Article of footwear with removably secured mechanical cushioning

Abstract

An article of footwear includes an upper and a sole structure secured to the upper, the upper having an interior volume adapted to receive a foot of a wearer. The sole structure includes a chassis plate disposed within the upper, a midsole secured to the chassis plate such that the upper extends between the chassis plate and the midsole, and an outsole tread element attached to a ground-facing surface of the midsole.

Description

[0001] Cross-reference to related applications

[0002] This application claims the benefit of priority to U.S. Provisional Patent Application No. 63 / 088,656, filed on October 7, 2020. Technical Field

[0003] This disclosure relates to a footwear article comprising a removably secured sole interlayer having mechanical cushioning elements.

[0004] background

[0005] Typical athletic footwear comprises two main components: the upper and the sole construction. The upper provides a covering that securely receives and positions the foot relative to the sole construction. Additionally, the upper may have a protective and ventilated structure to cool the foot and wick away sweat. The sole construction is attached to the underside of the upper and is typically positioned between the foot and the ground. Besides reducing ground reaction forces and absorbing energy (i.e., providing cushioning), the sole construction also provides traction and controls potentially harmful foot movements such as overpronation. Therefore, the upper and sole construction work together to provide a comfortable structure suitable for a variety of walking activities such as walking and running.

[0006] A typical shoe sole construction generally comprises multiple layers commonly referred to as the insole, midsole, and outsole. The insole is a thin, cushioning component located within the upper and adjacent to the sole (lower) surface of the foot to enhance comfort. The midsole, traditionally attached to the upper along its entire length, forms the middle layer of the sole construction and serves multiple purposes, including controlling foot movement and providing cushioning. The outsole forms the element of the footwear that contacts the ground and is typically made of durable, abrasion-resistant materials with textured surfaces to improve traction and friction.

[0007] Conventional midsoles are typically formed from an elastic polymer foam material (such as polyurethane or ethyl vinyl acetate) that extends the length of the footwear. The properties of the polymer foam material in the midsole depend primarily on several factors, including the dimensional construction of the midsole and the specific characteristics of the materials chosen for the polymer foam (including its density). By altering these factors throughout the midsole, the relative stiffness, the degree of ground reaction reduction, and energy absorption properties can be modified to meet the specific requirements of the activities in which the footwear is intended to be used. Brief description of the attached diagram

[0009] Figure 1This is a schematic top perspective view of a footwear item with removably fixed mechanical cushioning.

[0010] Figure 2 yes Figure 1 A schematic exploded view of footwear items.

[0011] Figure 3 It is a schematic exploded diagram of the sole structure used in footwear.

[0012] Figure 4 This is a schematic bottom perspective view of a footwear item with a removably fixed mechanical cushioning element.

[0013] Figure 5 yes Figure 4 A schematic top-down perspective view of footwear, showing the shoe through the ankle opening.

[0014] Figure 6 It is possible to be with Figure 1 A schematic side perspective view of a shoe sole sandwich structure used in footwear.

[0015] Figure 7 yes Figure 6 A schematic side view of the midsole structure of a shoe.

[0016] Figure 8 yes Figure 6 A schematic bottom-view perspective view of the heel section of a shoe with a midsole structure.

[0017] Figure 9 yes Figure 6 A schematic bottom-view perspective view of the forefoot portion of the shoe with a midsole structure.

[0018] Detailed description

[0019] The following discussion and figures disclose a footwear article 10 (also referred to as article 10) comprising a removable sole structure with mechanical cushioning elements (rather than relying primarily on foam). These designs allow any major component of the shoe to be selectively replaced, thereby extending the overall lifespan of the article. Furthermore, the ability to easily remove components allows end users to customize color schemes or achieve a specific look according to their own preferences. In some constructions, it may be preferred that some or all components be formed from thermoplastic polymers or other easily recyclable materials, thereby promoting sustainable design and minimizing manufacturing and / or post-consumer waste. The concepts disclosed herein can be applied to a wide range of footwear styles and should not be limited to the specific embodiments discussed below and depicted in the figures.

[0020] Beyond easy component replacement, this design enables new / different retail models or practices that are more autonomous, reduce overall packaging waste, allow for greater user customization, and / or reduce supply chain complexity. For example, in one construction, one or more components of a footwear item can be formed using 3D printing / rapid on-demand production technology and can be manufactured with colors and sizes customized for specific users. This reduces the need for individual packaging, inventory, and global distribution of these components. Similarly, in some embodiments, individual components can be supplied for sale from vending machines or other automated purchasing devices. Such vending machines can be placed in traditional retail locations for self-service walk-up commerce, or they can be placed at event venues to store limited-edition colors or designs to commemorate the event. Other applications of this technology are listed below.

[0021] refer to Figure 1 The image depicts a footwear article 10, which includes an upper 12 and a sole structure 14 attached to the upper 12. The footwear article 10 may be divided into one or more regions. These regions may include a forefoot region 16, a midfoot region 18, and a heel region 20. The forefoot region 16 may correspond to the toes and the joints connecting the metatarsal and phalangeal bones of the foot. The midfoot region 18 may correspond to the arch region of the foot, while the heel region 18 may correspond to the posterior portion of the foot, including the calcaneus. The footwear article 10 may also include a medial side 22 and a lateral side 24, which correspond to opposite sides of the footwear article 10 and extend through regions 16, 18, and 20. Footwear article 10 may extend generally between the forefoot 26 or forefoot portion (which may correspond to the foremost point of the forefoot region 16) and the rearfoot 28 or rearfoot portion (which may correspond to the rearmost point of the heel region 20). The longitudinal axis of the footwear article may be defined as extending between the forefoot 26 and the rearfoot 28. As used herein, anatomical references such as anterior and posterior should be understood as reference directions for the footwear article that, when the shoe is worn on the wearer's foot, will coincide with the aforementioned defined ends 26, 28 and be consistent with established anatomical conventions.

[0022] The upper 12 includes an inner surface defining an internal cavity 30 that receives and secures the foot for support on the sole structure 14. An ankle opening 32 in the heel region 20 provides an entrance to the internal cavity 30. For example, the ankle opening 32 may receive the foot to secure it within the cavity 30 and facilitate entry and exit of the foot from the internal cavity 30.

[0023] In some examples, one or more fasteners or other closure systems may extend across the upper 12 to adjust the fit of the internal cavity 30 around the foot, while simultaneously accommodating the foot's entry into and exit from the internal cavity. Fasteners or other closure systems may include shoelaces, straps, cords, locking mechanisms, buckles, snaps, hooks, or any other suitable type of fastener.

[0024] The upper 12 can be formed from one or more materials stitched or adhesively bonded together to form the internal cavity 30. Suitable materials for the upper 12 may include textiles, foam, leather, and synthetic leather. In one embodiment, the upper 12 may be formed from a knitted fabric to provide a more sock-like feel than a conventional rigid upper. These materials can be selected and positioned to impart properties of durability, breathability, abrasion resistance, flexibility, and comfort to the foot when positioned within the internal cavity 30.

[0025] The sole structure 14 is attached to the underside of the upper 12 and provides support and cushioning for the footwear 10 during use. That is, the sole structure 14 reduces the ground reaction force caused by the footwear 10 impacting the ground during use. Therefore, and as stated below, the sole structure 14 can incorporate energy-absorbing design characteristics to allow the sole structure 14 to minimize the impact experienced by the user when wearing the footwear 10.

[0026] Reference Figures 2-3 Typically, the sole structure 14 may include a sole interlayer 36 and an outsole 38 (or one or more outsole components or inserts). For example... Figure 1 As generally illustrated, the midsole 36 extends from the forefoot 26 to the proximal end 28 of the footwear, and may further extend beyond the forefoot and proximal ends of the upper 12. This overextension, for example, can provide a suitable foothold to help the wearer remove the shoe. The midsole 36 is attached to the lower portion of the upper 12 and positioned such that it extends beneath the foot during bipedal use. Among other purposes, the midsole 36 is designed to reduce ground reaction forces and absorb energy (i.e., provide cushioning) when the user walks or runs.

[0027] Continue to refer to Figures 2-3The outsole 38 or multiple outsole components are disposed on the ground-facing surface of the lower portion of the sole interlayer 36 and on the side of the sole interlayer 36 opposite to the upper 12. The outsole 38 may define a ground-contact surface 40 operable to provide abrasion resistance and enhance adhesion friction between the footwear article 12 and the ground. The outsole 38 may be formed of an elastic material, such as, for example, rubber or durable thermoplastic polyurethane, which can improve adhesion friction and durability. The ground-contact surface 40 may include one or more adhesion friction elements 42 (such as... Figure 3 (as best illustrated in the diagram) or protrusion, the adhesion friction element 42 or protrusion extends outward to provide increased adhesion friction for footwear 10 during use.

[0028] When fully assembled, the upper surface 44 of the midsole 36 can contact and be secured to the lower, ground-facing portion 46 of the upper 12. In one configuration, the upper surface 44 of the midsole can be attached to the upper 12 using a suitable adhesive that establishes a permanent bond between the two components. However, in other configurations, the midsole 36 can be secured to the upper 12 by attaching it to a mating sole component integrated into the ground-facing portion 46 of the upper 12. For example, as... Figure 2 As shown, the sole structure 14 may also include a chassis plate 48, which slides within the internal cavity 30 to rest against the lower surface of the upper (similar to an insole or drop-in midsole), or is directly integrated into the upper 12, similar to strobel (midsole fabric). It is worth noting that, for ease of explanation, in... Figure 2 The exploded view shows the order of the components, and the chassis plate 48 is an embedded component that slides into or is integrally integrated with the upper 12.

[0029] Although Figure 2 and Figure 3 The illustration schematically depicts a relatively large outsole portion 38 that includes multiple adhesive friction elements, but... Figure 4 In the schematically illustrated embodiment, the outsole 38 may alternatively include a plurality of discrete outsole portions 38, wherein each outsole portion includes a single adhesion friction element 42.

[0030] In some constructions, the midsole 36 can be attached to the chassis plate 48 via direct attachment, which is achieved by welding (e.g., fusing two thermoplastic polymers together without an intermediate adhesive) or by adhering the components together using an intermediate adhesive. In another construction, such as Figure 4As shown, the sole structure 14 may include a plurality of threaded fasteners 60 extending between the sole interlayer 36 and the chassis plate 48 and operatively securing the sole interlayer 36 in a fixed position relative to the chassis plate 48. By releasing these fasteners 60, the sole interlayer 36 can be removed from both the chassis plate 48 and the upper 12 to facilitate easy repair or replacement of one or more components of the footwear article 10. While threaded fasteners for securing the sole interlayer 326 to the chassis plate 48 are shown and described herein, other types of fasteners may be used in other embodiments. For example, push-in fasteners, quarter-turn locking fasteners, or other forms of removable fasteners may be used.

[0031] like Figure 5 As shown, in one embodiment, the chassis plate 48 may include a plurality of threaded anchors 62, each threaded anchor 62 adapted to receive a different one of a plurality of threaded fasteners 60. During assembly, each threaded fastener 60 may extend through a corresponding hole 64 provided in the sole interlayer 36 and may thread-engage with a different one of the plurality of threaded anchors 62 to secure the sole interlayer 36 to the chassis plate 48. The plurality of threaded anchors 62 may include, for example, tapped / threaded holes directly formed in the chassis plate 48, press-fitted or otherwise secured within holes in the chassis plate 48, or as... Figure 5 The hexagonal nut shown is placed in the corresponding hexagonal hole 68 in the upper surface 70 of the base plate 48.

[0032] In some configurations, once assembled, the material of the upper 12 may extend at least partially between the chassis plate 48 and the upper surface 44 of the sole interlayer 36. The chassis plate 48 and the sole interlayer 36 may apply compressive forces to the trapped material of the upper 12, which can provide sufficient resistance to prevent and / or inhibit separation of the upper from the sole interlayer 36 / sole structure 14. In one configuration, the upper 12 may also include one or more reinforcing eyelets or loops on the ground-facing portion 36 through which threaded fasteners may pass when secured to the chassis plate. These eyelets / loops can further aid in stabilizing the upper 12 relative to the sole structure 14.

[0033] Reference Figures 6-7In some embodiments, the footwear article 10 may rely at least in part on the structural design of the midsole 36 to mitigate ground reaction forces during use. This structural design typically relies on the midsole 36 flexing upon impact and rebounding as the force dissipates. The midsole 36 may include an upper plate 80 integrally coupled to one or more ground-facing lower plates 82 to form one or more spring-like shock absorbers. As generally discussed above, the upper plate 80 may extend from at least the forefoot 26 across the entire length of the upper 12 to the rearfoot 28. Furthermore, the upper plate 80 may define a plurality of holes 64 through which threaded fasteners 60 may be passed to secure the midsole 36 to the upper 12.

[0034] One or more ground-facing lower plates 82 may each have a length measured parallel to the longitudinal axis, which is less than the similarly measured length of the upper plate 80. Alternatively, each ground-facing lower plate 82 may extend only beneath a portion of the upper plate 80. Figures 6-7 As generally illustrated, in one configuration, the sole interlayer 36 may include a first lower plate 86 facing the ground, substantially located within the heel region 20, and a second lower plate 88, substantially located within the forefoot region 16.

[0035] Each ground-facing lower plate 86, 88 may have a respective central portion 90, a front portion 92, and a rear portion 94, wherein the central portion 90 is located between the front portion 92 and the rear portion 94. At least one of the front portion 92 or the rear portion 94 of each lower plate 86, 88 may be fixed to or otherwise connected to the upper plate 80, while the central portion 90 may be spaced apart from the upper plate 80. In some configurations, the sole interlayer 36 may define a cavity 96 or open space between the upper plate 80 and one or both of the lower plates 86, 88. This cavity 96 may allow the respective lower plates 86, 88 to yield more readily in response to impact loading. Figure 5 As better illustrated, in one configuration, the first cavity 100 may extend between the central portion 90 of the first lower plate 86 and the upper plate 80, and may extend from the outer side through the sole interlayer 80 to the inner side. Furthermore, in some configurations, the second cavity 102 may extend between the central portion 90 of the second lower plate 88 and the upper plate 80, and may similarly extend from the outer side through the sole interlayer 36 to the inner side.

[0036] As further illustrated, in one configuration, a ground-facing first lower plate 86 located in the heel region 20 can be connected to the upper plate 80 via a first rounded transition 104 located at the rear end of the sole interlayer 36. Similarly, a ground-facing second lower plate 88 located in the forefoot region 16 can be connected to the upper plate 80 via a second rounded transition 106 located at the front end of the sole interlayer 36. In doing so, the sole interlayer 36 can have an appearance in which the upper plate 80 wraps downward at both the rear and front ends to form the respective first lower plate 86 and second lower plate 88. In doing so, this design leaves the sidewalls substantially open to provide corresponding cavities 96, 102 through the width of the sole interlayer 36. In this configuration, the upper plate 80, the first lower plate 86, and the second lower plate 88 can all be integrally formed, for example, by injection molding, 3D printing / additive manufacturing process, or thermoforming process.

[0037] In a general sense, this design can mitigate ground impact forces by enabling the respective lower plates 86, 88 to elastically deform in response to applied loads. As shown, in one configuration, each lower plate can operate similarly to a leaf spring, i.e., each lower plate 86, 88 is anchored at opposing front and rear end portions 92 and 94, and the central portion 90 is operable to deflect toward the upper plate 80 in response to applied lateral loads. In this embodiment, such as Figures 6-7 As shown, the front end portion 92 and the rear end portion 94 of each lower plate 86, 88 can be integrally formed with the upper plate 80. This can be achieved, for example, using one or more molding processes (including injection molding, compression molding, etc.). Similarly, in some embodiments, this can be achieved using 3D printing / additive manufacturing processes.

[0038] By further spacing the respective front portion 92 and rear portion 94 of each lower plate 86, 88, a greater travel distance can be provided in the lower plates 86, 88, thereby providing greater cushioning / force reduction. In one construction, a sole interlayer 36 with sufficient cushioning can be provided by a design in which the front portion 92 of the first heel-side lower plate 86 is attached to or otherwise terminates at a first position 110, which is located in front of a second position 112, at which the rear portion 94 of the second forefoot lower plate 88 is attached to or otherwise terminates at the upper 12. Figure 6As shown, in one embodiment of this design, the sole interlayer 36 may have a scissor-like appearance, wherein one of the two plates is attached at a central location between the inner side 22 and the outer side 24, while the other plate extends on the opposite side of the plate and is attached at a more peripheral location. In another embodiment, one plate may be attached closer to the inner side 22 of the upper plate 80, while the other plate may be attached closer to the outer side 24.

[0039] As described above and in Figures 4-5 As generally illustrated, the sole interlayer 36 can be removably secured to the chassis plate 48 and the upper 12 using a plurality of threaded fasteners 60, each threaded fastener 60 extending through a different corresponding orifice / hole 64 provided in the upper plate 80. In one embodiment, to provide access to these threaded fasteners, one or more lower plates 82 may include a plurality of access holes 120 extending fully through the thickness of the lower plate 82, wherein each access hole 120 is aligned with a different one of the plurality of holes 64 in the upper plate 80. The access holes 120 can facilitate the tightening of the corresponding threaded fasteners 60 by allowing a long tool, such as a screwdriver, to extend through the access holes 120 and come into contact with the fasteners 60.

[0040] Figures 8-9 The diagram schematically illustrates the alignment between each of the plurality of holes 64 in the upper plate 80 and each of the plurality of access holes 120 in the corresponding lower plate 82. Generally, in the context of hole alignment between two plates, the term “alignment” is intended to mean that each hole is centered about the longitudinal axis of the threaded fastener when the threaded fastener is screwed into the chassis plate 48 through the hole 64 in the upper plate 80.

[0041] In some embodiments, the sole interlayer 36 can be secured to the chassis plate 48 in both the heel region 20 and the forefoot region 16. Therefore, the first lower plate 86 includes a first plurality of access holes 122, and the second lower plate 88 includes a second plurality of access holes 124. Figure 8 As shown, the first plurality of entry holes 122 in the first lower plate 86 are aligned with the first subgroup of the plurality of holes 64 in the upper plate 80. Similarly, as Figure 9 As shown, the second plurality of entry holes 124 in the second lower plate 88 are aligned with the second subgroup of the plurality of holes 64 in the upper plate 80. Figures 8-9 As further illustrated, the number of entry holes 120 provided in the sole interlayer 36 may be less than the total number of holes provided in one or more lower plates 82. More specifically, the sole interlayer 36 may also include one or more auxiliary holes 126 that extend completely through the lower plate 82 but are not aligned with corresponding holes 64 in the upper plate 80. In one embodiment, the total number of auxiliary holes 126 may be greater than the total number of entry holes 120.

[0042] Refer again Figures 2-3 Instead of simply opening the inlet hole 120 and / or auxiliary hole 126, these holes can alternatively be used to hold or secure the outsole 38 to the insole interlayer 36. For example, in one construction, the outsole 38 may include a forefoot outsole portion 130 and a heel outsole portion 132, such as Figure 2 As shown. In this configuration, each of the forefoot outsole portion 130 and the heel outsole portion 132 may include a plurality of posts 134 extending upward into a plurality of access holes 120 in the lower plate 82. These posts 134 may be glued in place; however, in a more preferred embodiment, these posts 134 may simply be press-fitted into the openings. In one embodiment, each post 134 may include a retaining feature 140 (as shown in...). Figure 1 and Figure 2 As best seen in the image, retaining feature 140 protrudes to the opposite side of the lower plate 80 and has a diameter larger than the corresponding diameter of the hole through which retaining feature 140 extends. In this way, retaining feature 140 can provide mechanical interference that prevents post 134 from being easily removed from the hole.

[0043] exist Figure 4 In the illustrated embodiment, when using discrete outsole elements, each of the plurality of discrete outsole elements may extend at least partially into different holes among a plurality of holes in the lower plate. For example, each discrete outsole element may include a corresponding post, which may be press-fitted, adhered, or otherwise secured within the corresponding hole. Similar to... Figure 2 In the embodiments shown, each column may include a retaining feature, very similar to Figure 2 The design shown.

[0044] Generally, the aforementioned outsole is configured to be removable from the midsole layer to provide selective access to the threaded fasteners and allow the user to separate the midsole layer from the upper. In one configuration, the process of disassembling the fully assembled footwear item 10 may begin by removing the outsole 38 and / or multiple outsole components from holes in the lower plate. These holes are opened by removing the outsole 38, allowing tools such as screwdrivers, hex wrenches, socket drivers, etc., to be inserted through the various holes to individually engage each threaded fastener 60. By rotating the tool, each threaded fastener can be removed, which separates the midsole layer from the upper.

[0045] Once separated, further disassembly of the footwear can be achieved, for example, by removing the insole or insole from the internal cavity of the upper. Similarly, in some constructions, the chassis plate 48 can also be removed from the internal cavity 30 of the upper 12. Complete disassembly in this manner allows each component to be replaced individually as it begins to show signs of wear due to use.

[0046] Given that the footwear article 10 can be easily disassembled and its components can be easily replaced, it is preferable that each component can be recycled or reused in some way to advance the goal of sustainable manufacturing / product design. Therefore, in one construction, at least the sole interlayer 36 and the chassis plate 48 can be formed substantially of a thermoplastic polymer that can be easily melted and recycled. The term "substantially" is intended to consider that some bushings or threaded hexagonal nuts can be formed of metal, while the body of the components can be formed entirely of thermoplastic polymer. Furthermore, in some designs, the outsole 38 can also be formed of a thermoplastic polymer, and similarly, in some designs, the upper 12 can include a knitted material formed of yarn comprising a thermoplastic polymer. In some embodiments, the yarn used to form the knitted upper can be formed entirely of thermoplastic polymer filaments. In one construction, each of the upper 12, the chassis plate 48, the midsole 36, and the outsole 38 can be formed substantially of a thermoplastic polymer material (i.e., except for any threaded fasteners, retaining members, or bushings used to facilitate the connection of the various components). In this way, the footwear article 10 can be fully recyclable while retaining the ability to selectively replace one or more components that show signs of wear.

[0047] In one construction, each of the midsole 36 and the chassis plate 48 may be formed of a non-foamed polymer material, or alternatively, of a composite material comprising fibers such as carbon fiber. Suitable materials may include thermoplastic polyurethane (TPU), polyamides (e.g., PA6 or PA66), or other engineered polymers. Materials may include fiber fillers such as short-fiber or long-fiber glass, aramids, bamboo or carbon fibers, or materials may include similar continuous fabrics. Forming the midsole 36 with a relatively rigid material allows the midsole 36 to distribute the forces associated with the use of the article 10, while also preventing the structure from collapsing under the wearer's weight. In one construction, a foamed thermoplastic polymer material may be provided between the plates to prevent debris from being trapped in the intermediate recess / cavity 96 between the upper plate 80 and the lower plate 82. To facilitate access to the threaded fastener 60, the foamed thermoplastic polymer material may include through-holes extending between the inlet hole 120 in the lower plate 82 and the hole 64 in the upper plate 80.

[0048] Examples of upper constructions that can be used with this footwear article 10 are described in U.S. Patent Application Publication No. 2017 / 0311672 ('672). That application was filed July 20, 2017, and is incorporated herein by reference in its entirety. '672 generally describes a knitted upper having a multi-layered fabric construction similar to a sock or "bootie." As described, the upper may also have selectively reinforced or stiffening portions within the heel, outer sidewall, and / or inner sidewall. These stiffening portions may be provided, for example, by bonding thermoplastic stiffening panels between adjacent knitted layers, or by heat-treating regionally provided thermoplastic yarns within the knit to modify the material properties of the fabric.

[0049] The upper 12 can be constructed by pulling one or more layers of tubular knitted material onto a last and then closing the toe seam, for example, using RF or ultrasonic welding techniques. In one construction, the tubular knitted material may include more than one thermoplastic fiber. Similarly, in some embodiments, the upper may include other features typical of shoes, such as eyelet graphic decorations. Further details of the process for forming a strobel-less upper are explained in the aforementioned '672 application. While a strobel-less upper is preferred, in other embodiments, the upper 12 can be constructed in a standard manner by stitching the vamp and / or other shoe parts to a strobel.

[0050] In one embodiment, a business model suitable for commercializing this design may include offering at least one of the components sold separately from the remaining components. This can be achieved using vending machines or through traditional retail methods. This allows users to customize and / or repair their footwear items by replacing only a single component. In yet another embodiment, the global supply chain system can be significantly simplified by producing one or more shoe components locally at the point of sale. For example, the sole interlayer 36 can be produced using additive manufacturing processes, such as filament fabrication at the retail location or at a regional distribution / manufacturing center within a predefined local distance of the retail location. This model would not only simplify global supply chain logistics but also reduce the need for excess inventory production and storage by producing components on demand (i.e., directly to consumer demand or to retailer demand when inventory is low). It could also allow for a greater degree of user customization in terms of color, embellishment, fit, and / or cushioning / support properties.

[0051] The above features and advantages, as well as other features and advantages, of this teaching will become apparent when understood in conjunction with the accompanying drawings, based on this detailed description of the best mode for carrying out the teaching as defined in the appended claims and some of other embodiments.

[0052] The terms “a,” “an,” “the,” “at least one,” and “one or more” are used interchangeably to indicate that at least one of the items is present; unless the context clearly indicates otherwise, multiple such items may be present. All numerical values ​​of parameters (e.g., quantities or conditions) in this specification (including the appended claims) should be understood to be modified in all cases by the term “about,” regardless of whether “about” actually precedes the numerical value. “About” indicates that the stated numerical value allows for some slight imprecision (somewhat close to the accuracy of the value; approximately or moderately close to the value; almost). If the imprecision provided by “about” is not otherwise understood in this common sense in the art, then “about” as used herein at least indicates variations that may arise from common methods of measuring and using these parameters. Furthermore, the disclosure of a range includes all values ​​throughout the range and disclosure of further subdivided ranges. Thus, each value within the range and the endpoints of the range are disclosed herein entirely as separate embodiments. The terms “comprises,” “comprising,” “including,” and “have” are inclusive and therefore specify the existence of the stated items but do not exclude the existence of other items. As used in this specification, the term “or” includes any and all combinations of one or more of the listed items. When the terms first, second, third, etc., are used to distinguish items that are different from each other, these names are merely for convenience and do not limit those items.

[0053] Any directional references used in this article assume that the footwear is placed in an upright position on a flat, level ground, with the outsole in contact with the ground (i.e., as if worn by a user standing upright on a stable, flat surface).

[0054] The following clauses describe in detail additional embodiments and features of the technology currently described, and should be read with reference to the accompanying drawings where applicable. Each clause should be considered a non-limiting embodiment of the design currently described.

[0055] Clause 1. A footwear article comprising: an upper having an internal volume adapted to receive a wearer's foot; a sole structure fixed to the upper, the sole structure including: a chassis plate disposed within the upper; a sole interlayer removably fixed to the chassis plate via a plurality of fasteners extending between the chassis plate and the sole interlayer, the sole interlayer being positioned such that a portion of the upper extends between the chassis plate and the sole interlayer; and an outsole tread element removably attached to a ground-facing surface of the sole interlayer.

[0056] Clause 2. The footwear article according to Clause 1, wherein the plurality of fasteners comprises a plurality of threaded fasteners that extend between the sole interlayer and the chassis plate and removably secure the sole interlayer and the chassis plate.

[0057] Clause 3. The footwear article according to Clause 1, wherein: the chassis plate includes a plurality of threaded anchors; the sole interlayer includes a plurality of holes, each hole corresponding to a different threaded anchor among the plurality of threaded anchors; and wherein the plurality of fasteners includes a plurality of bolts, each bolt extending through a corresponding hole among the plurality of holes and threadedly engaging with a different threaded anchor among the plurality of threaded anchors to secure the sole interlayer to the chassis plate.

[0058] Clause 4. The footwear article according to Clause 3, wherein the sole interlayer includes a mechanical cushioning structure having an upper plate connected to a lower plate, the upper plate including the plurality of holes through which the plurality of threaded fasteners extend, the lower plate including a front portion, a rear portion, and a central portion disposed between the front portion and the rear portion; and wherein: the central portion of the lower plate is spaced apart from the upper plate; at least one of the front portion or the rear portion of the lower plate is fixed to the upper plate; and the outsole tread element is fixed to the lower plate.

[0059] Clause 5. The footwear article according to Clause 4, wherein the lower plate includes a plurality of holes, wherein the plurality of holes in the lower plate are aligned with the plurality of holes in the upper plate, such that each of the threaded fasteners can be fastened using an elongated tool passing through the corresponding hole in the plurality of holes in the lower plate.

[0060] Clause 6. The footwear article according to Clause 5, wherein the outsole tread element comprises a plurality of posts extending into a plurality of holes in the lower plate; and wherein the elongated tool is able to extend through a hole only when the posts of the outsole tread element are removed from holes in the plurality of holes in the lower plate.

[0061] Clause 7. The footwear article according to Clause 6, wherein each of the plurality of posts extends through the lower plate and further includes a retaining feature disposed on the side of the lower plate opposite the ground-facing surface.

[0062] Clause 8. The footwear article according to Clause 5, wherein the outsole tread element comprises a plurality of discrete outsole elements, and wherein each of the plurality of discrete outsole elements extends at least partially into a different hole among the plurality of holes in the lower plate.

[0063] Clause 9. The footwear article according to Clause 4, wherein the sole structure includes a forefoot region, a midfoot region, and a heel region, and wherein the lower plate is a first lower plate and disposed in the heel region; wherein the mechanical cushioning structure further includes a second lower plate disposed in the forefoot region, the second lower plate including a front portion, a rear portion, and a central portion disposed between the front portion and the rear portion; and wherein: the central portion of the second lower plate is spaced apart from the upper plate; and at least one of the front portion or the rear portion of the second lower plate is fixed to the upper plate.

[0064] Clause 10. The footwear article according to Clause 9, wherein the front portion of the first lower plate is connected to the upper plate at a first position, the rear portion of the second lower plate is connected to the upper plate at a second position, and wherein the first position is in front of the second position.

[0065] Clause 11. The footwear article according to Clause 9, wherein the front and rear portions of the first lower plate extend to contact and are secured to the upper plate; and wherein the front and rear portions of the second lower plate extend to contact and are secured to the upper plate.

[0066] Clause 12. The footwear article according to Clause 9, wherein the upper plate, the first lower plate, and the second lower plate are each formed of a common polymer, and wherein each of the first lower plate and the second lower plate extends integrally from the upper plate.

[0067] Clause 13. The footwear article according to Clause 9, wherein the first lower plate includes a first plurality of holes, wherein the first plurality of holes in the first lower plate are aligned with a first subgroup of the plurality of holes in the upper plate, such that each threaded fastener of the threaded fasteners extending through the first subgroup of the plurality of holes in the upper plate can be fastened using a tool passing through a corresponding hole in the first plurality of holes in the first lower plate; and wherein the second lower plate includes a second plurality of holes, wherein the second plurality of holes in the second lower plate are aligned with a second subgroup of the plurality of holes in the upper plate, such that each threaded fastener of the threaded fasteners extending through the second subgroup of the plurality of holes in the upper plate can be fastened using a tool passing through a corresponding hole in the second plurality of holes in the second lower plate.

[0068] Clause 14. The footwear article according to Clause 9, wherein the sole interlayer further comprises: an outer side and an inner side; a cavity extending from the outer side through the sole interlayer to the inner side; and wherein the cavity further extends between the central portion of the first lower plate and the upper plate.

[0069] Clause 15. The footwear article according to Clause 14, wherein the cavity is a first cavity; and wherein the sole interlayer further includes a second cavity extending from the outer side through the sole interlayer to the inner side, the second cavity being further located between the central portion of the second lower plate and the upper plate.

[0070] Clause 16. The footwear article according to Clause 9, wherein the sole interlayer includes a first rounded transition portion disposed at the rear end of the sole interlayer and a second rounded transition portion disposed at the front end of the sole interlayer; and wherein the first lower plate is fixed to the upper plate via the first rounded transition portion, and wherein the second lower plate is fixed to the upper plate via the second rounded transition portion.

[0071] Clause 17. The footwear article according to Clause 16, wherein the first lower plate, the first rounded transition portion and the upper plate are integrally formed, and wherein the second lower plate, the second rounded transition portion and the upper plate are also integrally formed.

[0072] Clause 18. Footwear articles according to Clause 1, wherein the upper is formed of a knitted material comprising a thermoplastic polymer, and the midsole is formed entirely of a thermoplastic polymer.

[0073] Clause 19. Footwear articles as described in Clause 1, wherein the sole interlayer is formed via an additive manufacturing process.

Claims

1. A type of footwear, comprising: The upper has an internal volume adapted to receive the wearer's foot; The sole structure is fixed to the upper, and the sole structure includes: A chassis plate, wherein the chassis plate is disposed within the shoe upper; A sole interlayer, removably secured to the chassis plate via a plurality of fasteners extending between the chassis plate and the sole interlayer, the sole interlayer being positioned such that a portion of the upper extends between the chassis plate and the sole interlayer; and An outsole tread element, said outsole tread element being removably attached to the ground-facing surface of the sole interlayer. in: The chassis plate includes multiple threaded anchors; The sole interlayer includes multiple holes, each hole corresponding to a different threaded anchor among the multiple threaded anchors; and The plurality of fasteners includes a plurality of bolts, each bolt extending through a corresponding hole in the plurality of holes and threadedly engaging with different threaded anchors in the plurality of threaded anchors to secure the sole interlayer to the chassis plate. The sole interlayer includes a mechanical cushioning structure having an upper plate connected to a lower plate, the upper plate including the plurality of holes through which the plurality of threaded fasteners extend; the lower plate includes a front portion, a rear portion, and a central portion disposed between the front portion and the rear portion; and in: The central portion of the lower plate is spaced apart from the upper plate; At least one of the front end portion or the rear end portion of the lower plate is fixed to the upper plate; and The outsole tread element is fixed to the lower plate.

2. The footwear article of claim 1, wherein the plurality of fasteners comprises a plurality of threaded fasteners extending between the sole interlayer and the chassis plate and removably securing the sole interlayer and the chassis plate.

3. The footwear article of claim 1, wherein the lower plate includes a plurality of holes, wherein the plurality of holes in the lower plate are aligned with the plurality of holes in the upper plate, such that each of the threaded fasteners can be fastened using an elongated tool passing through a corresponding hole in the plurality of holes in the lower plate.

4. The footwear article of claim 3, wherein the outsole tread element comprises a plurality of posts extending into the plurality of holes in the lower plate; and wherein the elongated tool is able to extend through the hole only when the posts of the outsole tread element are removed from the holes in the plurality of holes in the lower plate.

5. The footwear article of claim 4, wherein each of the plurality of posts extends through the lower plate, and further includes a retaining feature disposed on the side of the lower plate opposite the ground-facing surface.

6. The footwear article of claim 3, wherein the outsole tread element comprises a plurality of discrete outsole elements, and wherein each of the plurality of discrete outsole elements extends at least partially into a different hole among the plurality of holes in the lower plate.

7. The footwear article of claim 1, wherein the sole structure includes a forefoot region, a midfoot region, and a heel region, and wherein the lower plate is a first lower plate and is disposed in the heel region; The mechanical cushioning structure further includes a second lower plate disposed in the forefoot region of the shoe, the second lower plate including a front end portion, a rear end portion, and a central portion disposed between the front end portion and the rear end portion; and in: The central portion of the second lower plate is spaced apart from the upper plate; and At least one of the front end portion of the second lower plate or the rear end portion of the second lower plate is fixed to the upper plate.

8. The footwear article of claim 7, wherein the front portion of the first lower plate is connected to the upper plate at a first position, the rear portion of the second lower plate is connected to the upper plate at a second position, and wherein the first position is in front of the second position.

9. The footwear article of claim 7, wherein both the front portion of the first lower plate and the rear portion of the first lower plate extend to contact the upper plate and are both secured to the upper plate; and Both the front end portion and the rear end portion of the second lower plate extend to contact the upper plate and are fixed to the upper plate.

10. The footwear article of claim 7, wherein the upper plate, the first lower plate, and the second lower plate are each formed of a common polymer, and wherein each of the first lower plate and the second lower plate extends integrally from the upper plate.

11. The footwear article of claim 7, wherein the first lower plate includes a first plurality of holes, wherein the first plurality of holes in the first lower plate are aligned with a first subgroup of the plurality of holes in the upper plate, such that each threaded fastener of the threaded fasteners extending through the first subgroup of the plurality of holes in the upper plate can be fastened using a tool passing through a corresponding hole in the first plurality of holes in the first lower plate; and The second lower plate includes a second plurality of holes, wherein the second plurality of holes in the second lower plate are aligned with a second subgroup of the plurality of holes in the upper plate, such that each threaded fastener of the threaded fasteners extending through the second subgroup of the plurality of holes in the upper plate can be fastened using a tool passing through a corresponding hole in the second plurality of holes in the second lower plate.

12. The footwear article of claim 7, wherein the sole interlayer further comprises: Outer and inner surfaces; A cavity extending from the outer side through the sole interlayer to the inner side; and The cavity also extends between the central portion of the first lower plate and the upper plate.

13. The footwear article of claim 12, wherein the cavity is a first cavity; and The sole interlayer further includes a second cavity extending from the outer side through the sole interlayer to the inner side, and the second cavity is also located between the central portion of the second lower plate and the upper plate.

14. The footwear article of claim 7, wherein the sole interlayer includes a first rounded transition portion disposed at the rear end of the sole interlayer and a second rounded transition portion disposed at the front end of the sole interlayer; and The first lower plate is fixed to the upper plate via the first rounded transition portion, and the second lower plate is fixed to the upper plate via the second rounded transition portion.

15. The footwear article of claim 14, wherein the first lower plate, the first rounded transition portion, and the upper plate are integrally formed, and wherein the second lower plate, the second rounded transition portion, and the upper plate are all integrally formed.

16. The footwear article of claim 1, wherein the upper is formed of a knitted material comprising a thermoplastic polymer, and the sole interlayer is formed entirely of a thermoplastic polymer.

17. The footwear article of claim 1, wherein the sole interlayer is formed by an additive manufacturing process.

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