Sole structure for footwear

Abstract

A sole structure for footwear articles with an upper includes a cushioning member and a base. The cushioning member includes a first series of protruding angles alternating with a first series of recesses along its length. The first series of protruding angles and the first series of recesses extend along either the inner side or the outer side of the sole structure. The base is disposed between the cushioning member and the upper and includes a series of first supports alternating with a second series of recesses. Supports in this series of first supports are aligned with and contact corresponding protruding angles in the first series of protruding angles, and the second series of recesses are aligned with the first series of recesses.

Description

[0001] Cross-reference to related applications

[0002] This application claims priority under 35 USC §119(e) to the following applications: U.S. Provisional Patent Application Serial No. 63 / 300,259, filed January 17, 2022; U.S. Provisional Patent Application Serial No. 63 / 300,246, filed January 17, 2022; U.S. Provisional Patent Application Serial No. 63 / 300,252, filed January 17, 2022; U.S. Provisional Patent Application Serial No. 63 / 253,022, filed October 6, 2021; U.S. Provisional Patent Application Serial No. 63 / 194,327, filed May 28, 2021; and U.S. Provisional Patent Application Serial No. 63 / 194,314, filed May 28, 2021, the entire contents of which are incorporated herein by reference. Technical Field

[0003] This disclosure generally relates to sole structures for footwear articles, and more specifically, to sole structures comprising a base for receiving a fluid-filled bladder. Background Technology

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

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

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

[0007] Midsole soles using fluid-filled bladders typically comprise a bladder formed by two sealed or bonded polymer material barrier layers. The fluid-filled bladder is pressurized with a fluid such as air and may incorporate tension members within the bladder to maintain its shape when elastically compressed under applied loads, such as during athletic activity. Typically, the bladder design emphasizes a balance between support and cushioning characteristics for the foot, which relate to the bladder's responsiveness to elastic compression under applied loads. In such respects, the midsole sole may include a base for engaging with the bladder to form a monolithic structure. Attached Figure Description

[0008] The accompanying drawings described herein are for illustrative purposes only and are not intended to limit the scope of this disclosure. In the drawings:

[0009] Figure 1 It is a perspective view of a footwear article including a sole structure according to the principles of the present invention;

[0010] Figure 2A yes Figure 1 An exploded top-down perspective view of the shoe sole structure;

[0011] Figure 2B yes Figure 1 An exploded bottom perspective view of the shoe sole structure;

[0012] Figure 3 It is used in Figure 1 Top perspective view of the first aspect of the cushioning component in the sole structure;

[0013] Figure 4 yes Figure 3 Bottom perspective view of the buffer component;

[0014] Figure 5A yes Figure 3 A top view of the buffer component;

[0015] Figure 5B It is used in Figure 1 A top view of another aspect of the cushioning component in the sole structure;

[0016] Figure 5C It is used for Figure 1 A top view of another aspect of the cushioning components in the shoe sole structure;

[0017] Figure 6A yes Figure 5A The buffer member shown is a cross-sectional view along line 6A-6A;

[0018] Figure 6B yes Figure 5B The buffer component along Figure 5B Sectional view of line 6B-6B;

[0019] Figure 6C yes Figure 5C The buffer component along Figure 5C A sectional view taken from line 6C-6C;

[0020] Figure 7 It is along Figure 5A The line 7-7 was cut Figure 3 A cross-sectional view of the buffer component;

[0021] Figure 8 It is along Figure 5A The line cut from 8-8 Figure 3 A cross-sectional view of the buffer component;

[0022] Figure 9 yes Figure 1 A top view of the shoe sole structure;

[0023] Figure 10 yes Figure 1 A bottom view of the shoe sole structure;

[0024] Figure 11 It is along Figure 10 The line 11-11 cut Figure 1 A cross-sectional view of the shoe sole structure;

[0025] Figure 12 It is along Figure 10 The line 12-12 cut Figure 1 A cross-sectional view of the shoe sole structure;

[0026] Figure 13 It is along Figure 10 The line 13-13 was cut off Figure 1 A cross-sectional view of the shoe sole structure;

[0027] Figure 14 It is along Figure 10 The line 14-14 was cut Figure 1 A sectional view of the sole structure; and

[0028] Figure 15 It is along Figure 10 The line cut at 15-15 Figure 1 A cross-sectional view of the shoe sole structure.

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

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

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

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

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

[0034] One aspect of the present invention provides a sole structure. The sole structure includes a cushioning member and a base. In some configurations, the cushioning member is a fluid-filled chamber comprising a cushioning member material. In another aspect, the cushioning member is a solid body comprising a cushioning member material. In yet another aspect, the cushioning member comprises a solid, fabric, or foam element encapsulated in a barrier membrane.

[0035] The cushioning element comprises or is primarily composed of a cushioning material comprising one or more polymers. In many examples, including when the cushioning element is a fluid-filled chamber, the cushioning material comprises or is substantially composed of a barrier membrane, the barrier membrane comprising a barrier material containing one or more gas-barrier compounds. The cushioning member extends from the forefoot region of the sole structure to the heel region of the sole structure. The cushioning member may include a first series of protrusions alternating with a first series of recesses along the length of the cushioning member. The first series of protrusions and the first series of recesses extend along one of the inner side and the outer side of the sole structure. A base is disposed between the cushioning member and the upper. The base includes a series of first supports alternating with a second series of recesses along the length of the base, the supports in the series of first supports being aligned with and contacting a corresponding protrusion in the first series of protrusions, and the second series of recesses being aligned with the first series of recesses.

[0036] Embodiments of the present invention may include one or more of the following optional features. In some embodiments, the base includes a cushioning support. The base may also include a plate mounted between the upper and the cushioning support to the top surface of the cushioning support. This plate may be longer than the cushioning support.

[0037] In some configurations, at least one of the series of first supports may include an upper portion that extends from the body of the at least one support in a direction toward the upper and outward.

[0038] In some constructions, the plate may be made of a material with higher rigidity than the material forming the cushioning support, which may be made of foam. The series of first supports may include a pair of rear supports configured to align with and contact a pair of toe convex angles of the first series of convex angles. The toe convex angles are located in the forefoot region and are formed only on the plate. The series of first supports includes multiple forefoot supports and multiple heel supports, which may be integrally formed from the cushioning support. In other aspects, the cushioning support includes a continuous recess extending the width of the cushioning support and separating the heel region from the midfoot region. Footwear articles may incorporate a sole structure.

[0039] Another aspect of the invention provides a sole structure. A base can be incorporated as part of the sole structure of a footwear article. The footwear article includes an upper. The sole structure includes a cushioning member extending from a forefoot region of the sole structure to a heel region of the sole structure. The cushioning member includes a first series of protruding angles alternating with a first series of recesses along the length of the cushioning member. The first series of protruding angles and the first series of recesses extend along one of the inner side and the outer side of the sole structure. The base includes a cushioning support disposed between the cushioning member and the upper, and includes a series of first supports alternating with a second series of recesses along the length of the cushioning support. Supports in this series of first supports are aligned with and contact corresponding protruding angles in the first series of protruding angles, and the second series of recesses are aligned with the first series of recesses.

[0040] Embodiments of the present invention may include one or more of the following optional features. In some embodiments, the base may further include a plate mounted between the upper and the cushioning support to the top surface of the cushioning support. This plate may be longer than the cushioning support.

[0041] In some configurations, at least one of the series of first supports includes an upper portion that extends from the body of the at least one support in a direction toward and outward of the upper. One of the recesses in the first series may be configured to extend across the width of the cushioning support, thereby separating the heel area from the midfoot area.

[0042] In some configurations, the cushioning support includes a series of ridges configured to reside within a corresponding recess of a series of recesses formed on the top side of the cushioning member. The cushioning support may include a series of wings extending along its periphery, configured to rest on the bottom surface of the plate. In yet another configuration, the series of first supports includes multiple forefoot supports and multiple heel supports, which may be integrally formed from the cushioning member. The footwear may be combined with a base.

[0043] The materials described herein may differ in one or more aspects of appearance, physical properties, and composition. These materials may differ in appearance in color (including hue or brightness, or both), or in transparency or translucency levels, or both. These materials may differ in one or more physical properties, such as hardness or elongation, or hardness and elongation. One or more physical properties may differ by at least 5%, at least 10%, or at least 20%. The composition of these materials may differ. For example, the materials may differ based on the type or variety of polymers present, based on the concentration of the type or variety of polymers, or based on both. The composition of the materials may differ based on the presence of additives, or based on the concentration of the additives present, or based on both. Optionally, the concentrations of one or more polymers and / or one or more additives may differ by at least 5% by weight, at least 10% by weight, or at least 20% by weight of the material.

[0044] refer to Figure 1-1 6. A footwear article 10 is provided, comprising a sole structure 100 and an upper 200 attached to the sole structure 100. The footwear article 10 may be divided into one or more regions. Regions may include a forefoot region 12, a midfoot region 14, and a heel region 16 (in... Figures 5A-5C (As shown in the diagram). The forefoot region 12 can be further described as including a toe portion 12T corresponding to the metatarsophalangeal joint and a ball portion 12B corresponding to the metatarsophalangeal (MTP) joint. The midfoot region 14 can correspond to the arch region of the foot, while the heel region 16 can correspond to the rear portion of the foot, including the calcaneus. The footwear 10 may also include a front end 18 associated with the foremost point of the forefoot region 12 and a rear end 20 corresponding to the rearmost point of the heel region 16. Figure 10 As shown, the longitudinal axis A10 of the footwear 10 extends along the length of the footwear 10 from the front end 18 to the rear end 20, and generally divides the footwear 10 into an inner side 22 and an outer side 24. Therefore, the inner side 22 and the outer side 24 correspond to opposite sides of the footwear 10 and extend through regions 12, 14, and 16, respectively.

[0045] Footwear item 10, more specifically, sole structure 100, can be further described as including a peripheral area 28 and an internal area 26, such as Figure 1 As shown. The peripheral region 28 is generally described as the region between the inner region 26 and the outer periphery of the sole structure 100. Specifically, the peripheral region 28 extends from the forefoot region 12 to the heel region 16 along each of the inner side 22 and the outer side 24, and surrounds each of the forefoot region 12 and the heel region 16. Thus, the inner region 26 is externally confined by the peripheral region 28 and extends from the forefoot region 12 to the heel region 16 along the central portion of the sole structure 100.

[0046] refer to Figure 2A and 2B The sole structure 100 includes a sole interlayer 102 configured to provide cushioning features to the sole structure 100 and an outsole 104 configured to provide a ground contact surface 30 for the footwear article 10. Unlike conventional sole structures, the sole interlayer 102 of the sole structure 100 can be formed in a composite manner and includes multiple sub-components for providing the desired form of cushioning and support throughout the sole structure 100. For example, the sole interlayer 102 includes a cushioning member 106 and a base 108, wherein the base 108 is attached to the upper 200 and provides an interface between the upper 200 and the cushioning member 106.

[0047] refer to Figure 1-5C The longitudinal axis A106 of the buffer member 106 (e.g., Figures 5A-5C (As shown) Extending from a first end 110 in the forefoot region 12 to a second end 112 in the heel region 16. The cushioning member 106 can be further described as including a top surface or top side 114 and a bottom surface or bottom side 116, the bottom surface or bottom side 116 being formed on the side of the cushioning member 106 opposite to the top side 114. See below for reference. Figure 6A-8 In more detail, the thickness T106 of the buffer member 106 or the thickness T106 of the element of the buffer member 106 is defined by the distance from the top side 114 to the bottom side 116.

[0048] The cushioning member 106 is configured to provide cushioning for the foot by reducing ground reaction force. In one aspect, the cushioning member 106 is a fluid-filled bladder 106A, and in another aspect, it is a foam element 106B. The difference between the fluid-filled bladder 106A and the foam element 106B lies in the attenuation of ground reaction force. For example, when the cushioning member 106 is a fluid-filled bladder 106A, fluid (air) is contained within the fluid-filled bladder 106A itself. Therefore, the fluid within the fluid-filled bladder 106A is displaced at the points of ground reaction and forced into other areas of the fluid-filled bladder 106A in the form of reaction force. However, in the case where the cushioning member 106 is a foam element 106B, the ground reaction force is absorbed by the foam element at the point of impact. Thus, the remaining portion of the foam element 106B does not experience reaction force in the same way as the fluid-filled bladder 106A. This feature is preferred for users who desire a better cushioning response than that provided by the fluid-filled bladder 106A.

[0049] like Figure 6A and Figure 7-8As shown in the cross-sectional view, the buffer member 106 is shown as a fluid-filled bladder 106A. The fluid-filled bladder 106A may be formed from a pair of opposing barrier layers 118, which may be joined together at discrete locations to define the overall shape of the bladder 106A. Alternatively, the bladder 106A may be made from any suitable combination of one or more barrier layers. As used herein, the term "barrier layer" (e.g., barrier layer 118) includes monolayer and multilayer films. In some embodiments, one or both of the barrier layers 118 are made of a monolayer film (monolayer) (e.g., thermoformed or blow-molded). In other embodiments, one or both of the barrier layers 118 are made of a multilayer film (multiple sublayers) (e.g., thermoformed or blow-molded). In either aspect, each layer or sublayer may have a film thickness ranging from about 0.2 micrometers to about 1 millimeter. In further embodiments, the film thickness of each layer or sublayer may range from about 0.5 micrometers to about 500 micrometers. In another embodiment, the film thickness of each layer or sublayer can be in the range of about 1 micrometer to about 100 micrometers.

[0050] One or both of the barrier layers 118 may be independently transparent, translucent, and / or opaque. As used herein, for barrier layers and / or capsules, the term "transparent" means that light passes through the barrier layer in a substantially straight line and that an observer can see through the barrier layer. In contrast, for an opaque barrier layer, light does not pass through the barrier layer and it is not possible to see through the barrier layer clearly at all. A translucent barrier layer falls between a transparent barrier layer and an opaque barrier layer because light passes through the translucent layer, but some light is scattered, making it impossible for a viewer to see through the layer clearly.

[0051] In one aspect, the airbags or bladders disclosed herein include or consist of a barrier membrane. As used herein, a barrier membrane is understood to be a membrane having a relatively low fluid permeability. When used alone or in combination with other materials in the airbag or bladder, the barrier membrane elastically retains fluid. Depending on the structure and purpose of the airbag or bladder, the barrier membrane can retain fluid at pressures above, equal to, or below atmospheric pressure. In some aspects, the fluid is a liquid or a gas. Examples of gases include air, oxygen (O2), and nitrogen (N2), as well as inert gases. In one aspect, the barrier membrane is a nitrogen-barrier material.

[0052] For membranes with a thickness of approximately 72 micrometers to approximately 320 micrometers, the gas permeability of the barrier membrane, when measured at 23 degrees Celsius and 0% relative humidity, may be less than 4, less than 3, or less than 2 cubic centimeters per square meter per atmosphere per day. In another example, when measured at 23 degrees Celsius and 0% relative humidity, the gas permeability of the barrier membrane for a membrane with a thickness of approximately 72 micrometers to approximately 320 micrometers is approximately 0.1 to approximately 3, or approximately 0.5 to approximately 3, or approximately 0.5 to approximately 3 cubic centimeters per square meter per atmosphere per day. Gas transport rates, such as oxygen or nitrogen transport rates, can be measured using ASTM D1434.

[0053] In one aspect, the barrier film includes a multilayer film comprising a plurality of layers, the plurality of layers including one or more barrier layers, the one or more barrier layers comprising a barrier material comprising or primarily consisting of one or more gas barrier compounds. The multilayer film comprises at least 5 layers or at least 10 layers. Optionally, the multilayer film comprises about 5 to about 200 layers, about 10 to about 100 layers, about 20 to about 80 layers, about 20 to about 50 layers, or about 40 to about 90 layers.

[0054] In one aspect of a multilayer film, the plurality of layers comprises a series of alternating layers, wherein each of the alternating layers comprises two or more barrier layers, each of the two or more barrier layers individually comprising a barrier material, the barrier material comprising or primarily comprising one or more gas barrier compounds. In the series of alternating layers, adjacent layers are each formed based on materials that differ from each other at least chemically in: the presence of various components (e.g., the materials of adjacent layers may differ based on the presence or absence of a gas barrier compound, or based on the type or kind of gas barrier compound present), the concentration of a single component present (e.g., the materials of adjacent layers may differ based on the concentration of a particular type of gas barrier compound present); or they may differ based on the presence of components and their concentrations.

[0055] The plurality of layers of the multilayer film may include a first barrier layer containing a first barrier material and a second barrier layer containing a second barrier material, wherein the first and second barrier materials are different from each other, as described above. The first barrier material may be described as comprising a first gas barrier component consisting of all gas barrier compounds present in the first barrier material, and the second barrier material may be described as comprising a second barrier material component consisting of all gas barrier compounds present in the second barrier material. In a first example, the first barrier component consists only of one or more gas barrier polymers, and the second barrier component consists only of one or more inorganic gas barrier compounds. In a second example, the first barrier component consists of a first one or more gas barrier polymers, and the second component consists of a second one or more gas barrier polymers, wherein the first one or more gas barrier polymers differ from the second one or more gas barrier polymers in polymer species, type, or concentration. In a third example, both the first and second barrier components comprise the same type of gas barrier compounds, but the concentrations of the gas barrier compounds differ, optionally by at least 5% by weight based on the weight of the barrier material. In these multilayer films, the first barrier layer and the second barrier layer may alternate with each other, or may alternate with other barrier layers (e.g., a third barrier layer including a third barrier layer material, a fourth barrier layer including a fourth barrier layer material, etc.), wherein each of the first, second, third and fourth barrier materials, etc., is different from each other as described above.

[0056] Barrier materials (including first barrier materials, second barrier materials, etc.) have low gas permeability. For example, when forming a monolayer membrane that is essentially composed of a barrier material, for a membrane with a thickness of about 72 micrometers to about 320 micrometers, measured at 23 degrees Celsius and 0% relative humidity, and measurable using ASTM D1434, the monolayer membrane has a gas permeability of less than 4 cubic centimeters / square meter / atmosphere / day. The barrier material comprises or is essentially composed of one or more gas-barrier compounds. These one or more gas-barrier compounds may comprise one or more gas-barrier polymers, or may comprise one or more inorganic gas-barrier compounds, or may comprise a combination of at least one gas-barrier polymer and at least one inorganic gas-barrier compound. The combination of at least one gas-barrier polymer and at least one inorganic gas-barrier compound may comprise a blend or mixture, or may comprise a composite material in which fibers, particles, or sheets of the inorganic gas-barrier compound are surrounded by the gas-barrier polymer.

[0057] In one aspect, the barrier material comprises or is substantially composed of one or more inorganic gas-barrier compounds. The one or more inorganic gas-barrier compounds may take the form of fibers, particles, sheets, or combinations thereof. Fibers, particles, and sheets may comprise or are substantially composed of nanoscale fibers, particles, sheets, or combinations thereof. Examples of inorganic barrier compounds include, for example, carbon fibers, glass fibers, glass sheets, silica, silicates, calcium carbonate, clay, mica, talc, carbon black, microparticle graphite, metal sheets, and combinations thereof. The inorganic gas-barrier compound may comprise or be substantially composed of one or more clays. Examples of suitable clays include bentonite, montmorillonite, kaolinite, and mixtures thereof. In one example, the inorganic gas-barrier compound is composed of clay. Optionally, the barrier material may further comprise one or more additional components, such as polymers, processing aids, colorants, or any combination thereof. In the aspect where the barrier material comprises or is substantially composed of one or more inorganic barrier compounds, the barrier material can be described as comprising an inorganic gas-barrier component consisting of all inorganic barrier compounds present in the barrier material. When one or more inorganic gas barrier compounds are included in a barrier material, the total concentration of the inorganic gas barrier components present in the barrier material may be less than 60% by weight, or less than 40% by weight, or less than 20% by weight of the total composition. Alternatively, in other examples, the barrier material is substantially composed of one or more inorganic gas barrier materials.

[0058] In one aspect, the gas-barrier compound comprises or is substantially composed of one or more gas-barrier polymers. The one or more gas-barrier polymers may include thermoplastic polymers. In one example, the barrier material may comprise or is substantially composed of one or more thermoplastic polymers, meaning that the barrier material comprises or is substantially composed of a variety of thermoplastic polymers, including thermoplastic polymers that are not gas-barrier polymers. In another example, the barrier material comprises or is substantially composed of one or more thermoplastic gas-barrier polymers, meaning that all polymers present in the barrier material are thermoplastic gas-barrier polymers. The barrier material can be described as comprising a polymer component consisting of all polymers present in the barrier material. For example, the polymer component of the barrier material may consist of a single type of gas-barrier polymer, such as one or more polyolefins, or may consist of a single type of gas-barrier polymer, such as one or more ethylene-vinyl alcohol copolymers. Optionally, the barrier material may further comprise one or more non-polymer additives, such as one or more fillers, processing aids, colorants, or combinations thereof.

[0059] Many gas barrier polymers are known in the art. Examples of gas barrier polymers include: vinyl polymers such as vinylidene chloride polymers, acrylic polymers such as acrylonitrile polymers, polyamides, epoxy polymers, amine polymers, polyolefins such as polyethylene and polypropylene, copolymers thereof, such as ethylene-vinyl alcohol copolymers, and mixtures thereof. Examples of thermoplastic gas barrier polymers include thermoplastic vinyl homopolymers and copolymers, thermoplastic acrylic homopolymers and copolymers, thermoplastic amine homopolymers and copolymers, thermoplastic polyolefin homopolymers and copolymers, and mixtures thereof. In one example, the one or more gas barrier polymers comprise or are substantially composed of one or more thermoplastic polyethylene copolymers, such as one or more thermoplastic ethylene-vinyl alcohol copolymers. The one or more ethylene-vinyl alcohol copolymers may comprise an ethylene content of about 28 mol% to about 44 mol%, or an ethylene content of about 32 mol% to about 44 mol%. In yet another example, the one or more gas barrier polymers may comprise or are substantially composed of one or more polyethyleneimines, polyacrylic acid, polyethylene oxide, polyacrylamide, polyamide-type amines, or any combination thereof.

[0060] In another embodiment, in addition to the one or more barrier layers (e.g., including a first barrier layer, a second barrier layer, etc.), the multilayer film also includes one or more second layers comprising a second material. In one such configuration of the multilayer film, the one or more barrier layers comprise a plurality of barrier layers alternating with a plurality of second layers. For example, each of the one or more barrier layers may be located between two second layers (e.g., one second layer is located on a first side of the barrier layer, and another second layer is located on a second side of the barrier layer, the second side opposite the first side).

[0061] The second material of the one or more second layers may include one or more polymers. Depending on the type of gas barrier compound used and the intended use of the multilayer membrane, the second material may have a higher gas permeability than the barrier material, meaning that the gas barrier properties of the second material are worse than those of the barrier material. In some aspects, the one or more second layers act as a substrate for the one or more barrier layers and can be used to increase the strength, elasticity, and / or durability of the multilayer membrane. Alternatively or additionally, the one or more second layers can be used to reduce the amount of the required gas barrier material(s), thereby reducing the overall material cost. Even when the second material has a relatively high gas permeability, the presence of the one or more second layers—particularly when the one or more second layers are located between one or more barrier layers—can help maintain the overall barrier performance of the membrane by increasing the distance between cracks in the barrier layers, thereby increasing the distance that gas molecules must travel between cracks in the barrier layers to pass through the multilayer membrane. While small breaks or cracks in the barrier layers of a multilayer membrane may not significantly affect the overall barrier performance of the membrane, using a large number of thinner barrier layers can avoid or reduce visible cracks, fissures, or hazing in the multilayer membrane. The one or more second layers may include, but are not limited to, an adhesive layer that bonds two or more layers together, a structural layer that provides mechanical support for the multilayer film, a bonding layer that provides an adhesive material such as a hot melt adhesive for the multilayer film, and / or a covering layer that provides protection for the outer surface of the multilayer film.

[0062] In some aspects, the second material is an elastomeric material, comprising or consisting primarily of at least one elastomer. Many gas barrier compounds are brittle and / or relatively inflexible, and therefore the one or more barrier layers may easily break when subjected to repeated, excessive stress loads, such as those that may occur during the flexure and release of a multilayer film. Compared to films without an elastomeric second layer, multilayer films comprising one or more barrier layers alternating with a second layer of elastomeric material result in multilayer films that are better able to withstand repeated flexure and release while maintaining their gas barrier properties.

[0063] The second material comprises or is primarily composed of one or more polymers. As used herein, one or more polymers present in the second material are referred to herein as one or more "second polymers" or "second polymers" because these polymers are present in the second material. Reference to "(multiple) second polymers" does not imply that the "first polymer" is present in the second material, or is present as a whole in the multilayer film, although in many respects, there are multiple classes or types of polymers. In one aspect, the second material comprises or is substantially composed of one or more thermoplastic polymers. In another aspect, the second material comprises or is substantially composed of one or more elastic polymers. In yet another aspect, the second material comprises or is substantially composed of one or more thermoplastic elastomers. The second material can be described as comprising a polymeric component consisting of all the polymers present in the second material. In one example, the polymeric component of the second material consists of one or more elastomers. Optionally, the second material may further comprise one or more non-polymeric additives, such as fillers, processing aids, and / or colorants.

[0064] Many polymers suitable for use in the second material are known in the art. Exemplary polymers (e.g., the second polymer) that may be included in the second material include polyolefins, polyamides, polycarbonates, polyimides, polyesters, polyacrylates, polyesters, polyethers, polystyrene, polyureas, and polyurethanes, including their homopolymers and copolymers (e.g., polyolefin homopolymers, polyolefin copolymers, etc.), and combinations thereof. In one example, the second material comprises or is substantially composed of one or more polymers selected from polyolefins, polyamides, polyesters, polystyrene, and polyurethanes, including their homopolymers and copolymers, and combinations thereof. In another example, the polymeric component of the second material comprises one or more thermoplastic polymers, or one or more elastomers, or one or more thermoplastic elastomers, including thermoplastic vulcanizates. Alternatively, one or more second polymers may comprise one or more thermosetting or heat-curable elastomers, such as natural rubber and synthetic rubber, including butadiene rubber, isoprene rubber, silicone rubber, etc.

[0065] Polyolefins are a class of polymers comprising monomer units derived from simple olefins such as ethylene, propylene, and butene. Examples of thermoplastic polyolefins include polyethylene homopolymers, polypropylene homopolymers, polypropylene copolymers (including polyethylene-polypropylene copolymers), polybutene, ethylene-octene copolymers, olefin block copolymers; propylene-butane copolymers and combinations thereof, including blends of polyethylene homopolymers and polypropylene homopolymers. Examples of polyolefin elastomers include polyisobutylene elastomers, poly(α-olefin) elastomers, ethylene-propylene elastomers, ethylene-propylene diene monomer elastomers, and combinations thereof.

[0066] Polyamides are a class of polymers comprising monomer units linked by amide bonds. Natural polyamides include proteins, such as wool and silk, and synthetic amides, such as nylon and aromatic polyamides. The one or more second polymers may include thermoplastic polyamides, such as nylon 6, nylon 6-6, nylon-11, and thermoplastic polyamide copolymers.

[0067] Polyesters are a class of polymers comprising monomeric units derived from ester functional groups, typically formed by the condensation of a diacid such as terephthalic acid with one or more polyols. In one example, the second material may comprise or consist substantially of one or more thermoplastic polyester elastomers. Examples of polyester polymers include homopolymers such as polyethylene terephthalate, polybutylene terephthalate, and poly(1,4-cyclohexyl-dimethylene terephthalate), and copolymers such as polyester polyurethane.

[0068] Styrene polymers are a class of polymers comprising monomer units derived from styrene. One or more second polymers may comprise or consist substantially of styrene homopolymers, styrene random copolymers, styrene block copolymers, or combinations thereof. Examples of styrene polymers include styrene block copolymers, such as acrylonitrile-butadiene-styrene block copolymers, styrene-acrylonitrile block copolymers, styrene-ethylene-butene-styrene block copolymers, styrene-ethylene-butadiene-styrene block copolymers, styrene-ethylene-propylene-styrene block copolymers, styrene-butadiene-styrene block copolymers, and combinations thereof.

[0069] Polyurethanes are a class of polymers comprising monomer units linked by urethane bonds. Polyurethanes are most commonly formed by reacting polyisocyanates (e.g., diisocyanates or triisocyanates) with polyols (e.g., diols or triols), optionally in the presence of chain extenders. Monomer units derived from polyisocyanates are generally referred to as hard segments of polyurethanes, while monomer units derived from polyols are generally referred to as soft segments. Hard segments can be derived from aliphatic polyisocyanates, organic isocyanates, or mixtures of both. Soft segments can be derived from saturated polyols, unsaturated polyols such as polydiene polyols, or mixtures of both. When multilayer films are to be bonded to natural or synthetic rubber, including soft segments derived from one or more polydiene polyols can promote adhesion between the rubber and the film when they come into contact and crosslink, for example, during vulcanization.

[0070] Examples of suitable polyisocyanates that can derive hard segments from polyurethanes include: hexamethylene diisocyanate (HDI), isophorone diisocyanate (IPDI), succinate diisocyanate (BDI), diisocyanate cyclohexylmethane (HMDI), 2,2,4-trimethylhexamethylene diisocyanate (TMDI), diisocyanate methylcyclohexane, diisocyanate methyltricyclodecane, norbornane diisocyanate (NDI), cyclohexane diisocyanate (CHDI), 4,4′-dicyclohexylmethane diisocyanate (H12MDI), diisocyanate decane, lysine diisocyanate, and toluene diisocyanate. The polyurethane comprises or is substantially composed of hard segments derived from toluene diisocyanate (TDI), TDI with trimethylolpropane (TMP), methylene diphenyl diisocyanate (MDI), xylene diisocyanate (XDI), tetramethylxylene diisocyanate (TMXDI), hydrogenated xylene diisocyanate (HXDI), naphthalene 1,5-diisocyanate (NDI), 1,5-tetrahydronaphthalene diisocyanate, p-phenylene diisocyanate (PPDI), 3,3′-dimethyldiphenyl-4,4′-diisocyanate (DDDI), 4,4′-dibenzyl diisocyanate (DBDI), 4-chloro-1,3-phenylene diisocyanate, and any combination thereof. In one aspect, the polyurethane comprises or is substantially composed of hard segments derived from toluene diisocyanate (TDI) or methylene diphenyl diisocyanate (MDI), or both.

[0071] The soft segments of polyurethane can be derived from a variety of polyols, including polyester polyols, polyether polyols, polyester-ether polyols, polycarbonate polyols, polycaprolactone polyethers, and combinations thereof. In one aspect, the polyurethane comprises or is substantially composed of monomer units derived from C4-C12 polyols, or C6-C10 polyols, or C8 or lower polyols, meaning polyols having 4 to 12 carbon molecules, or 6 to 10 carbon molecules, or 8 or fewer carbon molecules in their chemical structure. In another aspect, the polyurethane comprises or is substantially composed of monomer units derived from polyester polyols, polyester-ether polyols, polyether polyols, and any combination thereof. In yet another aspect, the polyurethane comprises or is substantially composed of soft segments derived from polyols or diols having polyester functional units. The soft segments derived from polyols or diols having polyester functional units may account for about 10 to about 50, or about 20 to about 40, or about 30% by weight of the soft segments present in the polyurethane.

[0072] Multilayer films can be produced by various methods, such as co-extrusion, lamination, and layer-by-layer deposition. When one or more barrier layers are co-extruded alone or with one or more second layers, selecting materials with similar processing properties, such as melt temperature and melt flow index (e.g., a first barrier material and a second barrier material, or a single barrier material and a second material), can reduce interlayer shear during extrusion and allow alternating barrier layers and second layers to be co-extruded while maintaining their structural integrity and the desired layer thickness. In one example, the one or more barrier materials and an optional second material (when used) can be extruded into separate individual films, which can then be laminated together to form a multilayer film.

[0073] Multilayer films can be produced using a layer-by-layer deposition process. A substrate optionally containing a second material or barrier material can be constructed into a multilayer film by depositing multiple layers on the substrate. These layers may include one or more barrier layers (e.g., a first barrier layer, a second barrier layer, etc.). Optionally, these layers may include one or more second layers. The one or more barrier layers and / or second layers can be deposited by any method known in the art, such as dipping, spraying, coating, or other methods. One or more barrier layers can be applied using charged solutions or suspensions, such as cationic solutions or suspensions or anionic solutions or suspensions, including charged polymer solutions or suspensions. One or more barrier layers can be applied sequentially using two or more solutions with opposite charges, for example, by applying a cationic solution, then an anionic solution, then another cationic solution, then another anionic solution, and so on.

[0074] The total thickness of the barrier film, including the multilayer film, is about 40 micrometers to about 500 micrometers, or about 50 micrometers to about 400 micrometers, or about 60 micrometers to about 350 micrometers. In one aspect, the thickness of each individual layer of the multiple layers of the multilayer film is about 0.001 micrometers to about 10 micrometers. For example, the thickness of a single barrier layer can be about 0.001 micrometers to about 3 micrometers, or about 0.5 micrometers to about 2 micrometers, or about 0.5 micrometers to about 1 micrometer. The thickness of a single second layer can be about 2 micrometers to about 8 micrometers, or about 2 micrometers to about 4 micrometers.

[0075] In another aspect, the thickness of the membrane and / or its individual layers can be measured by any method known in the art, such as ASTM E252, ASTM D6988, ASTM D8136, or using an optical microscope or an electron microscope.

[0076] In some aspects, including multilayer films, the Shore hardness of barrier films is from about 35A to about 95A, optionally from about 55A to about 90A. In these aspects, the hardness can be measured using Shore A ASTM D2240.

[0077] In one aspect, when a barrier film is formed from multiple alternating barrier layers and a second layer using a co-extrusion process, the barrier material has a melt flow index of about 5 to about 7 g / 10 min at 190°C when using a weight of 2.16 kg, while the second material has a melt flow index of about 20 to about 30 g / 10 min at 190°C when using a weight of 2.16 kg. In another aspect, when measured at 190°C using a weight of 2.16 kg, the melt flow index of the barrier material is about 80% to about 120% of the melt flow index of the barrier material per 10 min. In these aspects, the melt flow index can be measured using ASTM D1238. Alternatively or additionally, the barrier material or the second material, or both, have a melting temperature from about 165°C to about 183°C, or from about 155°C to about 165°C. In one such example, the barrier material has a melting temperature ranging from approximately 165 degrees Celsius to approximately 183 degrees Celsius, while the second material has a melting temperature ranging from approximately 155 degrees Celsius to approximately 165 degrees Celsius. Furthermore, in these aspects, the melting temperature can be measured using ASTM D3418.

[0078] In the illustrated embodiment, the barrier layer 118 includes a first upper barrier layer 118 forming the top side 114 of the sac 106A and a second lower barrier layer 118 forming the bottom side 116 of the sac 106A. In the illustrated example, the internal opposing surfaces (i.e., facing each other) of the barrier layer 118 are joined together at discontinuous locations to form the web region 120 and the peripheral seam 122. The peripheral seam 122 extends around the outer periphery of the sac 106A and defines the outer peripheral contour of the sac 106A. Figure 3-5A As shown in 6A, 7 and 8, the upper and lower barrier layers 118 are spaced apart from each other between the abdominal region 120 and the peripheral seam 122 to define a plurality of chambers 126a-126c, 128a-128b, each chamber forming a corresponding portion of the internal void 130 of the sac 106A.

[0079] The sac 106A may include a plurality of U-shaped or horseshoe-shaped chambers 126a-126c, as shown in U.S. Patent Application Serial No. 17 / 133,732 by Chan et al., the disclosure of which is incorporated herein by reference in its entirety. As discussed in more detail below, portions of these chambers 126a-126c extend along the inner and outer sides 22, 24 of the peripheral region 28. Thus, these chambers 126a-126b may be referred to as peripheral chambers 126a-126c. The peripheral chambers 126a-126c include a heel peripheral chamber 126a, a forefoot peripheral chamber 126b, and a toe peripheral chamber 126c. Generally, the peripheral chambers 126a-126c are arranged sequentially along the longitudinal axis A106 from a first end 110 to a second end 112 of the sac 106A. Thus, the chambers 126a-126c are rotated relative to each other along the length of the sac 106A.

[0080] refer to Figure 3-5A One or more of the peripheral chambers 126a-126c may have a variable cross-sectional area from one end to the other. In addition to the peripheral chambers 126a-126c, the capsule 106A includes one or more internal chambers 128a, 128b disposed in the internal region 26 of the capsule 106A. Here, each of the internal chambers 128a, 128b is at least partially surrounded by a corresponding peripheral chamber 126a, 126b. The peripheral chambers 126a-126c and the internal chambers 128a, 128b define an internal void 130. Typically, each of the internal chambers 128a, 128b extends from a first end 132a, 132b of an intermediate segment 134a, 134b connected to an adjacent peripheral chamber 126b, 126c to a terminal second end 136a, 136b adjacent to the rear end 20 of a corresponding peripheral chamber 126a, 126b. The intermediate sections 134a and 134b fluidly connect the inner side 22 of the sac 106A to the outer side 24 of the sac 106A.

[0081] As shown in the figure, the heel periphery chamber 126a, the forefoot periphery chamber 126b, and the toe periphery chamber 126c include a series of convex angles 138a-138i that are interconnected and arranged along the periphery of the sac 106A. The series of convex angles 138a-138i extends in a direction along the longitudinal axis A106 of the sac 106A. Each of the convex angles 138a-138i has a variable cross-sectional area, tapering from the midpoint of the respective convex angle 138a-138i towards its end. For example, each of the convex angles 138a-138i includes a first end 140a-140i with a first cross-sectional area, a second end 142a-142i with a second cross-sectional area, and an intermediate portion 144a-144i disposed between the first end 140a-140i and the second end 142a-142i and having a third cross-sectional area larger than the first and second cross-sectional areas. Therefore, each of the convex angles 138a-138i tapers from the middle portion 144a-144i toward the corresponding first end 140a-140i and second end 142a-142i to define a first series of recesses 146a-146h, wherein each recess 146a-146h is disposed between a pair of adjacent convex angles 138a-138i so as to alternate with the series of convex angles 138a-138i along the length of the chamber 126a-126c. In some examples, the width and thickness of each of the convex angles 138a-138i taper from the middle portion 144a-144i.

[0082] In the illustrated example of sac 106A, the plurality of convex angles 138a-138i are arranged sequentially end-to-end along the peripheral region 28, such that the cross-sectional area of ​​the heel peripheral chamber 126a alternates between larger and smaller dimensions. As shown, the series of convex angles 138a-138i includes a first pair of toe convex angles 138a and 138b disposed on the toe peripheral chamber 126c, a pair of forefoot convex angles 138c and 138d disposed on the forefoot peripheral chamber 126b, a pair of midfoot convex angles 138e and 138f disposed at the front end of the heel peripheral chamber 126a in the midfoot region 14, a pair of heel convex angles 138g and 138h disposed in the heel region 16 between the midfoot convex angles 138e and 138f and the second end 112, and a rear convex angle 138i disposed at the second end 112 of sac 106A. The midfoot convex angles 138e and 138f, the heel convex angles 138g and 138h, and the posterior convex angle 138i define a first series of 148 convex angles forming the heel peripheral cavity 126a. A pair of toe convex angles 138a and 138b and a pair of forefoot convex angles 138c and 138d define a second series of 150 convex angles. When viewed along a plane defined by the width and length of the base 108, the pair of toe convex angles 138a and 138b are spaced apart from each other to define a generally U-shaped recess.

[0083] The medial ...

[0084] Continue to refer to Figure 3-5A A convex angle 138i is disposed at the second end 112 of the sac 106A, and the intermediate portion 144i of the convex angle 138i is aligned with the longitudinal axis A106 of the sac 106A. In the illustrated example, the convex angle 138i extends from a first end 140i on the inner side 22 of the sac 106A to a second end 142i on the outer side 24 of the sac 106A. As described above, the cross-sectional area of ​​the intermediate portion 144i is larger than that of each of the first end 140i and the second end 142i.

[0085] The heel protrusions 138g and 138h of the heel periphery chamber 126a include a medial heel protrusion 138g located on the inner side 22 of the pouch 106A and a lateral heel protrusion 138h located on the outer side 24 of the pouch 106A. As shown in the figure, the first ends 140g and 140h of the heel protrusions 138g and 138h are respectively connected to the second ends 142e and 142f of the medial and lateral heel protrusions 138e and 138f. The second end 142g of the medial heel protrusion 138g is connected to the first end 140i of the posterior protrusion 138i. Similarly, the second end 142f of the lateral heel protrusion 138h is connected to the second end 142i of the posterior protrusion 138i. Similar to the midfoot convex angles 138e, 138f and the posterior convex angle 138i, the heel convex angles 138e-138h provide protrusions along the inner and outer sides 22, 24 of the heel peripheral chamber 126a.

[0086] Continue to refer to Figure 3-5A A rear convex angle 138i is disposed at the second end 112 of the sac 106A, and the intermediate portion 144i of the rear convex angle 138i is aligned with the longitudinal axis A106 of the sac 106A. In the illustrated example, the rear convex angle 138i extends from a first end 140i on the inner side 22 of the sac 106A to a second end 142i on the outer side 24 of the sac 106A. As described above, the intermediate portion 1441 has a larger cross-sectional area than each of the ends 1401 and 1421.

[0087] The heel protrusions 138g and 138h of the heel periphery chamber 126a include a medial heel protrusion 138g located on the inner side 22 of the pouch 106A and a lateral heel protrusion 138h located on the outer side 24 of the pouch 106A. As shown in the figure, the first ends 140g and 140h of the heel protrusions 138g and 138h are respectively connected to the second ends 142e and 142f of the medial and lateral heel protrusions 138e and 138f. The second end 142g of the medial heel protrusion 138g is connected to the first end 140i of the posterior protrusion 138i. Similarly, the second end 142h of the lateral heel protrusion 138h is connected to the second end 142i of the posterior protrusion 138i. Similar to the midfoot convex angles 138e, 138f and the posterior convex angle 138i, the heel convex angles 138g, 138h provide protrusions along the inner and outer sides 22, 24 of the heel peripheral chamber 126a.

[0088] The intermediate segments 134a and 134b extend across the width of the sac 106A. Intermediate segment 134b is adjacent to the midfoot region 14 and connects a pair of forefoot protrusions 138c and 138d to each other. As shown, intermediate segment 134b extends along an arcuate path from the inner side 22 to the outer side 24. Intermediate segment 134a separates the toe portion 12T from the midfoot region 14 and connects the second ends 142a and 142b of a pair of toe protrusions 138a and 138b to each other. As shown, intermediate segment 134a extends along an arcuate path from the inner side 22 to the outer side 24, thereby facilitating the formation of a U-shaped recess between the pair of toe protrusions 138a and 138b.

[0089] Still referencing Figure 3-5A The forefoot periphery chamber 126b includes a pair of forefoot protrusions 138c and 138d, which extend through the ball portion 12B of the forefoot region 12 and are located between the heel periphery chamber 126a and the toe periphery chamber 126c. Specifically, the forefoot protrusions 138c and 138d include a medial forefoot protrusion 138c and a lateral forefoot protrusion 138d. A first recess 146a is formed at the position where the second end 142a of the medial toe protrusion 138a meets the first end 140c of the medial forefoot protrusion 138c. Similarly, a second recess 146b is formed at the position where the second end 142b of the lateral toe protrusion 138b meets the first end 140d of the lateral forefoot protrusion 138d. A third recess 146c is formed at the position where the second end 142c of the medial forefoot protrusion 138c meets the first end 140e of the medial midfoot protrusion 138e. Similarly, the fourth recess 146d is formed at the position where the second end 142d of the outer front leg convex angle 138d and the first end 140f of the outer middle leg convex angle 138f meet.

[0090] In some examples, one or both of the anterior convex angles 138c and 138d of the anterior limb peripheral chamber 126b may be spherical, so that the dimensions (e.g., cross-section, width, thickness) of the intermediate portions 144c and 144d are larger than those of the first ends 140c and 140d and the second ends 142c and 142d. For example, in the illustrated configuration, the width of each of the first ends 140c and 140d and the second ends 142c and 142d increases from the corresponding intermediate portions 144c and 144d, such that the first ends 140c and 140d and the second ends 142c and 142d converge inward toward the longitudinal axis A106 of the capsule 106A. (Continue to refer to...) Figure 3-5A One or two toe protrusions 138a, 138b of the peripheral cavity 126c of the toe can be spherical, thereby the dimensions (e.g., cross-section, width, thickness) of the middle portion 144a, 144b are greater than the first end 140a, 140b and the second end 142a, 142b.

[0091] Unlike the heel periphery chamber 126a and forefoot periphery chamber 126b, which are fully attached to the sternum region 120, the toe periphery chamber 126c may only be partially attached to the sternum region 120. For example, the toe protrusions 138a and 138b of the toe periphery chamber 126c may protrude beyond the sternum region 120, such that the distal end of each of the toe protrusions 138a and 138b hangs freely. Thus, each of the toe protrusions 138a and 138b can move independently of the other. In another configuration, the toe protrusions 138a and 138b of the toe periphery chamber 126c may be formed into a generally circular shape (not shown).

[0092] like Figure 5A As shown, the forefoot internal chamber 128a extends along the longitudinal axis A106 from a first end 132a of the intermediate segment 134a connected to the toe peripheral chamber 126c to a second end 136a adjacent to the terminal end of the intermediate segment 134b of the forefoot peripheral chamber 126b. As shown, the outer periphery of the forefoot internal chamber 128b is offset inwardly by a substantially constant distance from the inner periphery of the forefoot peripheral chamber 126b. In the illustrated example, the forefoot internal chamber 128b includes a necked portion 152 adjacent to the first end 132b, which extends between the recesses 146a, 146b of the forefoot peripheral chamber 126b. The second end 136b of the forefoot internal chamber 128b may also be spherical and externally connected by the forefoot protrusions 138c, 138d of the forefoot peripheral chamber 126b.

[0093] The heel cavity 128a extends along the longitudinal axis A106 from a first end 132a of the intermediate segment 134b connected to the forefoot periphery cavity 126b to a second end 136b adjacent to the terminal end of the convex angle 138i of the heel periphery cavity 126a. The outer periphery of the heel cavity 128a is offset inward from the inner periphery of the heel periphery cavity 126a by a substantially constant distance. Thus, the width of the heel cavity 128b can increase along the direction from the first end 132b to the second end 136b.

[0094] Internal chambers 128a and 128b are attached to corresponding peripheral chambers 126a and 126b via a ventral region 120, such that each internal chamber 128a and 128b is surrounded by a portion of the ventral region 120. Therefore, the ventral region 120 includes a generally U-shaped first portion 154a surrounding the heel internal chamber 128a and a generally U-shaped second portion 154b surrounding the forefoot internal chamber 128b, as shown. The U-shaped first portion 154a of the ventral region 120 extends between and attaches to the outer periphery of the heel internal chamber 128a and the inner periphery of the heel peripheral chamber 126a. Similarly, the second U-shaped portion 154b extends between and attaches to the outer periphery of the foreleg internal chamber 128b and the inner periphery of the foreleg peripheral chamber 126b. As shown, regarding the aforementioned portion of the web region 120, the term "U-shaped" is not strictly limited to a shape having two straight legs connected by a constant curvature, but refers to any shape that extends from the first end along a generally first direction line, then folds back and extends along the first direction line to a second end adjacent to or facing the first end. Therefore, the U-shaped portion of the web region can also be described, for example, as horseshoe-shaped, bell-shaped, or hairpin-shaped.

[0095] The adjacent chambers in chambers 126a-126c and 128a-128b are separated from each other by a portion of the ventral region 120, such that recesses or spaces 156a-158c and 160a-160c are formed between the adjacent chambers in chambers 126a-126c and 128a-128b on opposite sides 114 and 116 of the sac 106A, as shown below. Figure 7 and 8 As best shown in the diagram. In other words, sac 106A includes a series of upper depressions 156a-158c formed by the ventral region 120 and adjacent chambers 126a-126c, 128a-128b on the top side 114 of sac 106A, and a series of lower depressions 158a-158c formed by the ventral region 120 and adjacent chambers 126a-126c, 128a-128b on the bottom side 116 of sac 106A.

[0096] Continue to refer to Figure 5A A series of convex angles 138a-138i, with their first ends 140a-140i and second ends 142a-142i, and the first ends 132a and 132b of the internal chambers 128a and 128b forming a plurality of conduits, which fluidly connect adjacent peripheral chambers 126a-126c to each other. Therefore, portions of the internal voids 130 formed by each of the peripheral chambers 126a-126c and the internal chambers 128a and 128b are in fluid communication with each other, allowing fluid to transfer between the peripheral chambers 126a-126c.

[0097] For reference Figure 5B and 6B Another aspect of the cushioning member 106 is provided, wherein the cushioning member 106 is a foam element 106B. In one aspect, the foam element 106B is a solid monolithic piece extending the length, width, and height of the cushioning member 106. In such an aspect, the top side 114 and the bottom side 116 of the foam element 106B define the shape of the foam element 106B. The foam element 106B comprises a foam material comprising one or more polymers, examples of which are provided below. Figure 5B and 6B As shown, the shape of foam element 106B is the same as that of cushioning member 106 shown in all the figures. In other words, foam element 106B can be formed solely of a polymeric material, the shape of which is... Figure 5A and 6A The shape defined by the barrier layer 118 shown is the same. It should be noted that the foam element 106B may have the same shape as the peripheral chambers 126a-126c and internal chambers 128a, 128b described with respect to the fluid-filled bladder 106A, but does not enclose the space or define internal voids because the foam element 106B is formed as a single piece. When the cushioning member 106 is formed as the foam element 106B, features such as the web region 120 of the fluid-filled bladder 106A are also formed of an elastic polymeric material. The polymeric material can be formed to provide a similar shape to... Figure 5A and 6A The fluid-filled bladder 106A shown has essentially the same cushioning and load-bearing characteristics; however, as mentioned above, the ground reaction force can differ. That is, the ground reaction force is primarily dissipated by the foam element 106B, unlike the distribution throughout the fluid-filled bladder 106A. Thus, the applied load is typically absorbed rather than dispersed or attenuated to other locations of the cushioning member 106.

[0098] refer to Figure 5C and 6CThis provides another aspect of the cushioning member 106, wherein the cushioning member 106 includes a foam element 106B formed as a solid body comprising a foam material comprising one or more polymers, the polymer being accommodated within and between barrier layers 118 for encapsulation. The polymeric material and the associated barrier layers 118 can be formed to provide... Figure 5A and 6A The fluid-filled capsule 106A shown has essentially the same cushioning and load-bearing properties; however, the ground reaction force differs due to the foam element 106B disposed therein. Essentially, the combination of the barrier layer 118 and the encapsulated foam element 106B provides a hybrid cushioning element that shares the properties of both the fluid-filled capsule 106A and the foam element 106B. That is, an applied load will (i) cause displacement of the fluid trapped between the barrier layers 118, and (ii) be absorbed by the polymeric material of the foam element 106B. Encapsulating the polymeric material within the barrier layer 118 helps keep the polymeric material of the foam element 106B clean and dry, and helps the foam element 106B maintain its desired shape. Regardless of whether the cushioning member 106 includes the barrier layer 118 and the polymeric material, or simply defines the polymeric material of the cushioning member 106, Figure 6C The thickness T106 of the buffer member 106 shown is the same as... Figure 6A and 6B The thickness T106 of the buffer member 106 shown is the same. Therefore, the discussion of the details of the buffer member 106 applies to the case where the buffer member 106 is a fluid-filled chamber, and the buffer member 106 comprises a foam material containing one or more polymers, or is formed of a foam material containing one or more polymers encapsulated within the barrier layer 118.

[0099] Continue to refer to Figure 2A and 2B The base 108 is configured to mate with the cushioning member 106 to provide an integrated sole interlayer 102. It should be understood that the base 108 is configured to mate with any aspect of the cushioning member 106 described herein. The base 108 extends from a first end 160 at the front end 18 of the sole structure 100 to a second end 162 at the rear end 20 of the sole structure 100. The base 108 also includes a top surface 164 defining a portion of the footbed, and a bottom surface 166 formed on the side of the base 108 opposite the top surface 164 and configured to mate with the top side 114 of the bladder 106.

[0100] The base 108 may be formed as a single piece or may be formed from multiple elements, as discussed in more detail below. The base 108 includes a series of support members 168a-168g extending along the length of the base 108. Specifically, a plurality of inner support members 168a, 168c, 168e, and 168g extend along the inner side 22 of the base 108, a plurality of outer support members 168b, 168d, 168f, and 168h extend along the outer side 24 of the base 108, and a rear support member 168i is disposed at the rear end 20 of the base 108. The rear support member 168i is disposed between the series of inner support members 168a, 168c, and 168e and the series of outer support members 168b, 168d, and 168f. The series of support members 168a-168i alternates with a series of recesses 170a-170f, which also extend along the length of the base 108. Specifically, the outer recesses 170a, 170c and 170e of the second series of recesses 170a-170f extend along the outer side 24 of the base 108, and the inner recesses 170b, 170d and 170f of the second series of recesses 170a-170f extend along the inner side 22 of the base 108.

[0101] Outer recess 170a and inner recess 170b are provided between the midfoot region 14 and the forefoot region 12. The outer recess 170a and inner recess 170b each taper in width and height from the peripheral edge of the base 108 to the center of the base 108, terminating on an outer surface coplanar with the bottom of the base 108, thus forming a shape resembling half a cone when viewed in cross-section along the length of the cone. Outer recess 170c and inner recess 70d form a continuous midfoot recess 172 extending the width of the base 108. The continuous midfoot recess 172 separates the heel region 16 from the midfoot region 14. The continuous midfoot recess 172 is positioned to facilitate bending of the outsole 104 between the heel region 16 and the midfoot region 14.

[0102] Series of support members 168a-168i are aligned and contacted with series of convex corners 138a-138i. Thus, the distal end of each of the support members 168a-168i is entirely recessed, having an overall U-shaped cross-section cut along the width of the base 108 to receive the top surface of the corresponding convex corner in the first series of convex corners 138a-138i. Support members 168c-168i define a first series 174 of support members 168c-168i, which are configured to align and contact with the first series 148 convex corners 138c-138i. Support members 168a-168b define a second series 176 of support members, which are configured to align with the second series 150 convex corners 38a-138b provided in the toe portion 12T of the forefoot region 12.

[0103] In cases where the base 108 is composed of multiple elements, the base 108 may include a cushioning support 178 and a plate 180. In this respect, the plate 180 is wider than the cushioning support 178, and the cushioning support 178 is configured to be located below the plate 180 and above the cushioning member 106. The plate 180 has a continuous surface defined by its peripheral edges. Furthermore, in this respect, a first series 174 of support members 168c-168i are formed entirely on the bottom surface of the cushioning support 178, and a second series 176 of second support members 168a-168b are formed entirely on the bottom surface of the plate 180.

[0104] Continue to refer to Figure 2A and 2B The base 108 can be configured to support the periphery of the user's feet. In this respect, the base 108 may further include a series of upper portions 184a-184h disposed on the peripheral edge of the base 108. In the case where the base 108 is formed by a cushioning support 178 and a plate 180, the series of upper portions 184a-184h are formed only on the plate 180.

[0105] The upper portions 184a-188h of this series are arranged along the periphery of the base 108 and are curved along the width and height of the base frame 108 to conform to the shape of the bottom of the foot. The upper portions 184a-184h include a front upper portion 184a, a rear upper portion 184h, a series of inner upper portions 184b, 184d, 184f and a series of outer upper portions 184c, 184e, 184g, which extend along the periphery of the corresponding inner and outer sides 24 of the base 108.

[0106] The upper rear portion 184h is located at the rear end 20 of the base 108, and the upper front portion 184a is located at the front end 18 of the base 108. The series of inner upper portions 184b, 184d, 184f and outer upper portions 184c, 184e, 184g extend from the opposite end of the upper rear portion 184h to the corresponding end of the upper front portion 184a. The upper rear portion 184h forms a cup shape to help support the rear of the heel. The upper front portion 184a curves along the periphery of the rear end 20 of the base 108 and may have a substantially constant height. The heights of the upper portions 184a-184h may be the same or different. In the aspect where the base 108 is formed as a single piece, the upper portions 184a-188h are adjacent to a series of support members 168a-168i. In the case where the base 108 is formed by multiple elements, such as a buffer support 178 and a plate 180, the upper portions 184a-184h of this series can be formed entirely on the plate 180.

[0107] As described above, the base 108 can be formed by assembling the cushioning support 178 onto the plate 180. In this aspect, the plate 180 is mounted to the top surface of the cushioning support 178, thereby being positioned between the upper 200 and the cushioning support 178. The plate 180 is longer than the cushioning support 178, and outer and inner support members 168a, 168b (which are configured to align with and contact the corresponding toe convex corners 138a, 138b) are formed on the bottom surface of the plate 180.

[0108] The bottom surface of plate 180 includes an inner peripheral wall 186 that defines a space that defines a cushioning recess 188. The cushioning recess 188 is configured to receive a cushioning support 178, which can be secured to plate 180 to form a single unit. In one aspect, the cushioning support 178 can be secured to the cushioning pouch 188 using any securing means or technique, illustratively including adhesives, stitching, welding vibration fusion, etc., alone or in combination.

[0109] In one aspect, the base 108 is composed of a buffer support 178 and a plate 180. The buffer support 178 includes a series of wings 190a-190h disposed along the periphery of the base 108, extending from the front end 18 to the rear end 20 along the inner side 22 and the outer side 24. The series of wings 190a-190h includes a front wing 190a disposed on the front end 18 of the base 108, a rear wing 190h disposed on the rear end 20 of the base 108, a series of inner wings 190b, 190d, 190f disposed along the inner side 22 of the base 108 between the rear wing 190h and the front wing 190a, and a series of outer wings 190c, 190e, 190g disposed along the outer side 24 of the base 108 between the rear wing 190h and the front wing 190a.

[0110] The inner peripheral wall 186 of the plate 180 is sized to accommodate the cushioning support 178. The inner peripheral wall 186 includes a series of flanges 192a-192h defining the cushioning recess 188. The height of the inner peripheral wall 186 is substantially the same as the height of the series of wings 190a-190h, thus creating a substantially seamless transition between the series of wings 190a-190h and the bottom surface of the plate 180. The dimensions of each flange in the series of flanges 192a-192h are designed to lie between a pair of adjacent wings in the series of wings 190a-190h.

[0111] The series of flanges 192a-192h includes a pair of front flanges 192a and 192b, disposed on the front end 18 of the base 108 and spaced apart from each other to accommodate the front wing 190a. The series of flanges 192a-192h also includes a pair of rear flanges 192g and 192h, disposed on the rear end 20 of the base 108 and spaced apart from each other to accommodate the rear wing 190h. A series of inner flanges 192c and 192e are disposed on the inner side 22 of the plate 180, located between the pair of rear wings 190g and 190h and the pair of front wings 190a and 190b. A series of outer flanges 192d and 192f are disposed on the outer side 24 of the plate 180, located between the pair of rear wings 190g and 190h and the pair of front wings 190a and 190b. The inner flanges 190b, 190d, and 190f are disposed between the corresponding flanges of the inner flanges 192c and 192e. Similarly, the outer flanges 190c, 190e, and 190g are disposed between the corresponding flanges of the outer flanges 192d and 192f.

[0112] The base 108 includes a series of ridges 194a-194c, which, when assembled to the cushioning member 106, can be configured to reside in one of the upper recesses 156a-156c. The series of ridges 194a-194c are formed on the underside of the cushioning support 178 and include a front ridge 194a, a middle ridge 194b, and a rear ridge 194c. The front ridge 194a is disposed on the front foot region 12 and has a generally U-shaped structure forming a front recess 198a, which is configured to engage the internal cavity 128b. The intermediate ridge 194b is formed by a pair of spaced-apart legs 196a, 196b disposed on the respective outer 24 and inner 22 of the base 108, thereby forming an elongated intermediate recess 198b configured to engage the internal cavity 128b. The rear ridge 194c is formed in a generally U-shaped dimension to define the rear recess 198c configured to engage the internal cavity 128a. In the example shown, the ridges 194a-194c can be configured to extend fully into the ventral region 120 of the upper recesses 158a-156c in some areas and be spaced apart from the ventral region 120 of the upper recesses 158a-156c in other areas when the sole interlayer 102 is assembled. Therefore, the bottom surface of the ridges 194a-194c can contact the ventral region 120 at selected locations. In other embodiments, one or more of the ridges 194a-194c may be configured such that the distal end is spaced apart from the web region 120, or may be omitted from the base 108.

[0113] For reference Figure 9 and Figure 10This provides one aspect of a base 108, which is composed of a cushioning support 178 and a plate 180. The cushioning support 178 and the plate 180 can be secured to each other using any technique such as adhesives, welding, etc., to form a single unit. Alternatively, the cushioning support 178 and the plate 180 can be simply mounted to each other and held in place by attachment to the outsole 104 and the upper 200. The plate 180 has a continuous top surface between its peripheral edges.

[0114] Now for reference Figure 11 The base 108 and outsole 104 shown are assembled onto the cushioning member 106. Ridge 194c is shown in contact with the web region 120, while ridge 194a is spaced apart from the web region 120. Plate 180 is longer than the cushioning support 178, and the second series of convex angles 138a-138b extend beyond the front end of the cushioning support 178. Outsole 104 is mounted to the bottom surface of the cushioning member 106 to protect the cushioning member 106 during engagement with the ground. The top surfaces of the corresponding internal chambers 128a, 128b lie within the corresponding recesses 198a-198c of the corresponding ridges 194a-194c. Rear support 1681 has a generally hemispherical cross-section corresponding to the top surface of the rear convex angle 1381. The rear end of the rear ridge 194c is spaced apart from the web region 120. The rear end of the front ridge 194a rests against the web region 120. The continuous recess 172 of the middle leg separates the posterior ridge 194a from the intermediate ridge 194b.

[0115] For reference Figure 12 Provided along Figure 10 Cross-sectional view taken at centerline 12-12. Figure 12 The engagement of the toe protrusions 138a, 138b with the base 108 is shown. In this respect, the second series 176 second support members 168a-168b are formed entirely from the plate 180. The buffer support member 178 does not extend to the toe protrusions 138a, 138b and forms a gap 202 between the pair of toe protrusions 138a, 138b. The gap 202 allows the toe protrusions 138a, 138b to flex freely relative to the protrusions 138c-138i, which are connected at the corresponding first ends 140a-140i and second ends 142a-142i.

[0116] For reference Figure 13 Provided along Figure 10A cross-sectional view taken along centerline 13-13. The base 108 rests completely against the top side 114 of the cushioning member 106. The inner support 168c and outer support 168d engage with a pair of front leg convex angles 138c, 138d. The outer support 168c is fully formed on the cushioning support 178, and the plate 180 rests on the top surface of the cushioning support 178. The rear recess 198c of the cushioning support 178, defined by the rear ridge 194c, is arc-shaped, thus resting against the top surface of the front leg internal cavity 128a. The bottom surface of the front ridge 194a engages with the web region 120.

[0117] For reference Figure 14 Provided along Figure 10 The cross-sectional view is taken from line 14-14. The inner support 168e and the outer support 168f are aligned and in contact with the top surface of the corresponding one of the pair of center leg protrusions 138e, 138f. The inner support 168f and the outer support 168e are sized to be positioned completely against the corresponding center leg protrusions 138e, 138f. The intermediate recess 198b between the legs 196a, 196b of the intermediate ridge 194b is arc-shaped so as to be positioned against the top surface of the inner cavity 128b. Figure 14 One aspect is shown in which the bottom surface of the intermediate ridge 194b is separated from the web region 120.

[0118] For reference Figure 15 Provided along Figure 10 The cross-sectional view is taken from line 15-15. The inner support 168h and the outer support 168g are aligned and in contact with the top surface of the corresponding one of the pair of heel protrusions 138h, 138g. The dimensions of the inner support 168h and the outer support 168g are designed to be positioned completely against the corresponding heel protrusions 138h, 138g. The rear recess 198c, defined by the rear ridge 194c, is arc-shaped so as to be positioned against the top surface of the internal cavity 128b. Figure 14 One aspect is shown in which the bottom surface of the intermediate ridge 194b is separated from the web region 120.

[0119] Components 178 and 180 of the base 108 may include a base material containing one or more polymers (such as foam or rubber) to impart cushioning, responsiveness, and energy distribution characteristics to the wearer's foot. In the illustrated example, cushioning support 178 includes a first foam material, and plate 180 includes a second foam material. For example, cushioning support 178 may include a foam material that provides greater cushioning and impact distribution, while plate 180 may include a foam material with greater stiffness to provide increased lateral and medial stiffness to the peripheral area 28 of upper 200. Upper portions 184b-184h are located within corresponding wings 190b-190h. Wings 184b-184h and upper portions 184b-184h extend outward and upward from the periphery of plate 180. Wings 184b-184h and upper portions 184b-184h are aligned with corresponding supports 168c-168i.

[0120] Refer again Figure 2A and Figure 11-15 In one aspect, the buffer support 178 has a generally V-shaped cross-section along its height direction. Specifically, the center of the buffer support 178 defining the wings 190b-190h from the supports 168c-168i is recessed inward relative to the wings 190b-190h and the corresponding supports 168c-168i. The series of supports 168c-168i cooperate with the corresponding wings 184b-184h to provide compressive and reaction forces in response to loads. As an example, the series of supports 168c-168i and the corresponding wings 184b-184h act as springs in response to compressive loads.

[0121] The base material contains one or more polymers. Example base materials include foam or solid materials, including molded foam and molded solid materials.

[0122] The various materials described herein (e.g., outsole materials, cushioning materials, base materials, etc.) comprise one or more polymers, or are substantially composed of one or more polymers. One or more polymers may include one or more thermoplastic polymers, one or more thermosetting or heat-curable polymers (i.e., polymers capable of crosslinking but not yet crosslinked), or one or more thermosetting polymers. One or more polymers may include one or more elastomers, including thermoplastic elastomers (TPEs) or thermosetting elastomers, or both. One or more polymers may include aliphatic polymers, aromatic polymers, or mixtures thereof; or may include homopolymers, copolymers (including terpolymers), or mixtures thereof.

[0123] In some aspects, the one or more polymers may include olefin homopolymers, olefin copolymers, or blends thereof. Examples of olefin polymers include polyethylene, polypropylene, and combinations thereof. In other aspects, the one or more polymers may include one or more ethylene copolymers, such as ethylene-vinyl acetate (EVA) copolymers, EVOH copolymers, ethylene-ethyl acrylate copolymers, ethylene-unsaturated monofatty acid copolymers, and combinations thereof.

[0124] In another aspect, the one or more polymers may include one or more polyacrylates, such as polyacrylic acid, esters of polyacrylic acid, polyacrylonitrile, polyacrylate, polymethyl acrylate, ethyl acrylate, butyl acrylate, polymethyl methacrylate, and polyvinyl acetate; including derivatives thereof, copolymers thereof, and any combination thereof.

[0125] In another aspect, one or more polymers may include one or more ionomer polymers. In these aspects, ionomer polymers may include polymers having carboxylic acid functional groups, sulfonic acid functional groups, their salts (e.g., sodium, magnesium, potassium, etc.), and / or their anhydrides. For example, one or more ionomer polymers may include one or more fatty acid-modified ionomer polymers, polystyrene sulfonates, ethylene-methacrylic acid copolymers, and combinations thereof.

[0126] In other respects, one or more polymers may include one or more styrene block copolymers, such as acrylonitrile butadiene styrene block copolymers, styrene acrylonitrile block copolymers, styrene ethylene butene styrene block copolymers, styrene ethylene butadiene styrene block copolymers, styrene ethylene propylene propylene styrene block copolymers, styrene butadiene styrene block copolymers, and combinations thereof.

[0127] In other respects, one or more polymers may include one or more polyamide copolymers (e.g., polyamide-polyether copolymers) and / or one or more polyurethanes (e.g., crosslinked polyurethanes and / or thermoplastic polyurethanes). Examples of suitable polyurethanes include those discussed above with respect to barrier layer 118. Alternatively, one or more polymers may include one or more natural and / or synthetic rubbers, such as polybutadiene and polyisoprene.

[0128] When the material is a foam, it can be foamed using a physical blowing agent that transforms into a gas based on temperature and / or pressure changes, or a chemical blowing agent that forms a gas when heated above its activation temperature. For example, a chemical blowing agent can be an azo compound, such as hexamethylenetetramine, sodium bicarbonate, and / or isocyanate.

[0129] In some constructions, the foam polymer material may be a cross-linked foam material. In these constructions, peroxide-based cross-linking agents, such as dicumyl peroxide, may be used. Furthermore, the foam polymer material may include one or more fillers, such as pigments, modified or natural clay, modified or unmodified synthetic clay, talc glass fiber, powdered glass, modified or natural silica, calcium carbonate, mica, paper, wood chips, and the like.

[0130] A molding process can be used to form the material. In one instance, when the material comprises a molded elastomer, the uncured material (e.g., uncured rubber) can be mixed in a Banbury mixer with optional fillers and curing packs (such as sulfur-based or peroxide-based curing packs), calendered, molded, placed in a mold, and vulcanized.

[0131] In another example, when the material is a foam, it can be foamed during a molding process such as injection molding. Thermoplastic polymer material can be melted in the barrel of an injection molding system and mixed with a physical or chemical foaming agent and optionally a crosslinking agent, then injected into a mold under conditions where the foaming agent is activated, thereby forming molded foam.

[0132] Optionally, when the material is a foam material, the foam material may be a compression-molded foam. Compression molding can be used to change the physical properties of the foam (e.g., density, stiffness, and / or hardness), or to change the physical appearance of the foam (e.g., fusing two or more foam pieces to form a foam, etc.), or both.

[0133] Compression molding supply is intended to begin by forming one or more foam preforms, for example, by injection molding and foaming the material, by foaming the material to form foam particles or beads, by cutting foam sheet raw materials, etc. Compression-molded foam can then be manufactured by placing one or more foam preforms in a compression mold and applying sufficient pressure to the preforms to compress them within a closed mold. Once the mold is closed, sufficient heat and / or pressure are applied to the preforms within the closed mold for a sufficient time to modify the preform(s) by forming a skin on the outer surface of the compression-molded foam, fusing individual foam particles together, increasing the density of the foam retained in the finished product, or any combination thereof. After heating and / or applying pressure, the mold is opened and the molded foam article is removed from the mold.

[0134] In some examples, the outsole 104 extends over the midsole 102 to provide increased durability and resilience. In the illustrated example, the outsole 104 is provided as a polymer layer overmolded onto the cushioning member 106 to provide increased durability to the exposed portion of the lower barrier layer 118 of the cushioning member 106. Therefore, the outsole 104 is formed of a different material than the cushioning member 106 and includes at least one of a different thickness, different hardness, and different abrasion resistance than the lower barrier layer 118. In some examples, the outsole 104 may be integrally formed with the lower barrier layer 118 of the cushioning member 106 using an overmolding process. In other examples, the outsole 104 may be formed separately from the lower barrier layer 118 of the cushioning member 106 and may be bonded to the lower barrier layer 118.

[0135] The upper 200 is attached to the sole structure 100 and includes an inner surface defining a cavity configured to receive and secure the foot for support on the sole structure 100. The upper 200 may be formed of one or more materials stitched or adhesively bonded together to form the cavity. Suitable materials for the upper may include, but are not limited to, mesh, textiles, foam, leather, and synthetic leather. Materials can be selected and positioned to impart durability, breathability, abrasion resistance, flexibility, and comfort.

[0136] The following terms provide exemplary constructions of the aforementioned airbags, sole structures, and footwear articles.

[0137] Clause 1: A sole structure for footwear articles having an upper, comprising a cushioning member and a base. The cushioning member extends from a forefoot region of the sole structure to a heel region of the sole structure and includes a first series of protrusions alternating with a first series of recesses along the length of the cushioning member. The first series of protrusions and the first series of recesses extend along one of the medial side and the lateral side of the sole structure. The cushioning member also includes a second series of protrusions in a toe portion. The base includes: a first series of supports, each support aligned with and contacting a corresponding protrusion of the first series of protrusions; and a second series of supports, each support aligned with and contacting a corresponding protrusion of the second series of protrusions; each of the first series of supports includes a first material, and each of the second series of supports includes a second material different from the first series of supports.

[0138] Clause 2: The sole structure according to Clause 1, wherein at least one of the first series of supports and the second series of supports includes an upper portion extending outwardly from the body of the at least one support.

[0139] Clause 3: The sole structure as described in Clause 2, wherein the base includes a cushioning support.

[0140] Clause 4: The sole structure according to Clause 3, wherein the cushioning support includes a continuous recess extending across the width of the cushioning support between the heel region and the midfoot region.

[0141] Clause 5: The sole structure according to Clause 3, wherein the base further includes a plate attached to the side of the cushioning support opposite to the cushioning member.

[0142] Clause 6: The sole structure according to Clause 5, wherein the plate is longer than the cushioning support.

[0143] Clause 7: The sole structure according to Clause 5, wherein the cushioning support comprises a first material having a first hardness, and the plate comprises a second material having a second hardness greater than the first hardness.

[0144] Clause 8: The sole structure according to any one of the preceding clauses, wherein the first material comprises foam material.

[0145] Clause 9: The sole structure according to any one of the preceding clauses, wherein the second series of supports includes a pair of supports configured to align with and contact a pair of toe convex angles of the second series of convex angles, the toe convex angles being located in the forefoot region.

[0146] Clause 10: The sole structure according to any one of the preceding clauses, wherein the first series of support members includes a plurality of forefoot support members and a plurality of heel support members, the plurality of forefoot support members and the plurality of heel support members being integrally formed of a first material.

[0147] Clause 11: The sole structure according to any one of the preceding clauses, wherein the cushioning member is one of a foam element and a fluid-filled bladder, the foam element being a solid monolithic piece extending the length, width and height of the cushioning member.

[0148] Clause 12: The sole structure according to Clause 11, wherein the fluid-filled bladder is formed by a pair of opposing barrier layers.

[0149] Clause 13: The sole structure according to any one of the preceding clauses, wherein the cushioning member comprises foam elements encapsulated in a pair of opposing barrier layers.

[0150] Clause 14: A footwear article comprising a sole structure pursuant to any of the preceding clauses.

[0151] Clause 15: A sole structure comprising a cushioning member including (i) a peripheral chamber including a first series of convex corners arranged along a peripheral region of the sole structure from a forefoot region to a heel region of the bladder; and (ii) an internal chamber at least partially surrounded by the peripheral chamber and spaced apart from the peripheral chamber by a ventral region; and a base including a cushioning support defining a first series of supports arranged along a peripheral region of the sole structure, each of the first series of supports being separated from an adjacent support by a recess and contacting a corresponding convex corner.

[0152] Clause 16: The sole structure according to Clause 15, wherein the base further includes a plate attached to the side of the cushioning support opposite to the cushioning member.

[0153] Clause 17: The sole structure according to Clause 16, wherein the plate is longer than the cushioning support.

[0154] Clause 18: The sole structure according to Clause 16, wherein the cushioning support includes a series of wings extending along the periphery of the cushioning support, the series of wings being configured to position against the bottom surface of the plate.

[0155] Clause 19: The sole structure according to any one of the preceding clauses, wherein at least one of the first series of supports includes an upper portion extending upward and outward from the body of the at least one of the first series of supports.

[0156] Clause 20: The sole structure according to any one of the preceding clauses, wherein the recess extends across the width of the cushioning support.

[0157] Clause 21: The sole structure according to any one of the preceding clauses, wherein the recess is disposed between the midfoot region and the heel region.

[0158] Clause 22: The sole structure according to any one of the preceding clauses, wherein the cushioning support comprises a series of ridges configured to be located within a corresponding recess of a series of recesses formed on the top side of the bladder.

[0159] Clause 23: The sole structure according to any one of the preceding clauses, wherein the cushioning support includes an internal support configured to align with an intermediate chamber disposed between the inner and outer sides of the sole structure.

[0160] Clause 24: The sole structure according to any one of the preceding clauses, wherein the first series of support members includes a plurality of forefoot support members and a plurality of heel support members, the plurality of forefoot support members and the plurality of heel support members being integrally formed by the cushioning support members.

[0161] Clause 25: The sole structure according to any one of the preceding clauses, wherein the cushioning member is one of a foam element and a fluid-filled bladder, the foam element being a solid monolithic piece extending the length, width and height of the cushioning member.

[0162] Clause 26: The sole structure according to Clause 25, wherein the fluid-filled bladder is formed by a pair of opposing barrier layers.

[0163] Clause 27: The sole structure according to any one of the preceding clauses, wherein the cushioning member comprises foam elements encapsulated in a pair of opposing barrier layers.

[0164] Clause 28: A footwear article comprising a sole structure pursuant to any of the preceding clauses.

[0165] The foregoing description has been provided for illustrative purposes. It is not intended to be exhaustive or limiting of this disclosure. Elements or features of a particular construction are generally not limited to that particular construction, but are interchangeable where applicable, and may be used in the chosen construction even if not specifically shown or described. It can also be varied in many ways. Such variations should not be considered a departure from this disclosure, and all such modifications are intended to be included within the scope of this disclosure.

Claims

1. A sole structure, comprising: a cushioning member including a first series of lobes arranged along one of a medial side and a lateral side of the sole structure from a forefoot region to a heel region and a second series of lobes located in a toe portion; and a chassis including a cushioning support and a plate attached on a side of the cushioning support opposite the cushioning member, the cushioning support including a first series of supports each aligned with and contacting a respective lobe of the first series of lobes; the plate including a second series of supports each aligned with and contacting a respective lobe of the second series of lobes; each of the first series of supports includes a first material, each of the second series of supports includes a second material different from the first series of supports, the plate is longer than the cushioning support.

2. The sole structure of Claim 1, wherein, at least one of the first series of supports and the second series of supports includes an upper portion extending in an outward direction from a body of the at least one support.

3. The sole structure of claim 1, wherein, the cushioning support includes a continuous recess extending across a width of the cushioning support between the heel region and a midfoot region.

4. The sole structure of claim 1, wherein, the cushioning support includes a first material having a first hardness, the plate includes a second material having a second hardness greater than the first hardness.

5. The sole structure of claim 1, wherein, the first material includes a foam material.

6. The sole structure of claim 1, wherein, the second series of supports includes a pair of supports configured to align with and contact a pair of toe lobes of the second series of lobes, the pair of toe lobes disposed in the forefoot region.

7. The sole structure of claim 1, wherein, the first series of supports includes a plurality of forefoot supports and a plurality of heel supports, the plurality of forefoot supports and the plurality of heel supports are integrally formed from a first material.

8. The sole structure of claim 1, wherein, the cushioning member is one of a foam element and a fluid-filled bladder, the foam element is a solid monolithic piece extending a length, a width, and a height of the cushioning member.

9. The sole structure of claim 8, wherein, the fluid-filled bladder is formed from an opposing pair of barrier layers.

10. The sole structure of claim 1, wherein, the cushioning member includes a foam element encapsulated in an opposing pair of barrier layers.

11. An article of footwear including the sole structure of claim 1.

12. A sole structure, comprising: a cushioning member including (i) a perimeter chamber including a first series of lobes arranged along a perimeter region of the sole structure from a forefoot region to a heel region of the cushioning member and (ii) an interior chamber at least partially enclosed by the perimeter chamber and spaced apart from the perimeter chamber by a web region; and a chassis including a cushioning support and a plate attached on a side of the cushioning support opposite the cushioning member, the cushioning support defining a first series of supports arranged along the perimeter region of the sole structure, each of the first series of supports separated from an adjacent one by a recess and contacting a respective lobe, the plate longer than the cushioning support; and an outsole mounted to a bottom surface of the cushioning member so as to protect the cushioning member during engagement with a ground surface.

13. The sole structure of claim 12, wherein, The cushioning support includes a series of wings extending along a perimeter of the cushioning support, the series of wings configured to be positioned against a bottom surface of the plate.

14. The sole structure of claim 12, wherein, At least one support of the first series of supports includes an upper portion extending upwardly and outwardly from a body of the at least one support of the first series of supports.

15. The sole structure of claim 12, wherein, The recess extends across a width of the cushioning support.

16. The sole structure of Claim 12, wherein, The recess is disposed between the midfoot region and the heel region.

17. The sole structure of claim 12, wherein, The cushioning support includes a series of ridges configured to be seated within a respective one of a series of pockets formed on a top side of the cushioning member.

18. The sole structure of claim 12, wherein, The cushioning support includes an interior support configured to be aligned with a medial chamber disposed between a medial side and a lateral side of the sole structure.

19. The sole structure of claim 12, wherein, The first series of supports includes a plurality of forefoot supports and a plurality of heel supports, the plurality of forefoot supports and the plurality of heel supports being integrally formed from the cushioning support.

20. The sole structure of Claim 12, wherein, The cushioning member is one of a foam element and a fluid-filled bladder, the foam element being a solid monolithic piece extending a length, a width, and a height of the cushioning member.

21. The sole structure of claim 20, wherein, The fluid-filled bladder is formed from an opposing pair of barrier layers.

22. The sole structure of claim 12, wherein, The cushioning member includes a foam element encapsulated in an opposing pair of barrier layers.

23. An article of footwear comprising the sole structure of claim 12.

Images