Footwear with traction sole assembly

Abstract

A footwear construction includes a sole assembly having a convoluted lower surface with a plurality of undulations of peaks and valleys, and first and second midsoles of different durometers to provide dynamic stability, cushioning, and / or traction. The second midsole can include apertures extending into some of the peaks, so those peaks are compressible and conform well to the terrain underfoot. The sole assembly can include certain lateral or medial peaks that transition to the periphery of the sole assembly, and have a truncated shape with a sidewall to provide solidity and / or rigidity around the periphery of the sole assembly. Other peaks can be disposed inward from the lateral or medial peaks and can have less solidity, so those central peaks can provide cushioning and / or macro-traction capabilities. An associated method of manufacture is also provided.

Description

TECHNICAL FIELD

[0001] The present invention relates to footwear, and more particularly to footwear including a sole assembly having a crimped lower surface to provide dynamic three-dimensional traction, stability, and / or cushioning. BACKGROUND

[0002] A wide variety of different sole assemblies are used in footwear. Many sole assemblies include a midsole composed of foam, and a lower overlying outsole composed of a rubber sheet for durability and ease of assembly. The foam provides cushioning under the foot, and the outsole provides traction. Many times, the outsole sheet includes a plurality of lugs integrally formed with the sheet at different locations for gripping and wear resistance. The outsole rubber sheet and integral plurality of lugs are typically composed of a unitary continuous material. The sheet spans between the individual lugs, such that the midsole is covered by the sheet. This can protect the midsole from damage, but also presents some problems.

[0003] For example, the rubber sheet is typically heavy. Therefore, all of the material spanning between the individual lugs adds to the overall weight of the footwear. For performance and hiking footwear where every gram counts, this can detract from the wearer's performance, and prematurely fatigue the wearer and / or slow their pace. In addition, because of the sheet of material spanning between the individual lugs, the outsole is very stiff. Therefore, the individual lugs protruding directly from the sheet act as a large assembly rather than individual lugs. In turn, this prevents the individual lugs from reacting to and engaging the underfoot surface, which can detract from traction therewith.

[0004] For common outsole sheet constructions, the sole assembly can be less flexible, and can provide less cushioning. In addition, it can be less able to conform to large underfoot three-dimensional contours and terrain. As a result, the sole assembly often does not provide acceptable proprioceptive feedback to the user about the contours and terrain, which can be detrimental to the user's balance and movement. In addition, the above-described sole assembly can not provide macro traction well, that is, traction over or on large three-dimensional objects and uneven surfaces, such as large rocks, tree branches, and other structures.

[0005] With the above conventional sole assemblies, users must be aware of the different traction characteristics of their footwear on different types of terrain. To achieve acceptable performance, users need to understand the feedback from the terrain under their feet, particularly where the terrain varies greatly in three dimensions, to determine whether it is hard, soft, or uneven, and thus which type of traction is available to them for their activities using that particular footwear and sole assembly. From this, users can adjust their movements and reactions on that terrain accordingly. If the user is inexperienced or unfamiliar with the terrain type, the user can inadvertently overestimate the amount of traction available, which can be detrimental to movement, balance, and performance.

[0006] Accordingly, there is still room for improvement in the construction of sole assemblies to improve cushioning, traction, and functionality on different types of terrain, and to reduce the overall weight of footwear for improved performance. SUMMARY

[0007] A footwear construction includes a sole assembly having a convoluted lower surface with a plurality of undulations of peaks and valleys, and can include one or more midsoles of different hardness to provide dynamic stability, enhanced cushioning, and / or traction on three-dimensional terrain.

[0008] In one embodiment, the footwear can include a first midsole composed of a first material having a first hardness and a second midsole composed of a second material having a second hardness that is less than the first hardness. The first midsole can be above the second midsole and can provide a stable platform for the user's foot. The softer second midsole can be below the first midsole and can cooperate with the outsole layer to provide enhanced macroscopic traction on large three-dimensional foot objects and terrain features.

[0009] In another embodiment, the first midsole can be composed of a first material that is a foam having a first hardness between 40 and 60 Asker C. The second midsole can be composed of a second material that is a polyurethane having a second hardness between 20 and 40 Asker C.

[0010] In yet another embodiment, the second midsole can include apertures extending into some of the peaks, so that these peaks are compressible and conform well to the terrain underfoot. The apertures can extend within the peaks such that less than 2 or 4 mm of the second material is disposed between the end of each aperture and the top end of each peak. With this construction, the peaks can be made more compliant and compressible, thereby providing greater cushioning or ability to conform to large three-dimensional terrain and objects underfoot and enhancing traction.

[0011] In yet another embodiment, the sole assembly can include lateral peaks and / or medial peaks that transition into the perimeter of the sole assembly on respective lateral sides and medial sides of the sole assembly. These lateral peaks or medial peaks can have truncated shapes and include in the outsole layer and / or the second midsole.

[0012] In even another embodiment, one or more of the lateral peaks and medial peaks can include a second midsole lateral wall. This lateral wall can form a portion of the perimeter of the sole assembly on the lateral side or the medial side. The lateral wall can provide solidity and / or rigidity to the sole assembly around the perimeter.

[0013] In another embodiment, the sole assembly can include inwardly or centrally disposed peaks. These peaks can be disposed inwardly from the lateral peaks or medial peaks and can have less solidity. With this configuration, the centrally disposed peaks can provide cushioning and / or macro traction capabilities.

[0014] In still another additional embodiment, the sole assembly can include different kinds of peaks. For example, there can be first peaks having a horizontally disposed substantially circular cross-section that decreases in size as the peak extends away from the first midsole. These first peaks can provide a first solidity. There can also be second peaks having a horizontal cross-section that is truncated by the second midsole lateral wall. These second peaks can provide a second solidity greater than the first solidity along the outer perimeter of the second midsole. This can provide enhanced rigidity and solidity along the perimeter so that the footwear does not rock as much laterally or medially when worn by a user.

[0015] In even still another embodiment, the lateral peaks and medial peaks can be partially spherical, can be truncated by the midsole lateral wall, and can further include a flat and / or planar lower surface and / or ground contact surface. This flat surface can provide more ground contact and increase the solidity of those peaks to dampen any lateral or medial rocking of the footwear when worn by a user.

[0016] In yet another additional embodiment, the first peaks can form a partially spherical shape. The second peaks can form a partially spherical shape that is itself truncated by a generally vertical lateral wall. In some cases, the second peaks can be encased by an outsole lateral wall that extends upward from the ground contact surface of the outsole layer toward the first midsole. This outsole lateral wall can increase the rigidity of the second peaks along the perimeter.

[0017] In yet another embodiment, a method is provided that includes placing an outsole layer in a mold, the outsole layer having a contoured outsole upper surface including a plurality of peaks and a plurality of valleys; introducing a second midsole material within the mold on the contoured upper surface to conform to or follow the contoured outsole upper surface and bond with the contoured outsole upper surface; defining a plurality of downwardly extending first apertures and a plurality of downwardly extending second apertures in the second midsole material, the first apertures extending toward the plurality of peaks; and curing the second midsole material to form a second midsole.

[0018] In another embodiment, the method can include joining a first midsole to an upper surface of a second midsole, the first midsole being composed of a first material having a first hardness that is greater than a second hardness of a second midsole material forming the second midsole.

[0019] In another embodiment, the method can include defining the first apertures such that a thickness of the second midsole between a bottom of each aperture and the outsole layer is less than 3 mm.

[0020] The present footwear construction provides previously unattainable benefits in traction, cushioning, and stability. The present sole assembly, with its contoured lower surface having peaks and valleys, can provide excellent traction over three-dimensional foot objects and terrain. The multi-hardness midsole, if included, can enhance the cushioning provided by the sole assembly, allowing the outsole layer to quickly and efficiently conform to foot objects and absorb impact forces. When the outsole layer includes lug patterns, the sole assembly can also dynamically react to different types of terrain to provide both macro and micro traction on slippery or wet surfaces.

[0021] These and other objects, advantages, and features of the present application will be more fully understood and appreciated by reference to the description of the current embodiments and attached drawings.

[0022] Before the embodiments of the application are explained in detail, it is to be understood that the application is not limited in its application to the details of construction or the arrangement of the components set forth in the following description or illustrated in the drawings. The application is capable of other embodiments and of being practiced or being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of "including," "comprising," or "having" and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items and equivalents thereof. Further, enumeration can be used herein to describe various embodiments. Unless otherwise expressly stated, the use of enumeration should not be construed as applying to any specific order or number of components. The use of enumeration also should not be construed as excluding from the scope of the application any additional steps or components that might be combined with, or into, the enumerated steps or components. BRIEF DESCRIPTION OF DRAWINGS

[0023] Figure 1 is a side perspective view of footwear of the current embodiment including a sole assembly having a crimped structure;

[0024] Figure 2 is an exploded view of footwear showing various components;

[0025] Figure 3 is a bottom perspective view of the sole assembly showing the crimped structure of the sole assembly having undulating peaks and valleys;

[0026] Figure 3A is a cross-section of a first type of peak;

[0027] Figure 3B is a cross-section of a second type of peak;

[0028] Figure 4 is a cross-sectional view of the sole assembly taken along line IV-IV in Figure 3

[0029] Figure 5 is a cross-sectional view of the sole assembly taken along line V-V in Figure 3

[0030] Figure 6 is a cross-sectional view of the sole assembly taken along line VI-VI in Figure 3

[0031] Figure 7 is a top view of the sole assembly showing an aperture in the first midsole hidden by the second midsole. DETAILED DESCRIPTION

[0032] The current embodiment of footwear is in Figures 1-7 ​​​The present embodiments are shown in the context of a hiking shoe and are generally designated 10. In this embodiment, the footwear includes a sole assembly 20 that includes a first midsole 30, a second midsole 40, and an outsole layer 50 with a corrugated lower surface having an array of raised peaks 60 and valleys 70. Although the present embodiments are shown in the context of a hiking shoe, the sole assembly thereof can be incorporated into any type or style of footwear, including performance shoes, trail shoes and boots, work boots, all-terrain shoes, athletic shoes, running shoes, soccer shoes, regular tennis shoes, walking shoes, multi-purpose footwear, casual shoes, dress shoes, or any other type of footwear or footwear component. It should also be noted that directional phrases such as "vertical," "horizontal," "top," "bottom," "upper," "lower," "inner," "inwardly," "outer," and "outwardly" are used to assist in describing the present invention based on the orientation of the embodiments shown in the illustrations. In addition, the phrases "medial side," "lateral side," and "longitudinal" are used in the manner generally associated with footwear. For example, when used in reference to the sides of a shoe, the phrase "medial side" refers to the side facing inward (i.e., the side facing the other shoe), and "lateral side" refers to the side facing outward. When used in reference to direction, the phrase "longitudinal direction" refers to the direction extending generally between the toe and the heel of the shoe along the length of the shoe, and the phrase "lateral direction" refers to the direction extending generally between the medial side and the lateral side of the shoe across the width of the shoe.

[0033] The use of directional phrases should not be interpreted to limit the present invention to any particular orientation. In addition, as used herein, the phrase "arch region" (or arch or midfoot) generally refers to the portion of the footwear or sole assembly corresponding to the arch or midfoot of the wearer's foot; the phrase "forefoot region" (or forefoot) generally refers to the portion of the footwear forward of the arch region that corresponds to the forefoot of the wearer's foot (e.g., including the ball and toes); and the phrase "heel region" (or heel) generally refers to that portion of the footwear rearward of the arch region that corresponds to the heel of the wearer's foot. The forefoot region 12, the arch region or midfoot region 14, and the heel region 16 are generally in the order of 18-22 mm in length along the longitudinal direction, 14-18 mm in width along the lateral direction, and 8-10 mm in height along the vertical direction in the illustrated embodiment; however, the partitioning of these regions can vary depending on the construction of the sole assembly and / or footwear. Figure 1 The forefoot region 12, the arch region or midfoot region 14, and the heel region 16 are generally in the order of 18-22 mm in length along the longitudinal direction, 14-18 mm in width along the lateral direction, and 8-10 mm in height along the vertical direction in the illustrated embodiment; however, the partitioning of these regions can vary depending on the construction of the sole assembly and / or footwear.

[0034] Reference is made to Figures 1-2In some embodiments, footwear 10 can include a sole assembly 20. Sole assembly 20 can include a first midsole 30 positioned above a second midsole 40, an outsole layer 50, and a lower surface having a crimped configuration with a plurality of peaks 60 and valleys 70 of an undulating curved profile, optionally equipped with lug 55. In some embodiments, more or fewer elements of sole assembly 20 can be included. The components of the sole assembly, individually and / or collectively, can provide articles of footwear 10 with many attributes, such as energy return, roll, support, rigidity, flexibility, stability, cushioning, comfort, weight reduction, and / or other attributes. In general, whatever components are present, sole assembly 20 can form the bottom-most portion of footwear 10. Sole assembly 20 can include a side-to-side width W, a heel-to-toe longitudinal length L, and a longitudinal axis LA, which can be shared by the footwear, sole assembly, first and second midsole platforms, plate, and / or outsole.

[0035] Footwear 10 can include a textile upper 17 joined with sole assembly 20. Upper 17 can be formed from a variety of material elements that are joined together to cover at least a portion of a wearer's foot. The material elements can be selected based on the intended use of the article of footwear 10, and can include, for example, synthetic textiles, mesh textiles, polymers, or leather. Upper 17 can be configured to improve the rigidity of sole assembly 20. For example, the upper can be constructed of leather, plastic, canvas, or other materials. Upper 17 can include one or more closure elements, including, for example, a lace (not shown). Upper 17 also includes an upper opening 19 for receiving a wearer's foot and a lower perimeter 13 for attachment to sole assembly 20.

[0036] A footbed (not shown) can be positioned within the void defined by the upper and can be inelastic and lightweight, and joined to the upper to provide a void for receiving a wearer's foot. The footbed can be constructed of a sheet of material, such as foam, EVA, PU, latex, gel, or other materials, and by virtue of its compressibility, provides cushioning, and can also conform to the foot to provide comfort, support, and stability. The lower perimeter allowance or edge of the upper can be stitched, glued, or otherwise fastened to the footbed around the perimeter of the footbed. Sole assembly 20 can be combined with any other type or style of upper construction capable of being properly joined therewith, for example, a Strobel construction. The joining of the sole assembly / outsole and upper can be accomplished using adhesives, glues, injection molding, cast molding, or any other technique for joining an upper and sole assembly.

[0037] With reference to Figures 1-5The components of sole assembly 20 will now be described in greater detail. As mentioned above, sole assembly 20 can include an outsole layer 50, as well as one or more midsoles, such as a first midsole 30 and a second midsole 40 disposed between upper 17 and outsole layer 50. Optionally, first midsole 30 can be constructed of a foam, such as ethyl vinyl acetate (EVA), and second midsole 40 can be constructed of a polymeric material, such as polyurethane (PU). Of course, other foams or polymeric materials can be selected for the midsoles.

[0038] Midsoles 30 and 40 can also be constructed to have different stiffnesses to provide different performance characteristics. For example, first midsole 30 can be constructed to be more robust and stiffer to provide a relatively stable platform under the user's foot. The first platform can be constructed of a first material having a first stiffness, which is optionally between 40 and 60 Asker C, between 40 and 50 Asker C, between 42 and 48 Asker C, between 44 and 45 Asker C, about 45 Asker C, or higher than about 40 Asker C. The second midsole can be constructed to be softer to provide more cushioning and impact absorption, and / or to be more compliant to provide macroscopic traction to allow the underlying outsole layer to better grip the terrain and three-dimensional objects underfoot. The second midsole can be constructed of a second material having a second stiffness, which is optionally between 20 and 40 Asker C, between 30 and 40 Asker C, between 32 and 38 Asker C, between 35 and 38 Asker C, about 38 Asker C, or lower than about 40 Asker C. The first and second stiffnesses can be different, optionally wherein the first stiffness is greater than the second stiffness.

[0039] Turning to the structure of first midsole 30, reference is made to Figure 2 and Figure 4 which can include a first upper surface 31 that can take the shape of the upper and be configured to the contours of the wearer's foot. The first upper surface 31 can be at least partially bounded by a first upstanding midsole wall 32. This first upstanding midsole wall 32 can extend from the toes to the heel, generally slightly increasing in height Hl as it extends toward the heel region. In the heel region, the wall 32 can form a heel cup to add stability to the upper 17 and the wearer's heel when positioned in the upper. The first upstanding midsole wall 32 can extend upward adjacent the lower peripheral excess of the upper 17, at least partially concealing this lower peripheral excess 17A or lower portion of the upper 17. The upstanding midsole wall 32 can approximate the shape of the wearer's foot.

[0040] The first midsole 30 can include a first midsole lower surface 33 disposed opposite the first midsole upper surface 31 of the first midsole platform 30. This first midsole lower surface 33 can be substantially flat and / or planar across a majority of the width W of the sole assembly and can be configured to place a top of the second midsole 40 thereunder. The first midsole lower surface can be joined with the second midsole upper surface with cement, adhesive, glue, welding, molding, or other element or technique.

[0041] Turning now to the second midsole 40, this member can include a second midsole upper surface 41 and a second midsole lower surface 43 opposite the second midsole upper surface. As described below, the second midsole can extend through the heel region and then through the arch region, and the lower surface 43 can be contoured and can include a plurality of peaks 60 surrounded by a plurality of valleys 70. The second midsole upper surface can be generally flat and / or planar, but can be slightly contoured to follow the contours of a wearer's foot, e.g., in some applications, optionally, it can include a raised arch portion and / or some slight concavity or convexity in the heel and / or forefoot, but still be considered flat.

[0042] The second midsole upper surface 41 can define a plurality of downwardly extending apertures 80 that extend downwardly into the height or thickness H2 of the second midsole. The apertures 80 can include first apertures 81 and second apertures 82. Respective first apertures of the first apertures 81 can extend downwardly from the second midsole upper surface 41 a first distance D1 into a respective peak 60 of the plurality of peaks 60. This distance D1 can be selected so that the first apertures 81 extend within the plurality of peaks 60 so that optionally less than 5 mm, less than 4 mm, less than 3 mm, less than 2 mm, less than 1 mm, or 0 mm of the second material is disposed between the end 81E of each aperture and the top end 60T of each peak 60. With this configuration, the peaks can be made generally more pliable and more compressible.

[0043] The first apertures 81 optionally can have a tapered shape so that their overall size decreases as the aperture extends away from the lower surface 33 of the first midsole or the upper surface 41 of the second midsole 40. Optionally, as shown in FIG. 4, the first apertures 81 can be centered about a vertical axis VA of the respective first aperture 81. As shown in FIG. 5, the first apertures 81 can include an upper dimension or width 81UW and a lower dimension or width 81LW. The upper width 81UW can be greater than the lower width 81LW. As further shown in FIG. 6, the apertures can be circular and partially frustoconical in shape. In this case, the respective width can be the diameter of the aperture. Figure 5 Figures 4-5 Figure 7

[0044] ​​​As noted above, the first apertures 81 can extend down to a lower end or termination location 81E. The lower end 81E can be closest to the outsole layer 50. Depending on the application, the lower end 81E can have a rounded, contoured flat, planar, or other configuration. As further noted above, there can be a thickness Tl between the end 81E and the top end 60T of the peak 60 of the second midsole 40. In some cases, the first apertures can extend all the way through the peak, such that a hole is defined at the peak 60T. In this case, the outsole layer 50 can cover the hole, or further optionally, can include a corresponding hole, such that the first apertures 81 are in fluid communication with the environment.

[0045] Returning to Figure 4 and Figure 7 , the midsole 40 optionally can include second apertures 82. These second apertures 82 can extend down from the second midsole upper surface 41 toward the valley 70 a second distance D2 that is less than the first distance Dl of the first apertures 81. The second apertures 82 also can be offset relative to the peak 60. The second apertures can have a similar frustoconical shape and can include a rounded, flat, planar, or other shaped end or bottom, similar to the first aperture end. As further shown in Figure 4 and Figure 7 , the second apertures can have an upper end that is open to the second midsole upper surface 41. Generally, the width of the opening of the second apertures 82 can be smaller in size or dimension or diameter than the opening of the first apertures 81 at the second midsole upper surface.

[0046] The first apertures 81 and the second apertures 82 can be mixed and matched among one another corresponding to the array of respective peaks and valleys. For example, as further shown in Figure 7 , the first apertures 81 can be aligned in a pattern and uniformly spaced apart along the upper surface 41. The pattern can correspond to the peaks 60 of the contoured lower surface of the sole assembly. The second apertures 82 can be interspersed between the first apertures in a pattern that likewise corresponds to the pattern of valleys and contoured lower surface of the sole assembly 20.

[0047] Referring to Figure 1 and 4 -6, as noted above, the lower surface of the sole assembly includes a contoured shape that includes a plurality of peaks 60 and valleys 70. These peaks and valleys can be associated with the second midsole and / or an outsole layer overlying the second midsole. As shown, the outsole layer 50 can follow the contours and undulations of the contoured lower surface and can include corresponding peaks and valleys of the second midsole 40. The outsole layer 50 can be constructed of natural or synthetic rubber, thermoplastic polyurethane elastomer, nylon, polymer blends, abrasion resistant polymers, elastomers, and / or other materials. Other materials can be used, such as fiber reinforced polymers, which can include epoxy resins, polyethylene, or thermoset plastics reinforced with carbon, glass, and / or aramid fibers for added protection.

[0048] Optionally, as shown, the outer layer 50 may be a generally thin, flexible, compliant, and elastic layer. The outer layer 50 may include a thickness T3 extending between the upper surface 51 and the lower surface 52 of the outsole. Optionally, this thickness T3 may be between 0.5 mm and 10 mm, between 1 mm and 5 mm, between 12 mm and 4 mm, or about 3.5 mm, or less than 4 mm, or less than 5 mm. With these reduced thicknesses, the outer layer 50 can be compliant, allowing the multiple peaks 60, particularly the midsole material forming the peaks, to compress when placed on the terrain or three-dimensional surface underfoot to provide cushioning and / or energy absorption. The reduced thickness of the outer layer underfoot also allows it to easily conform to the three-dimensional object and / or terrain underfoot to promote macroscopic traction, which is generally the traction force against larger three-dimensional objects encountered by the sole assembly 20.

[0049] Optionally, the outsole 50 may include a sipes pattern 55, which may include a plurality of grooves, recesses, or slots extending across the outsole on the ground contact surface 52. The sipes pattern may be in the form of a specific shape, such as a sine wave or other waveform, to provide enhanced traction on slippery footholds, such as wet, icy, muddy, greasy, or other low-friction service surfaces. The sipes pattern generally provides micro-traction to smooth and / or slippery surfaces. The sipes pattern 55 may extend uniformly across the width W of the sole assembly 20 and may follow the three-dimensional profile of the curled underside, traveling upwards and downwards along the peaks and through corresponding valleys between the peaks. In some cases, the sipes pattern may extend upwards along the vertical sidewalls of the outsole 20 around the perimeter 69 of the sole assembly 20 and / or the outsole 50 or midsole 30 and 40.

[0050] As mentioned above and Figure 3 , Figures 4-6 As shown, the second midsole 40 may include a second midsole underside surface that is curled and includes a plurality of peaks 60 surrounded by a plurality of valleys 70. The peaks 60 may have a wide variety of configurations and may include different types of peaks. For example, the peaks may include a first peak 61, which may again be formed by both the second midsole 40 and the overlying outer underside 50. The first peaks may be in the form of at least a partially spherical shape and / or profile. These first peaks 61 may be positioned substantially closer to the longitudinal axis along the length L of the sole assembly than the second type of peaks 62. The partially spherical shape of the first peaks 61 may be a true partial sphere, such as a quarter, third, or half of a sphere, but in other cases, the partially spherical shape may be slightly parabolic in three dimensions, or have some other outwardly convex or curved shape; again, all of these may be referred to as partially spherical shapes.

[0051] The partially spherical shape of the first peak 61 can have certain horizontal cross sections that decrease in size as the first peak 61 extends away from the second midsole upper surface 41 or generally away from the first midsole 30. As Figure 3A As shown in

[0052] Optionally, a plurality of first peaks 61 can be aligned generally along the longitudinal axis LA of the footwear and can span the length L from the heel region 16 to the forefoot region 12 of the footwear. These aligned first peaks 61 can have similar sizes. One of these first peaks 61 can be disposed in the heel region and can form a heel peak 61H that can be disposed directly under the heel of a user wearing the footwear 10 to provide cushioning at the heel.

[0053] As mentioned above, the sole assembly 20, the second midsole 40, and the outsole 50 can be configured to include a plurality of second peaks 62. As Figure 3 Figure 3B and Figure 6 As further shown in

[0054] As shown in Figure 3B ​As shown in the middle, the second peak 62 can include a horizontal cross-section that is truncated by the second midsole lateral wall 47 and / or the second outsole lateral wall 57. These lateral walls 47 and 57 can be disposed further from the longitudinal axis than the curved second midsole medial wall 48 or the curved medial-lateral outsole wall 58. These medial walls as shown can follow a partial spherical profile and / or and can be partially or fully rounded and / or curved. In some cases, these medial walls can be more angular. Further optionally, the second peak 62 can extend downward to a substantially flat and / or planar ground contact surface 52G. This flat and / or planar surface can be repeated between the plurality of second peaks 62 disposed around the perimeter 69 of the sole assembly. These flat ground contact surfaces in this region can attenuate the roll of the footwear and can enhance the lateral and medial stability of the sole assembly 20 for the user.

[0055] Optionally, the second peak 62 can be at least partially encased by an outsole lateral wall 57 extending therearound. This lateral wall 57 can extend upward from the ground contact surface of the outsole layer 50 toward the first midsole 30. This outsole lateral wall 57 can add rigidity to the second peak 62 and can also add a second robustness to those peaks around the perimeter 69. In some cases, the outsole lateral wall 57 can be thicker than the thickness T3 of the outsole layer overlying the first peak 61 to provide such enhanced robustness and / or rigidity. In other applications, the outsole lateral wall can not be present in this configuration and the midsole lateral wall can be fully exposed to the environment.

[0056] As Figure 1 As can be shown, the valleys along the perimeter 69 of the sole assembly 20 can transition to and from the respective peaks 60. In some cases, the valleys can include a lateral valley 70L that transitions to the second midsole lateral wall 47. The outsole lateral wall 57 of the outsole layer can join with one or both of the lateral valley 70L and the second midsole lateral wall 47. In some cases, the outsole lateral wall 57 can extend upward from the flat generally planar lower ground contact surface 52G of one or more of the respective second peaks 62.

[0057] Optionally, the second peak can include a contact heel pad 66 that can be substantially flat and / or planar on its ground contact surface such that the pad 66 can function as a heel ground contact pad. Again, the partially spherical heel peak 61H can be surrounded by a portion of the heel contact pad 66 and the heel region. As Figure 3 As shown in the middle, the peak 61H can be separated from the contact heel pad by a heel pad valley 72V. In other applications, the peak 61H and the pad 66 can be integrally formed in different configurations.

[0058] Various peaks 60 can be used to provide enhanced cushioning and macroscopic traction on large three-dimensional objects in the terrain underfoot. As an example, sole assembly 20 can be configured to absorb forces Fl exerted by the ball of the user's foot B against the sole assembly. In particular, peaks 60 can be configured such that first peaks 61 A, 61B and 61C and second peaks 62A can surround or encircle valleys 70B corresponding to the ball of the user's foot B. When forces Fl are exerted against the sole assembly by the ball of the foot B, the forces Fl are diverted to the first valleys 70B beneath the ball of the foot B. In turn, the first, second, third and fourth peaks can deflect in the direction of arrow A away from the first valleys 70B to provide cushioning to the ball of the user's foot B. Various peaks 60 can also be arranged in different arrays and configurations to provide impact absorption, cushioning and / or other types of traction depending on the application.

[0059] A method of making footwear 10 and particularly sole assembly 20 will now be described. Generally, the method can include placing an outsole layer in a mold, the outsole layer having a contoured outsole surface including a plurality of peaks and valleys; introducing a second midsole material on the contoured outsole surface, which can optionally be the upper surface of the outsole; defining downwardly extending apertures in the second midsole material, some of which extend toward the peaks; curing the second midsole material to form a second midsole; and optionally joining a first midsole to the upper surface of the second midsole. Further optionally, the first midsole can be composed of a first material having a first hardness that is greater than a second hardness of the second midsole material.

[0060] Prior to placing the outsole layer in the mold, it can be molded and formed with a tread pattern, such as a lug pattern. Various valleys and peaks of the contoured surface can also be formed in the molding operation of the outsole layer along with any outsole sidewalls that surround the perimeter of the outsole layer. The outsole layer can be suitably trimmed and shaped prior to being placed in the mold to ensure proper fit and processing.

[0061] When the second midsole material is introduced into the mold, another mold plate or portion can interact with the second material to define the above-described respective first and second apertures corresponding to the respective peaks and valleys. After the second midsole and outsole layer are joined, the first midsole 30 can likewise be joined to the second midsole 40 to complete the sole assembly having all of these components. With the sole 20 completed, the upper 17 can be joined with the sole assembly, and further trimming and processing can be performed to complete the footwear 10.

[0062] Directional terms such as "vertical," "horizontal," "top," "bottom," "upper," "lower," "inner," "inwardly," "outer" and "outwardly" are used to assist in describing the application based on the orientation of the embodiments shown in the drawings. The use of directional terms should not be interpreted to limit the application to any particular orientation.

[0063] Additionally, when a member, part, or layer is referred to as being "on", "connected to", "engaged to", "attached to", or "coupled to" another member, part, or layer, it can be directly on, connected to, engaged to, attached to, or coupled to the other member, part, or layer, or any number of intervening members, parts, or layers can be present. In contrast, when an element is referred to as being "directly connected to", "directly on", "directly engaged to", "directly attached to", or "directly coupled to" another element or layer, there are no intervening elements or layers present. Other words used to describe the relationship between elements, members, and parts should be interpreted in a like fashion, such as "adjacent" versus "directly adjacent" and similar words. As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items.

[0064] The above description is that of current embodiments of the application. Various alterations and changes can be made without departing from the spirit of the application, which is defined by the scope of the following claims, interpreted in the light of the prior art, and all equivalents thereto. This disclosure is presented throughout various embodiments to demonstrate the inventive process and functionality as provided herein. The disclosure is not, and is not intended to be, exhaustive or completely to encompass the full scope of possibilities for equivalents known now or later. It is intended, using the principles, examples, embodiments, examples, experiments, and details given herein, that others can and will make modifications and / or improvements to the disclosure and the associated concepts. For example, and without limitation, as the technology evolves, the function described herein will be implemented in various ways, as the structure changes, as the computer code changes, as the hardware changes, as the hardware components change, as the firmware changes, and / or as the software changes. These changes, and any others, are all contemplated in accordance with the disclosure.

Claims

1. A footwear construct comprising: a first midsole comprised of a first material having a first hardness, the first midsole including a first midsole upper surface and an opposing first midsole lower surface, the first midsole upper surface configured to face a user's foot placed within the footwear construct; a second midsole comprised of a second material having a second hardness, the second hardness less than the first hardness, the second midsole including a second midsole upper surface joined with the first midsole lower surface, the second midsole upper surface defining a plurality of downwardly extending first apertures and downwardly extending second apertures, the second midsole upper surface joined with the first midsole lower surface such that the first midsole lower surface covers the first apertures and the second apertures, the second midsole having a second midsole lower surface, the second midsole lower surface being contoured and including a plurality of peaks surrounded by a plurality of valleys, a plurality of the first apertures extending downwardly from the second midsole upper surface a first distance into the plurality of peaks, a plurality of the second apertures extending downwardly from the second midsole upper surface toward the valleys a second distance less than the first distance, the plurality of peaks including: a plurality of first peaks having horizontally disposed substantially circular cross sections that decrease in size as the first peaks extend away from the first midsole such that the first peaks provide a first firmness, and a plurality of second peaks having horizontal cross sections truncated by a second midsole lateral wall such that the second peaks provide a second firmness greater than the first firmness along an outer perimeter of the second midsole; and an outsole layer disposed on the plurality of first peaks, the plurality of second peaks, the plurality of valleys, and the second midsole lateral wall.

2. The footwear construct of claim 1, the first material being a foam having a first hardness between 40 and 50 Asker C, wherein wherein the second material is a polyurethane having a second hardness between 30 and 40 Asker C.

3. The footwear construct of claim 2, a plurality of the first apertures extending within the plurality of peaks such that less than 2 mm of the second material is disposed between an end of each aperture and an apex of each peak, thereby making each peak more pliable and compressible. wherein 4. The footwear construct of claim 1, each of the plurality of first peaks forming a partial spherical shape, wherein wherein the plurality of second peaks are wrapped by an outsole lateral wall extending upwardly from a ground contact surface of the outsole layer toward the first midsole, whereby the outsole lateral wall adds rigidity to the plurality of second peaks.

5. The footwear construct of claim 4, the plurality of valleys including a lateral valley transitioning to the second midsole lateral wall, wherein wherein the outsole lateral wall is joined with at least one of the lateral valley and the second midsole lateral wall.

6. The footwear construct of claim 1, ​ wherein The second midsole sidewall of each of the plurality of second peaks is disposed opposite a curved profile disposed inward from the second midsole wall and closer to a longitudinal axis of the footwear than the second midsole sidewall.

7. The footwear construct of claim 6, wherein, The plurality of first peaks forms an at least partially spherical shape and is disposed closer to the longitudinal axis than the plurality of second peaks.

8. The footwear construct of claim 1, comprising: wherein the outsole layer includes sipes, wherein the outsole layer is between 1 mm and 5 mm in thickness, whereby the outsole layer is compliant such that the plurality of peaks can compress to provide cushioning.

9. The footwear construct of claim 1, comprising: wherein the outsole layer includes sipes configured to provide traction relative to a slippery foothold, wherein the second midsole lower surface that is crimped is configured to have macroscopic traction on protruding subterranean terrain.

10. The footwear construct of claim 1, wherein The plurality of peaks includes a substantially flat contact heel pad, wherein the plurality of first peaks includes a heel peak that is partially spherical and is surrounded by a portion of the contact heel pad but separated from the contact heel pad by a heel pad valley.

11. A footwear construct, comprising: a first midsole, the midsole including a first midsole upper surface and an opposing first midsole lower surface, the first midsole upper surface configured to face a user's foot placed within the footwear construct; a second midsole including a second midsole upper surface below the first midsole lower surface, the second midsole upper surface defining a plurality of downwardly extending first apertures and a plurality of downwardly extending second apertures, the second midsole upper surface joined with the first midsole lower surface, the second midsole having a second midsole lower surface that is crimped and includes a plurality of peaks surrounded by a plurality of valleys, the plurality of first apertures extending downward from the second midsole upper surface a first distance into the plurality of peaks, the plurality of second apertures extending downward from the second midsole upper surface toward the valleys a second distance less than the first distance; and an outsole layer disposed on and following the crimped second midsole lower surface, the plurality of first peaks, the plurality of second peaks, the plurality of valleys, and the second midsole outer sidewall.

12. The footwear construct of claim 11, wherein, The plurality of peaks includes a plurality of first peaks having horizontally disposed substantially circular cross sections that decrease in size as the peaks extend away from the first midsole, such that the plurality of first peaks provide a first firmness, wherein the plurality of peaks includes a plurality of second peaks having horizontal cross sections truncated by a second midsole outer sidewall, such that the second peaks provide a second firmness greater than the first firmness along an outer perimeter of the second midsole, whereby the second firmness provides greater lateral stability to a user's foot placed in the footwear construct around the outer perimeter.

13. The footwear construct of claim 12, comprising: a first peak, a second peak, a third peak, and a fourth peak, which surround a first valley configured to extend under a ball of a foot of a user placed in the footwear configuration, wherein the first peak, the second peak, the third peak, and the fourth peak are configured to deflect away from the first valley when the ball of the user's foot exerts force on the second midsole, whereby the first peak, the second peak, the third peak, and the fourth peak provide cushioning to the ball of the user's foot.

14. The footwear configuration of claim 11, wherein the outsole layer includes a lug pattern configured to provide traction against a slippery standing place, wherein the crimped second midsole lower surface is configured to have macroscopic traction against protruding sub-terrain.

15. The footwear configuration of claim 11, wherein the first midsole is comprised of a foam having a first hardness between 40 and 50 Asker C, wherein the second midsole is comprised of a polyurethane having a second hardness between 30 and 40 Asker C, wherein the second hardness is less than the first hardness.

16. The footwear configuration of claim 11, wherein, a plurality of the first apertures extend within the plurality of peaks such that less than 2 mm of second material is disposed between an end of each aperture and an apex of each peak, whereby each peak is made more pliable and compressible.

17. The footwear configuration of claim 11, wherein, a plurality of the first apertures include an aperture centered on a vertical axis of a first peak, the aperture extending down into the first peak to a termination location such that the first peak includes less than 2 mm of thickness adjacent the termination location.

18. The footwear configuration of claim 17, wherein, the outsole layer includes a lug pattern and extends over the crimped second midsole lower surface to conform to the plurality of peaks and the plurality of valleys, wherein the lug pattern extends over a first peak, into a first valley, and over a second peak.

19. A method of making a footwear configuration, the method comprising: placing an outsole layer having a thickness of less than 5 mm and a crimped outsole upper surface including a plurality of peaks and a plurality of valleys in a mold; introducing a second midsole material within the mold over the crimped outsole upper surface to conform to and bond with the crimped outsole upper surface; defining a plurality of downwardly extending first apertures and a plurality of downwardly extending second apertures in the second midsole material, the first apertures extending toward the plurality of peaks; curing the second midsole material to form a second midsole including a second midsole lower surface and a flat opposing second midsole upper surface, the second midsole lower surface following the crimped outsole upper surface including the plurality of peaks and the plurality of valleys; joining a first midsole to the second midsole upper surface, the first midsole comprised of a first material having a first hardness, the first hardness being greater than a second hardness of a second midsole material forming the second midsole.

20. The method of claim 19, comprising: defining the first apertures such that a thickness of the second midsole between a bottom of each aperture and the outsole layer is less than 3 mm.

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