Sole structure and article of footwear with fluid-filled bladder element

Abstract

The present application relates to sole structures and articles of footwear having fluid-filled bladder elements. An article of footwear can include a midsole having a lower surface with a first recessed portion and an outsole coupled to the lower surface of the midsole, where the outsole has an upper surface with a second recessed portion. A first bladder element and a second bladder element can be disposed in a stacked arrangement between the midsole and the outsole, where an upper portion of the first bladder element contacts the lower surface of the midsole and extends at least partially into the first recessed portion, and a lower portion of the second bladder element contacts the upper surface of the outsole and extends at least partially into the second recessed portion.

Description

[0001] This application is a divisional application of the application filed on January 27, 2020, with application number 202080010279.5 and invention title "Sole structure and footwear article having fluid filling bladder element".

[0002] field

[0003] This disclosure relates to cushioning systems in footwear articles, and more specifically, to sole structures having fluid-filled bladder elements. background

[0004] Footwear items may include cushioning systems to enhance the performance of the item and / or the comfort of the wearer. Continuous improvement of cushioning systems used in footwear items is necessary. Summary of the Invention

[0005] This disclosure also relates to the following:

[0006] Clause 1. A footwear article comprising:

[0007] A shoe sole interlayer having a lower surface with a first recessed portion;

[0008] The outsole is connected to the lower surface of the sole interlayer and has an upper surface with a second recessed portion.

[0009] A first bladder element having at least one fluid-filled chamber, the first bladder element having an upper portion that contacts the lower surface of the sole interlayer and extends at least partially into the first recessed portion; and

[0010] The second bladder element has at least one fluid-filled chamber and a lower portion that contacts the upper surface of the outsole and extends at least partially into the second recessed portion.

[0011] The first capsule element has a first internal recess, and the second capsule element has a second internal recess.

[0012] The first recessed portion includes a first protrusion extending downward from the first recessed portion into the first internal recess, and the second recessed portion includes a second protrusion extending upward from the second recessed portion into the second internal recess.

[0013] Clause 2. Footwear items as described in Clause 1 also include:

[0014] A window that extends between the outer and inner sides of the footwear article, the window being defined at least by the lower edge of the sole interlayer and the upper edge of the outsole;

[0015] The first exposed portion of the first capsule element exposed by the window and the first unexposed portion of the first capsule element not exposed by the window; and

[0016] The second exposed portion of the second capsule element that is exposed by the window and the second unexposed portion of the second capsule element that is not exposed by the window.

[0017] Clause 3. Footwear articles as described in Clause 2, wherein the window is located in the heel area of ​​the footwear article.

[0018] Clause 4. Footwear articles according to Clause 2 or 3, wherein the first unexposed portion includes a first peripheral joint of the first pouch element, and the second unexposed portion includes a second peripheral joint of the second pouch element.

[0019] Clause 5. Footwear article according to any one of Clauses 1-4, wherein the first internal recess is formed by a first internal welded area of ​​the first pouch element, and the second internal recess is formed by a second internal welded area of ​​the second pouch element.

[0020] Clause 6. The footwear article according to any one of Clauses 1-5, wherein the outsole extends along the entire length of the footwear article.

[0021] Clause 7. Footwear article according to any one of Clauses 1-5, wherein the outsole forms only a portion of the surface of the footwear article that contacts the ground.

[0022] Clause 8. Footwear articles as described in Clause 7, wherein the outsole extends across the heel area of ​​the footwear article.

[0023] Clause 9. Footwear articles as described in Clause 7 or 8, wherein the outsole includes a notch portion that engages with the sole interlayer.

[0024] Clause 10. The footwear article according to Clause 7 or 8, wherein the outsole is a first outsole member located in the heel region of the footwear article, and the first outsole member has a notch portion that engages with a mating portion of a second outsole member.

[0025] Clause 11. The footwear article according to any one of Clauses 1-10, wherein the upper portion of the first pocket element is secured to the lower surface of the sole interlayer, and the lower portion of the second pocket element is secured to the upper surface of the outsole.

[0026] Clause 12. The footwear article according to any one of Clauses 1-11, wherein the lower surface of the first pouch element is adhered to the upper surface of the second pouch element.

[0027] Clause 13. The footwear article according to Clause 2, wherein the first exposed portion and the second exposed portion are spaced apart from the heel side and the forefoot side of the window, and the heel side hole is defined between the heel side of the window and the first exposed portion and the second exposed portion, and the forefoot side hole is defined between the forefoot side of the window and the first exposed portion and the second exposed portion.

[0028] Clause 14. The footwear article according to any one of the preceding clauses further includes an upper attached to the sole interlayer and / or the outsole.

[0029] Clause 15. A method of manufacturing footwear articles, comprising:

[0030] A sole interlayer is formed, the sole interlayer having a first recessed portion located in the lower surface of the sole interlayer and a first protrusion extending from the first recessed portion;

[0031] A shoe outsole is formed, the shoe outsole having a second recessed portion located in the upper surface of the shoe outsole and a second protrusion extending from the second recessed portion;

[0032] The upper portion of the first pouch element is positioned to contact the lower surface of the sole interlayer, wherein the first pouch element extends at least partially into the first recessed portion, and wherein the first protrusion is received in a first recess in the inner region of the first pouch element;

[0033] The lower portion of the second pouch element is positioned to contact the upper surface of the outsole, wherein the second pouch element extends at least partially into the second recess, and wherein the second protrusion is received in a second recess in an internal region of the second pouch element; and

[0034] The upper surface of the outsole is fixed to the lower surface of the sole interlayer.

[0035] Clause 16. The method described pursuant to Clause 15 further includes:

[0036] The upper portion of the first bladder element is secured to the lower surface of the sole interlayer; and

[0037] The lower portion of the second bladder element is secured to the upper surface of the outsole of the shoe.

[0038] Clause 17. The method according to Clause 15 or 16 further includes securing the lower surface of the first capsule element to the upper surface of the second capsule element with an adhesive.

[0039] Clause 18. The method according to any one of Clauses 15-17, wherein the upper surface of the outsole is fixed to the lower surface of the sole interlayer to form a window extending between the outer and inner surfaces of the footwear article, the window being defined at least by the lower edge of the sole interlayer and the upper edge of the outsole.

[0040] Clause 19. The method described pursuant to Clause 18 further includes:

[0041] Position the first capsule element such that a first exposed portion of the first capsule element is exposed by the window, and a first unexposed portion of the first capsule element is not exposed through the window; and

[0042] Position the second capsule element such that the second exposed portion of the second capsule element is exposed by the window, and the second unexposed portion of the second capsule element is not exposed through the window.

[0043] Clause 20. The method according to Clause 19, wherein positioning the first capsule element includes positioning a first peripheral joint of the first capsule element such that the first peripheral joint is located within the first unexposed portion, and

[0044] Positioning the second capsule element includes positioning the second peripheral joint portion of the second capsule element such that the second peripheral joint portion is located in the second unexposed portion.

[0045] Clause 21. The method according to any one of Clauses 15-20, wherein the first recessed portion and the second recessed portion are formed in the heel region of the footwear article.

[0046] Clause 22. The method according to any one of Clauses 15-21, wherein the first recess is formed by a first internal welded region of the first capsule element, and the second recess is formed by a second internal welded region of the second capsule element.

[0047] Clause 23. The method according to any one of Clauses 15-22, wherein the outsole extends along the entire length of the footwear article.

[0048] Clause 24. The method according to any one of Clauses 15-22, wherein the outsole forms only a portion of the surface of the footwear article that contacts the ground, and the upper surface of the outsole is secured to the lower surface of the sole interlayer only covers a portion of the lower surface of the sole interlayer.

[0049] Clause 25. The method according to Clause 24, wherein the outsole is a first outsole component located in the heel region of the footwear article, and the method further includes securing a second outsole component to the footwear article.

[0050] Clause 26. The method according to any one of Clauses 15-25 further includes securing the upper to the sole interlayer and / or the outsole. Brief description of the attached diagram

[0051] Figure 1 This is an external view of the sole assembly with a cushioning system.

[0052] Figure 2 yes Figure 1 The top view of the sole component shown.

[0053] Figure 3 yes Figure 1 The image shows a bottom view of the shoe sole structure.

[0054] Figure 4 It is a perspective view of a pair of stacked sac elements.

[0055] Figure 5 yes Figure 4 The front view of the stacked cyst elements shown.

[0056] Figure 6 yes Figure 4 The side view of the stacked cyst elements shown.

[0057] Figure 7 yes Figure 4 The top view of the stacked sac elements shown.

[0058] Figure 8 yes Figure 4 The bottom view of the stacked bladder elements shown.

[0059] Figure 9 From Figure 3 A cross-sectional view taken from the sample.

[0060] Figure 10 From Figure 3 A cross-sectional view taken from the sample.

[0061] Figure 11 This is a side view of another embodiment of a shoe sole assembly with a cushioning system.

[0062] Figure 12 This is a side view of the sole interlayer of an exemplary sole component.

[0063] Figure 13 yes Figure 12The image shows a bottom view of the shoe sole interlayer.

[0064] Figure 14 yes Figure 12 The image shows a bottom perspective view of the shoe sole interlayer.

[0065] Figure 15 This is a side view of the outsole of an exemplary sole component.

[0066] Figure 16 yes Figure 15 The image shows a top view of the shoe outsole.

[0067] Figure 17 yes Figure 15 The image shows a top perspective view of the shoe outsole.

[0068] Figure 18 It is a side view of any footwear item with a sole assembly and an exemplary cushioning system.

[0069] Figure 19 yes Figure 18 A magnified view of a portion of the heel area of ​​the item shown.

[0070] Figure 20 yes Figure 18 The rear view of the item shown.

[0071] Figure 21 yes Figure 18 The side view of the sole component of the item shown. Detailed description

[0072] Overall considerations

[0073] The systems and methods described herein, and their various components, should not be construed as being limited in any way to the particular purpose or system described herein. Rather, this disclosure focuses individually, and in various combinations and sub-combinations with each other, on all novel and non-obvious features and aspects of the various disclosed embodiments. For example, as will be recognized by one of ordinary skill in the art based on the information disclosed herein, any feature or aspect of the disclosed embodiments may be used in various combinations and sub-combinations with each other. Furthermore, the disclosed systems, methods, and components are not limited to any particular aspect or feature or combination thereof, and the disclosed things and methods do not require any one or more specific advantages or solutions to any one or more specific problems.

[0074] As used herein, unless clearly indicated otherwise in the context, the singular forms “a,” “an,” and “the” include the plural forms. Additionally, the term “include” means “comprise.” Furthermore, the terms “joint” or “fixed” cover mechanical and chemical joints, as well as other practical ways of joining or connecting articles together, and do not exclude the presence of intermediate elements between joined articles, unless otherwise indicated, such as by reference to elements or surfaces that are “directly” joined or fixed. Moreover, as used herein, the term “and / or” means any one or a combination of the phrases.

[0075] As used herein, the term "exemplary" means an example, instance, or illustration used as a non-limiting example. As used herein, the terms "e.g." and "for example" introduce one or more non-limiting embodiments, examples, instances, and / or illustrations.

[0076] While some of the methods disclosed are described in a specific, sequential order for ease of presentation, it should be understood that this descriptive approach includes rearrangement unless the specific language of the following statements requires a particular order. For example, operations described sequentially may be rearranged or performed simultaneously in certain circumstances. Furthermore, for simplicity, the accompanying drawings may not show the various ways in which the disclosed things and methods can be used in conjunction with other things and methods. Additionally, terms such as “provide,” “generate,” “determine,” and “select” are sometimes used to describe the disclosed methods. These terms are high-level descriptions of the actual operations performed. The actual operations corresponding to these terms will vary depending on the specific implementation and will be readily discernible by those skilled in the art, while also benefiting from this disclosure.

[0077] As used herein, directional terms (e.g., “up” and “down”) generally correspond to the orientation of a footwear article or sole component when it is constructed to be worn by a wearer. For example, the “upward-facing surface” and / or “upper surface” of a sole component refers to the surface oriented in an “above” anatomical direction (i.e., toward the wearer’s head) when the footwear article is worn by a wearer. Similarly, the directional terms “down” and / or “under” refer to an anatomical direction “below” (i.e., toward the ground and away from the wearer’s head). “Front” means “in front” (e.g., toward the toes), and “back” means “back” (e.g., toward the heel). “Medial” means “towards the midline of the body,” and “lateral” means “away from the midline of the body.”

[0078] Although the accompanying drawings may depict footwear articles intended for use only on one foot (e.g., the right foot), those skilled in the art will recognize that the corresponding footwear articles for the other foot (e.g., the left foot) will be a mirror image of the right footwear article.

[0079] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure pertains. While methods and materials similar to or equivalent to those described herein may be used in the implementation or testing of this disclosure, suitable methods and materials will be described below. These materials, methods, and examples are illustrative only and are not intended to be limiting. Other features of this disclosure will be apparent from the detailed description, claims, abstract, and drawings.

[0080] The disclosed technology

[0081] This article discloses various sole structures and footwear items, including cushioning systems, and their manufacturing methods.

[0082] In some embodiments, the footwear article may include a sole interlayer having a lower surface and an outsole coupled to the lower surface of the sole interlayer, the lower surface having a first recessed portion, wherein the outsole has an upper surface having a second recessed portion. The footwear article may include a first bladder element and a second bladder element, each bladder element having at least one chamber filled with fluid (e.g., gas). The first bladder element may have a portion contacting the lower surface of the sole interlayer and extending at least partially into the upper portion of the first recessed portion, and the second bladder element may have a portion contacting the upper surface of the outsole and extending at least partially into the lower portion of the second recessed portion.

[0083] In some embodiments, the first capsule element may have a first internal recess, and the second capsule element may have a second internal recess, and the first recess may include a first protrusion extending downward from the first recess into the first internal recess, and the second recess may include a second protrusion extending upward from the second recess into the second internal recess.

[0084] In other embodiments, the window extends between the outer and inner sides of the footwear article, and the window is defined at least by the lower edge of the sole interlayer and the upper edge of the outsole. A first exposed portion of the first pocket element and a second exposed portion of the second pocket element can be seen from the outer and / or inner sides of the window, wherein a first unexposed portion of the first pocket element and a second unexposed portion of the second pocket element are not exposed (e.g., covered by the sole interlayer or the outsole, respectively).

[0085] In some embodiments, the window may be located in the heel area of ​​the footwear article. In other embodiments, a first peripheral joint of the first pouch element and a second peripheral joint of the second pouch element are located in an unexposed portion (e.g., covered by a midsole or outsole, respectively). In some embodiments, a first internal recess may be formed by a first internal welded area of ​​the first pouch element, and a second internal recess may be formed by a second internal welded area of ​​the second pouch element.

[0086] The outsole may extend along the entire length of the footwear article or form only a portion of the surface of the footwear article that contacts the ground. For example, the outsole may extend across the heel area of ​​the footwear article. In some embodiments, the outsole may have a notched portion that engages with a portion of the sole interlayer and / or a second outsole member.

[0087] The upper portion of the first pocket element can be secured to the lower surface of the sole interlayer, and the lower portion of the second pocket element can be secured to the upper surface of the outsole. Similarly, the lower surface of the first pocket element can be secured (e.g., adhered) to the upper surface of the second pocket element. In some embodiments, the first and second exposed portions are spaced apart from the heel side and the forefoot side of the window, and a heel-side hole is defined between the heel side of the window and the first and second exposed portions, and a forefoot-side hole is defined between the forefoot side of the window and the first and second exposed portions. The upper can be secured to the sole interlayer and / or the outsole.

[0088] In some embodiments, the sole structure includes the sole interlayer and outsole as described above, and the sole structure can be attached to the upper to form a footwear article.

[0089] In another embodiment, a method of manufacturing footwear is provided. The method includes: forming a sole interlayer having a first recessed portion in a lower surface of the sole interlayer and a first protrusion extending from the first recessed portion; forming an outsole having a second recessed portion in a upper surface of the outsole and a second protrusion extending from the second recessed portion; positioning an upper portion of a first pouch element in contact with the lower surface of the sole interlayer, wherein the first pouch element extends at least partially into the first recessed portion, and wherein the first protrusion is received in a first recess in an internal region of the first pouch element; positioning a lower portion of a second pouch element in contact with the upper surface of the outsole, wherein the second pouch element extends at least partially into the second recessed portion, and wherein the second protrusion is received in a second recess in an internal region of the second pouch element; and securing the upper surface of the outsole to the lower surface of the sole interlayer.

[0090] In some embodiments, the method may further include securing an upper portion of a first pocket element to a lower surface of the sole interlayer and securing a lower portion of a second pocket element to an upper surface of the outsole. The lower surface of the first pocket element may also be secured to the upper surface of the second pocket element (e.g., with an adhesive).

[0091] In some embodiments, the act of securing the upper surface of the outsole to the lower surface of the sole interlayer creates a window extending between the outer and inner surfaces of the footwear article, the window being defined at least by the lower edge of the sole interlayer and the upper edge of the outsole. Positioning the first pouch element may include exposing a first exposed portion of the first pouch through the window and covering a first unexposed portion of the first pouch element such that the first unexposed portion of the first pouch element is not exposed (e.g., the first unexposed portion may be covered by the sole interlayer), and positioning the second pouch element may include exposing a second exposed portion of the second pouch element through the window and covering a second unexposed portion of the second pouch element such that the second unexposed portion of the second pouch element is not exposed (e.g., the second unexposed portion may be covered by the sole). The first and second unexposed portions may respectively include portions of the first and second pouch elements positioned by the peripheral joint.

[0092] In some embodiments, a first recess and a second recess may be formed in the heel region of the footwear article. The first internal recess may be formed by a first internal welded region of a first pouch element, and the second internal recess may be formed by a second internal welded region of a second pouch element.

[0093] The outsole may extend along the entire length of the footwear article, or the outsole may form only a portion of the surface of the footwear article that contacts the ground, such that securing the upper surface of the outsole to the lower surface of the midsole only covers a portion of the lower surface of the midsole. If the outsole forms only a portion of the surface that contacts the ground, the outsole may be a first outsole component in the heel region of the footwear article, and the method may include securing a second outsole component to the footwear article. The upper may be secured to the midsole and / or the outsole, which may collectively be considered as a sole structure or sole assembly.

[0094] Exemplary embodiments of sole components and footwear articles

[0095] Footwear articles (also referred to herein as "articles") may include running shoes, football boots, soccer boots, rugby boots, basketball shoes, baseball boots, tennis shoes, athletic shoes, boots, sandals, dress shoes, work shoes, and any other type of footwear to which the cushioning systems disclosed herein can be applied. Footwear articles typically include a sole structure (also referred to herein as a sole assembly) and an upper attached to the sole structure. The upper forms an internal cavity configured to receive the wearer's foot.

[0096] Figures 1-3 The illustration shows a sole assembly 10 for use with footwear. The sole assembly 10 includes a sole midsole 12 and an outsole 14. A pocket system 16 is positioned between the sole midsole 12 and the outsole 14.

[0097] The sole component (and corresponding footwear item) can be identified based on its location on or near the foot area of ​​the footwear item when the footwear is worn on a properly sized foot. For example, as Figure 1 As shown, footwear articles and / or sole assemblies can be considered to have a heel region 18 at the rear of the foot, a midfoot region 20 at the midfoot or arch region, and a forefoot region 22 at the front of the foot. Footwear and / or sole assemblies also include a lateral side 24 (the “outer” or “little toe” side of the foot) and a medial side 26 (the “inner” or “big toe” side of the foot). The lateral and medial sides of the footwear extend through the forefoot region, midfoot region, and heel region, and generally correspond to opposite sides of the footwear (and can be considered to be separated by a central longitudinal axis LA).

[0098] The midsole 12 can be formed of any suitable material. For example, the midsole 12 can be formed of an elastic polymer foam material, such as polyurethane foam or ethylene vinyl acetate (“EVA”) foam, extending throughout the length of the footwear article. The properties of the polymer foam material in the midsole depend primarily on factors including the dimensional configuration of the midsole and the specific properties of the material selected for the polymer foam, including the density of the polymer foam material. By changing these factors throughout the midsole, the associated stiffness and the degree of ground reaction force attenuation can be modified to meet the specific requirements of the activity in which the footwear is intended to be used. The profile of the top surface 28 of the midsole 12 can be configured, for example, to comfortably support and / or help position the sole surface of the wearer's foot. As discussed in more detail herein, the midsole 12 can be attached to the upper.

[0099] The outsole 14 is the component that contacts the ground and can be formed of, for example, a durable, abrasion-resistant material, which includes textures or other features to improve adhesion and friction. For example, the outsole 14 can be formed of rubber, phylon, phyllite, thermoplastic polyurethane, and other suitable materials.

[0100] like Figure 1 As shown, the outsole 14 can be fixed to the bottom surface 30 of the sole interlayer 12. For example, the top surface 32 of the outsole 14 can be joined to the bottom surface 30 of the sole interlayer 12, and the two surfaces can be fixed together, for example, with an adhesive.

[0101] Figures 4-8 The illustration shows a capsule system 16 comprising a pair of fluid-filled capsule elements 34, 36, which are stacked with capsule element 34 on top of capsule element 36. Each capsule element defines a respective sealable cavity 38, 40. The capsule elements 34, 36 may be formed with at least one upper recess 42 and at least one lower recess 44. The at least one upper recess 42 and the at least one lower recess 44 are respectively surrounded by an upper peripheral surface 46 and a lower peripheral surface 48, which extend above the recess 42 and below the recess 44, respectively. Thus, the recesses 42, 44 (also referred to herein as recesses) of the capsule elements include surfaces spaced apart from the peripheral surfaces and either lower in height than the upper peripheral surface or higher in height than the lower peripheral surface.

[0102] like Figure 4 As shown, the upper peripheral surface 46 and the lower peripheral surface 48 extend completely around the periphery of the sac elements 34, 36 to completely enclose the upper recess 42 and the lower recess 44. However, in some embodiments, the peripheral surfaces 46, 48 may only partially surround the upper recess and / or the lower recess (e.g., by forming a horseshoe shape, wherein one side of the upper recess and / or the lower recess is not surrounded by the upper peripheral surface and / or the lower peripheral surface).

[0103] Refer again Figure 1 The midsole 12 and outsole 14 are shaped to jointly define a window 50 (e.g., a gap or cutout) through the sole assembly 10. The window 50 extends from the outer side 24 to the inner side 26 in the heel region 18 of the sole assembly 10. A pocket system 16 is received between the midsole 12 and the outsole 14 such that only a portion of each of the pocket elements 34, 36 is visible from the inner and outer sides of the sole assembly.

[0104] For example, such as Figure 1 As shown, each of the capsule elements 34 and 36 has an exposed portion and a non-exposed portion. The non-exposed portion of the first capsule element 34 includes an upper portion (e.g., shown by a dashed line) that is not visible through the window 50. This non-exposed portion includes the area of ​​the first capsule element 34 located by the peripheral joint 60 (discussed below). Similarly, the non-exposed portion of the second capsule element 36 includes a lower portion (e.g., shown by a dashed line) that is not visible through the window 50, and this lower portion includes the area of ​​the second capsule element 36 located by the peripheral joint 60.

[0105] When viewed from the outside or inside, such as Figure 1 and Figure 6As shown, the adjacent peripheral surfaces of the stacked capsule elements 34 and 36 (i.e., the lower peripheral surface 48 of capsule element 34 and the upper peripheral surface 46 of capsule element 36) are in contact with each other along their outer and inner surface surfaces.

[0106] In some embodiments, such as Figure 1 As shown, the size of window 50 can be set such that the capsule elements 34 and 36 do not extend the entire length of window 50. For example, Figure 1 The illustration shows the rear gap 52 and the front gap 54 located on the rear and front sides of the capsule elements 34 and 36, respectively. The rear gap 52 and the front gap 54 can provide unobstructed views from the inner side to the outer side through the window 50, and vice versa.

[0107] The capsule elements 34, 36 can be formed in various ways. For example, each capsule element can be formed by attaching a first polymer sheet 56 to a second polymer sheet 58 to define a corresponding cavity 38, 40. The first polymer sheet 56 and the second polymer sheet 58 are substantially impermeable to fluid contained within the cavities 38, 40. The first polymer sheet 56 and the second polymer sheet 58 can be joined together (e.g., welded) around their respective peripheries to form a peripheral joint 60.

[0108] like Figure 5 As shown, the first polymer sheet 56 forms part of the upper peripheral surface 46 and sidewall 62 of the capsule element 34, and the second polymer sheet 58 forms part of the lower peripheral surface 48 and sidewall 62 of the capsule element 34. The peripheral joint 60 may be located at the midpoint of the sidewall 62, or alternatively, the peripheral joint 60 may be located closer to the lower peripheral surface 48 or the upper peripheral surface 46.

[0109] The bladder element can be thermoformed in a mold assembly, wherein a first polymer sheet 56 and a second polymer sheet 58 are vacuum-formed into the shape of the mold assembly during the thermoforming process. During the thermoforming process, the sheets can be compressed together to form a peripheral joint, and fluid can be supplied to the interior cavity of the bladder element through a filling tube. After the bladder element is inflated, the filling tube can be plugged and subsequently trimmed before assembling the sole assembly or footwear item. As used herein, "fluid" includes gases, including air, an inert gas such as nitrogen, or another gas.

[0110] In addition to the peripheral joint 60, the first polymer sheet 56 and the second polymer sheet 58 can be welded together at one or more internal regions to achieve the desired shape and configuration of the capsule element. For example, as Figure 7 and Figure 8As shown, the upper recessed portion 42 and the lower recessed portion 44 can be formed by bonding the first polymer sheet 56 and the second polymer sheet 58 together at an internal bonding region 64 (e.g., an internal welding region) spaced apart from the peripheral surfaces 46, 48. For example, as Figure 7 and Figure 8 As shown, when the internal bonding area is formed on both sides of the capsule element, the terms internal bonding area and internal welded area refer to the area on the top or bottom of the capsule element.

[0111] like Figure 9 and Figure 10 As shown, the midsole 12 and outsole 14 can be sized to receive corresponding pocket elements 34, 36. For example, the midsole 12 may include a peripheral recess 66 and raised surfaces, such as one or more protrusions 68 extending downward relative to the recess 66. The outsole 14 may similarly include a peripheral recess 70 and a central raised surface, such as one or more protrusions 72 extending upward relative to the recess 70. The peripheral recess 66 is sized to engage with the upper peripheral surface 46 of the pocket element 34, and the protrusions 68 are sized to engage with the upper recess 42. Similarly, the peripheral recess 70 is sized to engage with the lower peripheral surface 48 of the pocket element 34, and the protrusions 72 are sized to engage with the lower recess 44.

[0112] By providing mating surfaces in this manner (e.g., protrusions extending into the recesses of the bladder element and peripheral surfaces of the bladder element extending into the recesses of the midsole / outsole), the bladder element can be better secured in the desired position. In addition to the frictional engagement between the bladder element and adjacent surfaces of the midsole and outsole, an adhesive can be provided to further secure these elements relative to each other in place. Furthermore, due to the non-linear shape of the aforementioned adjacent surfaces, in some embodiments, a larger surface area can be used to apply the adhesive.

[0113] Refer again Figure 1 The recessed portions of the midsole and outsole are preferably sized to completely accommodate the peripheral joints of the corresponding pocket elements within the respective midsole or outsole area, so that the peripheral joints are not exposed by the window 50. For example, the peripheral joint 60 of the pocket element 34 is received within the midsole 12 (i.e., the inner surface of the midsole 12 contacts and / or covers the peripheral joint 60), so that the peripheral joint 60 of the pocket element 34 is not exposed by the window 50, and the peripheral joint 60 of the pocket element 36 is received within the outsole 14 (i.e., the inner surface of the outsole 14 contacts and / or covers the peripheral joint 60), so that the peripheral joint 60 of the pocket element 36 is not exposed by the window 50. Figure 1As shown, incorporating the peripheral joint 60 of the bladder element within the midsole element and outsole element can improve both the functionality and aesthetics of footwear. For example, an exposed peripheral joint may be more prone to failure due to undesirable contact with external elements, and it is less desirable to observe the exposed peripheral joint through window 50.

[0114] Figure 1 The outsole 14 is illustrated as a "cap" that only covers the heel area 18, while the midsole layer 12 directly contacts the ground in the midfoot area 20 and the forefoot area 22. Alternatively, as... Figure 11 As shown, the outsole 14 can extend the entire length of the bottom of the sole assembly 10. Specifically, Figure 11 The illustration shows a second outsole component 74. The second outsole component 74 may be integrally formed with the outsole 14, and both the second outsole component 74 and the outsole 14 together form an outsole structure connected to the sole interlayer 12. In other embodiments, the second outsole component 74 may be separate from the outsole 14, and may be separately fixed to the sole interlayer 12 before, after, or during the fixing of the outsole 14 to the sole interlayer 12. The second outsole component 74 may extend the length of the sole assembly 10, or the second outsole component 74 may extend only in the midfoot region 20 or the forefoot region 22 (e.g., from the forefoot portion of the outsole 14 to the toe side of the sole assembly 10).

[0115] Figures 12-17 The illustration shows the features of the midsole 12 and outsole 14, and how the midsole 12 and outsole 14 are shaped to receive the bladder element described herein. Figure 12 This is a side view of an exemplary shoe sole interlayer 12. Figure 13 This is a bottom view of an exemplary shoe sole interlayer 12, and Figure 14 This is a bottom perspective view of an exemplary sole interlayer 12. The sole interlayer 12 defines a portion of the window 50 by its cut-out shape in the heel area. Figure 13 and Figure 14 As shown, the peripheral recess 66 surrounds a protruding surface, namely, a protrusion 68, extending downward relative to the recess 66. The protrusion 68 is sized to be received within the upper recess 42 of the pouch element 34. Therefore, the shape of the protrusion 68 can vary depending on the shape of the upper recess 42. For example, Figure 14 The exemplary protrusion tapers towards the end to better accommodate Figure 4 The illustrated pouch element 34. Furthermore, the protrusion 68 in the illustrated embodiment is elliptical in shape, corresponding to the elliptical upper recess 42 of the pouch element 34. Different shapes and numbers of protrusions are possible depending on the shape of the pouch element to be received in the sole interlayer 12.

[0116] Figures 15-17 An exemplary outsole 14 is illustrated that can be fixed to the insole interlayer 12, wherein the bladder system 16 is positioned between the insole interlayer 12 and the exemplary outsole 14. Figure 15 This is a side view of the outsole 14. Figure 16 This is a top view of the outsole 14, and Figure 17 This is a top-view perspective view of the shoe outsole 14. (See image.) Figure 16 and Figure 17 As shown, the peripheral recessed portion 70 surrounds a central convex surface extending upward relative to the recessed portion 70, namely, the protrusion 72. This is in conjunction with the protrusion 68 above. Figures 12-14 In the same manner, the protrusion 72 is sized to be received in the recessed portion 44 of the sac element 36. Therefore, the shape of the protrusion 72 can also vary depending on the shape of the recessed portion 44.

[0117] The shape of the outsole 14 can be varied to provide a more secure attachment between the outsole 14 and the sole interlayer 12. For example, as... Figure 16 As shown, the outsole 14 has a notch 76 that is sized to be received in a corresponding mating portion 78 of the insole interlayer 12 to provide a stronger fit between the insole interlayer and the outsole when they are joined together (e.g., using an adhesive).

[0118] Figure 18 An exemplary embodiment of a footwear article having the sole assembly described herein is illustrated. Figure 18 As shown, the upper 80 is secured to a sole assembly including the sole interlayer 12 and the outsole 14. As described herein, a bladder system including bladder elements 34, 36 is secured within the window 50. Figures 18-21 As shown, the outsole 14 may include a notch 82 that engages with a corresponding portion 84 of the insole interlayer 12 to provide a stronger connection between the insole interlayer and the outsole.

[0119] It should be understood that the structure of the bladder element described herein can be varied. For example, instead of a single fluid-filled chamber, the bladder element can have multiple discrete fluid-filled chambers. Such discrete fluid-filled chambers can be filled at different pressures to create softer or firmer cushioning areas. Furthermore, as discussed above, more than one internal weld can be provided. For example, instead of a single welded area 64, two or more smaller, spaced welded areas can form an intermediate fluid-filled area (either as part of the main chamber of the bladder element or as separate, discrete chambers). If more than one welded area is provided, the number of protrusions provided, as well as the position and structure of the protrusions, can be changed accordingly. Thus, for example, if the bladder element has two circular internal welded areas instead of a single elliptical welded area, two circular protrusions can be provided instead of a single elliptical protrusion.

[0120] In addition to the peripheral joints and one or more internal welds, the shape and characteristics of the capsule element can be controlled by providing other structures within the capsule element, such as tension members. Further details regarding the use of tension members and / or other internal welds can be found in U.S. Patent Nos. 5,083,361, 6,385,864, 6,571,490, and 7,386,946, each of which is incorporated herein by reference in its entirety.

[0121] Capsule elements 34 and 36 may also be formed of different colors and / or have different transparency. For example, in some embodiments, the capsule elements may be substantially transparent. As used herein, a capsule element is "substantially transparent" if it has at least 80% transmittance (i.e., the percentage of incident light transmitted) and no more than 56% haze (i.e., the percentage of transmitted light scattered).

[0122] The various materials used for capsule elements 34, 36, and other embodiments of capsule elements discussed herein can be substantially transparent. Those skilled in the art will readily understand the various methods for determining the transmittance and haze of an object, such as a capsule element. For example, the transmittance and haze of a capsule element can be determined according to American Society for Testing and Materials (ASTM) Standard D1003-00, "Standard Test Method for Haze and Luminous Transmittance of Transparent Plastics." Additionally, in some embodiments, the capsule element may have a tinted color.

[0123] Although the bladder elements 34 and 36 are shown positioned in the heel area of ​​the footwear article, the bladder elements 34 and 36 may alternatively or additionally be positioned in the midfoot area or the forefoot area.

[0124] Given the many possible embodiments to which the principles of the disclosed invention can be applied, it should be understood that the illustrated embodiments are merely preferred examples of the invention and should not be considered as limiting the scope of the invention. Rather, the scope of the invention is defined by the appended claims. Therefore, I claim that everything falling within the scope and spirit of these claims is my invention.

Claims

1. A type of footwear, comprising: The sole assembly includes a sole midsole and an outsole; A first capsule element having at least one fluid-filled chamber, the first capsule element having a first capsule upper surface and a first capsule lower surface; The second capsule element has at least one fluid-filled chamber, and the second capsule element has a second upper capsule surface and a second lower capsule surface, with the first lower capsule surface in contact with the second upper capsule surface; and A window extending between the outer and inner sides of the sole assembly, wherein the window extends between the sole interlayer and the outsole. At least a portion of the first capsule element is exposed on the outer and inner sides through the window, and at least a portion of the second capsule element is exposed on the outer and inner sides through the window. The insole midsole has a lower surface and the outsole has an upper surface, wherein the lower surface of the insole midsole includes a first recessed portion and the upper surface of the outsole includes a second recessed portion, and wherein a first pocket element has a first upper portion that contacts the lower surface of the insole midsole and extends into the first recessed portion, and a second pocket element has a second lower portion that contacts the upper surface of the outsole and extends into the second recessed portion. The window has a length extending from the heel side to the forefoot side, and the first and second pouch elements do not extend the entire length of the window to provide a rear opening on the heel side adjacent to the window and a front opening on the forefoot side adjacent to the window, the rear opening and the front opening each extending between the outer and inner sides. The first bladder element further has a first lower portion and a first central region located between the first upper portion and the first lower portion, and the second bladder element further has a second upper portion and a second central region located between the second upper portion and the second lower portion, wherein the first bladder element gradually narrows in length from the first central region to the first lower portion, and the second bladder element gradually narrows in length from the second central region to the second upper portion, such that the rear hole and the front hole are longer in the central region of the window.

2. The footwear article of claim 1, wherein the front opening and the rear opening provide unobstructed visibility from the inner side to the outer side through the window.

3. The footwear article of claim 1, wherein the first pouch element has a first exposed portion of the first pouch element exposed by the window and a first unexposed portion of the first pouch element not exposed by the window, and the second pouch element has a second exposed portion of the second pouch element exposed by the window and a second unexposed portion of the second pouch element not exposed by the window.

4. The footwear article of claim 1, wherein the window is located in the heel area of ​​the footwear article.

5. The footwear article according to claim 1, wherein the lower surface of the first pouch adheres to the upper surface of the second pouch.

6. The footwear article according to claim 1, wherein the upper surface of the first bladder is fixed to the lower surface of the sole interlayer and the lower surface of the second bladder is fixed to the upper surface of the outsole.

7. The footwear article of claim 1, wherein the window is defined at least in part by a portion of the lower surface of the sole interlayer and a portion of the upper surface of the outsole.

8. The footwear article of claim 7, wherein the upper surface of the outsole is adhered to the lower surface of the sole interlayer in front of and behind the window.

9. The footwear article of claim 1, wherein the first pouch element has a first internal recess, and the second pouch element has a second internal recess, and The first recessed portion includes a first protrusion extending downward from the first recessed portion into the first internal recess, and the second recessed portion includes a second protrusion extending upward from the second recessed portion into the second internal recess.

10. The footwear article of claim 1, further comprising an upper fixed to the sole interlayer and / or the outsole.

11. A type of footwear, comprising: A sole assembly having a window extending from an outer side to an inner side, the sole assembly including a sole interlayer and an outsole, the sole interlayer and the outsole being shaped to jointly define the window; Upper, the upper being fixed to the sole assembly; and An upper bladder element and a lower bladder element are positioned within the window in the sole assembly in a vertically stacked arrangement, each of the upper and lower bladder elements having at least one fluid-filled chamber. At least a portion of the rear sides of the upper and lower pleated elements are spaced apart from the heel side of the window to define a heel-side opening of the window extending between the outer and inner sides of the sole assembly, and at least a portion of the front sides of the upper and lower pleated elements are spaced apart from the forefoot side of the window to define a forefoot-side opening of the window extending between the outer and inner sides of the sole assembly. The upper pouch element has a first upper portion, a first lower portion, and a first central region located between the first upper portion and the first lower portion, the first lower portion being exposed by the window in the sole assembly, and the lower pouch element has a second upper portion, a second lower portion, and a second central region located between the second upper portion and the second lower portion, the second upper portion being exposed by the window in the sole assembly. The upper pouch element gradually narrows in length from the first central region to the first lower portion, and the lower pouch element gradually narrows in length from the second central region to the second upper portion, such that the heel side hole and the forefoot side hole are longer in the central region of the window.

12. The footwear article of claim 11, wherein the first upper portion of the upper pouch element is not exposed through the window in the sole assembly, and The second lower portion of the lower bladder element is not exposed through the window in the sole assembly.

13. The footwear article of claim 12, wherein the upper bladder element and the lower bladder element are located between the sole interlayer and the outsole of the sole assembly, and the sole interlayer includes a first recessed portion receiving at least a portion of a first upper portion of the upper bladder element, and the outsole includes a second recessed portion receiving at least a portion of a second lower portion of the lower bladder element.

14. The footwear article of claim 13, wherein the first upper portion is adhered to the first recessed portion, and the second lower portion is adhered to the second recessed portion.

15. The footwear article of claim 11, wherein the upper pouch element and the lower pouch element are adhered to each other.

16. The footwear article according to any one of claims 11-15, wherein the window is in the heel area of ​​the footwear article.

Images