a lateral side and a medial side of the article of footwear. A lateral direction or axis can also be referred to as a side direction or axis or a mediolateral direction or axis.

[0107] The term "vertical" refers to a direction generally perpendicular to the lateral and longitudinal directions. For example, in a situation where a sole structure is disposed flat on a ground surface, a vertical direction can extend upward from the ground surface. It should be understood that each of these directional adjectives can be used in reference to individual components of a sole structure. The term "upward" or "upwards" refers to a vertical direction toward a top of a component, which can include an instep, a fastening region, and / or a throat of an upper. The term "downward" or "downwards" refers to a vertical direction opposite the upward direction and generally can refer to a direction toward a bottom of a sole structure of an article of footwear.

[0108] An "interior" of an article of footwear, such as a shoe, refers to a portion at a space occupied by a wearer's foot when the article of footwear is worn. An "inner side" of a component refers to that side or surface that is toward or will be toward an interior of an assembled article of footwear or component in an assembled article of footwear. An "outer side" or "exterior" of a component refers to that side or surface that is away from or will be away from an interior of an assembled article of footwear or component in an assembled article of footwear. In some cases, other components can be between the inner side of a component and an interior of an assembled article of footwear. Similarly, other components can be between the outer side of a component and a space outside of an assembled article of footwear. Further, the terms "inward" and "inwardly" shall mean a direction toward an interior of an article of footwear or component, while the terms "outward" and "outwardly" shall mean a direction away from an exterior of an article of footwear or component. Additionally, the term "proximal" refers to a direction closer to a center of a shoe component or toward a foot when the shoe is worn by a user with a foot inserted in the article of footwear. Likewise, the term "distal" refers to a direction away from a center of a shoe component or away from a foot when the shoe is worn by a user with a foot inserted in the article of footwear. As such, the terms proximal and distal can be understood to provide generally opposite terms to describe relative spatial positions.

[0109] While various embodiments have been described, this description is intended to be exemplary, rather than limiting and it will be apparent that frequent changes can be made within the scope of the embodiments and that many embodiments and implementations are possible. Any feature of any embodiment can be combined with or substituted for any other feature of any other embodiment, unless specifically excluded. Accordingly, in addition to the embodiments specifically described, even further embodiments and implementations will be apparent to those skilled in the art in view of this description. The embodiments are therefore to be considered in all respects as illustrative and not restrictive, unless otherwise indicated herein. Moreover, where any term is dependent on another term, the term "comprising" is not intended to exclude the possibility that the term can be "consisting of" or "consisting essentially of" the other term.

[0110] While several modes for carrying out various aspects of the present teachings have been described in detail, those familiar with the art to which these teachings relate will recognize alternatives for practicing the present teachings within the scope of the appended claims. It is intended that the entire range of equivalents to each element covered by the claims be embraced, and that the scope of the claims extend to all alternative combinations of features described or illustrated herein.

Claims

1. A sole structure for an article of footwear, the sole structure comprising: a midsole, a chassis, and a polymer bladder, each having a heel region, a midfoot region, and a forefoot region; wherein the midsole has a lower surface having first recesses and a peripheral bond region between an outer periphery of the chassis and an outer periphery of the first recesses; the chassis has an upper surface having second recesses disposed between the first recesses of the midsole; the first recesses and the second recesses together form a cavity between the chassis and the midsole; the upper surface of the chassis has a peripheral bond region between an outer periphery of the chassis and an outer periphery of the second recesses; the polymer bladder is nested in the cavity between the midsole and the chassis by a contoured upper surface of the polymer bladder inboard of the peripheral bond region of the midsole and a contoured lower surface of the polymer bladder inboard of the peripheral bond region of the chassis; and wherein the contoured upper surface of the polymer bladder includes a plurality of circular protrusions extending along an outer side of the polymer bladder and along an inner side of the polymer bladder, and a generally flat portion extending from the circular protrusions of the outer side to the circular protrusions of the inner side, wherein the plurality of circular protrusions are located in each of the heel region, the midfoot region, and the forefoot region on the inner side and the outer side, wherein the polymer bladder has a fluid-filled interior cavity and a peripheral flange forming at least a portion of an outer periphery of the polymer bladder and at least partially surrounding the fluid-filled interior cavity; and the peripheral flange is disposed between the peripheral bond region of the midsole and the peripheral bond region of the chassis, wherein the peripheral bond region of the midsole bonds to an upper side of the peripheral flange and the peripheral bond region of the chassis bonds to a lower side of the peripheral flange.

2. The sole structure of Claim 1, wherein, the peripheral bond region of the midsole bonds to the peripheral bond region of the chassis.

3. The sole structure of claim 1, wherein, the contoured upper surface of the polymer bladder mates with the lower surface of the midsole in the first recesses.

4. The sole structure of claim 3, wherein: the lower surface of the midsole includes a plurality of circular recesses extending in the heel region, the midfoot region, and the forefoot region of the midsole and corresponding to the plurality of circular protrusions.

5. The sole structure of claim 1, wherein, the polymer bladder includes an upper polymer sheet and a lower polymer sheet bonded to each other and enclosing the fluid-filled interior cavity; the sole structure further comprising: a tensile member disposed in the fluid-filled interior cavity, the tensile member including a first tensile layer secured to the upper polymer sheet, a second tensile layer, and a plurality of tethers connecting the first tensile layer to the second tensile layer; and wherein a plurality of lower bonds join the lower polymer sheet to the second tensile layer, and the lower polymer sheet is displaced from the second tensile layer by a fluid in the fluid-filled interior cavity between at least some of the lower bonds.

6. The sole structure of claim 5, wherein: a plurality of upper bonds join the upper polymer sheet to the first tensile layer; the upper polymer sheet is displaced from the first stretch layer by fluid in the fluid-filled interior cavity along the inner side of the polymer bladder and between at least some of the upper bonds along the outer side of the polymer bladder, forming a plurality of circular protrusions along the inner side and along the outer side where the upper polymer sheet is displaced from the first stretch layer; and the upper polymer sheet is fixed to the first stretch layer between the circular protrusions along the outer side and between the circular protrusions along the inner side and is substantially planar.

7. The sole structure of claim 5, wherein: the lower surface of the midsole includes a plurality of circular recesses corresponding to the plurality of circular protrusions of the upper polymer sheet and extending along the inner side of the polymer bladder and the outer side of the polymer bladder; and the contoured lower surface of the polymer bladder includes a plurality of domed portions at which the lower polymer sheet is displaced from the second stretch layer by fluid in the fluid-filled interior cavity, and the upper surface of the sole plate includes a plurality of circular recesses corresponding to the plurality of domed portions.

8. The sole structure of claim 1, wherein, the midsole defines a through-hole extending through the midsole over the polymer bladder.

9. The sole structure of claim 1, wherein, the sole plate has integral cleat mounting features.

10. A sole structure for an article of footwear, the sole structure comprising: a midsole, a sole plate, and a polymer bladder, each having a heel region, a midfoot region, and a forefoot region; wherein the midsole has a lower surface having a first recess and a peripheral bond region between an outer periphery of the midsole and an outer periphery of the first recess; the sole plate has an upper surface having a second recess, the first recess and the second recess together forming a cavity between the sole plate and the midsole, the upper surface of the sole plate having a peripheral bond region between an outer periphery of the sole plate and an outer periphery of the second recess; the polymer bladder nested in the cavity between the midsole and the sole plate, wherein a contoured upper surface of the polymer bladder is inward of the peripheral bond region of the midsole and a contoured lower surface of the polymer bladder is inward of the peripheral bond region of the sole plate; wherein the contoured lower surface of the polymer bladder mates with the upper surface of the sole plate in the second recess; and wherein the contoured lower surface of the polymer bladder includes a plurality of domed portions extending along an outer side of the polymer bladder and extending along an inner side of the polymer bladder, wherein the plurality of domed portions are located in each of the heel region, the midfoot region, and the forefoot region on the outer side and the inner side, and extend laterally across the heel region from the outer side to the inner side, and include a substantially planar portion in the forefoot region extending from the domed portions along the outer side to the domed portions along the inner side, wherein the polymer bladder has a fluid-filled interior cavity and a peripheral flange forming at least a portion of an outer periphery of the polymer bladder and at least partially surrounding the fluid-filled interior cavity; and the peripheral flange is disposed between the peripheral bond region of the midsole and the peripheral bond region of the sole plate, wherein the peripheral bond region of the midsole bonds to an upper side of the peripheral flange and the peripheral bond region of the sole plate bonds to a lower side of the peripheral flange.

11. The sole structure of claim 10, wherein, The upper surface of the sole plate includes a plurality of circular cavities corresponding to the plurality of domed portions.

12. The sole structure of any of claims 10-11, further comprising: a forked reinforcement plate secured to the sole plate; wherein the forked reinforcement plate has a central portion, an anterior medial arm, and an anterior lateral arm; wherein both the anterior medial arm and the anterior lateral arm extend anteriorly from the central portion; wherein the forked reinforcement plate has a posterior medial arm and a posterior lateral arm that both extend posteriorly from the central portion; wherein the anterior medial arm and the posterior medial arm abut the medial side of the sole plate; and wherein the anterior lateral arm and the posterior lateral arm abut the lateral side of the sole plate; and wherein the anterior medial arm, the anterior lateral arm, the posterior medial arm, and the posterior lateral arm of the forked reinforcement plate have recesses corresponding to and underlying the domed portions of the polymer bladder, the domed portions of the polymer bladder extending along the lateral side of the polymer bladder, and the domed portions of the polymer bladder extending along the medial side of the polymer bladder.

13. The sole structure of claim 12, wherein: the sole plate has an integral cleat mounting feature; and the forked reinforcement plate extends along the portion of the sole plate having the cleat mounting feature.

14. The sole structure of claim 12, wherein, the sole plate has a substantially planar bottom surface disposed beneath the substantially planar portion of the polymer bladder.

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