Hollow midsole with diagonal geometry

Abstract

A sole for an article of footwear includes a hollow midsole defining a top surface, a bottom surface, and a peripheral surface extending from the top surface to the bottom surface. The hollow midsole defines a hole extending obliquely from the top surface of the hollow midsole to the bottom surface of the hollow midsole.

Description

TECHNICAL FIELD

[0001] Embodiments described herein relate generally to footwear soles and articles of footwear; and more particularly, to footwear soles and articles of footwear having a cored midsole. BACKGROUND

[0002] Articles of footwear are used to enhance the walking and / or running experience of a wearer. For example, a midsole can provide cushioning, support, and stability. A midsole can also improve various aspects of the gait cycle. Improvements to footwear soles and articles of footwear that contribute to these and other features are desirable. SUMMARY

[0003] Disclosed are footwear soles and articles of footwear having a cored midsole. In some embodiments, a sole for an article of footwear includes a cored midsole defining a top surface, a bottom surface, and a peripheral surface extending from the top surface to the bottom surface. In some embodiments, the cored midsole defines a hole extending obliquely from the top surface of the cored midsole to the bottom surface of the cored midsole.

[0004] In some embodiments, the hole defined by the cored midsole extends at an angle between 55 degrees and 81 degrees relative to the bottom surface of the cored midsole.

[0005] In some embodiments, the sole includes a forefoot region, a midfoot region, and a heel region. In some embodiments, the hole is disposed in the forefoot region, the midfoot region, and the heel region. In some embodiments, an average size of the hole in the forefoot region is different than an average size of the hole in the heel region.

[0006] In some embodiments, a height of the cored midsole increases from the forefoot region to the midfoot region and decreases from the midfoot region to the heel region.

[0007] In some embodiments, the sole includes a non-elastic fabric disposed at the bottom surface of the cored midsole.

[0008] In some embodiments, the sole includes a recess disposed in the bottom surface of the cored midsole. In some embodiments, the recess extends from the peripheral surface of the cored midsole to one of the holes.

[0009] In some embodiments, the peripheral surface of the cored midsole includes a protrusion extending obliquely from the top surface of the cored midsole to the bottom surface of the cored midsole.

[0010] In some embodiments, the protrusion is disposed in the heel region and the midfoot region of the sole. In some embodiments, there is no protrusion in the forefoot region of the sole. In some embodiments, the protrusion maintains a consistent wall thickness between the peripheral surface and an adjacent hole.

[0011] In some embodiments, the article of footwear includes an upper and a hollow midsole coupled to the upper. In some embodiments, the hollow midsole includes a plurality of walls that define diagonal holes extending from a top surface to a bottom surface of the hollow midsole. In some embodiments, a surface area of the walls at the bottom surface of the hollow midsole is less than a combined area of the holes at the bottom surface of the hollow midsole.

[0012] In some embodiments, the holes defined by the plurality of walls of the hollow midsole extend diagonally toward the rearfoot region as they extend from the top surface to the bottom surface of the hollow midsole.

[0013] In some embodiments, the holes defined by the plurality of walls of the hollow midsole are arranged in an alternating pattern such that a center of one of the holes is not aligned with a center of an adjacent hole in a lateral direction.

[0014] In some embodiments, the article of footwear includes an outsole coupled to the bottom surface of the hollow midsole.

[0015] In some embodiments, the outsole of the article of footwear includes a plurality of components.

[0016] In some embodiments, the outsole of the article of footwear does not cover the holes.

[0017] In some embodiments, an average size of the holes disposed in the forefoot region of the hollow midsole is different than an average size of the holes disposed in the rearfoot region of the hollow midsole.

[0018] In some embodiments, the article of footwear includes a reinforcing member coupled to the bottom surface of the midsole and disposed in the forefoot region of the hollow midsole.

[0019] In some embodiments, the reinforcing member of the article of footwear includes a non-elastic fabric.

[0020] In some embodiments, the plurality of walls of the hollow midsole includes a perimeter wall. In some embodiments, the hollow midsole includes a recess disposed in the perimeter wall at the bottom surface of the midsole. In some embodiments, the recess extends from the perimeter surface of the hollow midsole to one of the holes.

[0021] In some embodiments, the walls include a perimeter wall. In some embodiments, the perimeter wall includes a protrusion extending diagonally from the top surface of the hollow midsole to the bottom surface of the hollow midsole. In some embodiments, the protrusion is disposed in the rearfoot region and the midfoot region of the hollow midsole. In some embodiments, there is no protrusion in the forefoot region of the hollow midsole. BRIEF DESCRIPTION OF DRAWINGS

[0022] The accompanying drawings, which are incorporated herein and form a part of the specification, illustrate the present disclosure and, together with the description, further serve to explain the principles of the disclosure and to enable a person skilled in the pertinent art to make and use the disclosure.

[0023] Figure 1 A perspective view of an article of footwear is shown in accordance with some embodiments.

[0024] Figure 2 A top perspective view of a sole for an article of footwear is shown in accordance with some embodiments.

[0025] Figure 3 A bottom perspective view of a sole for an article of footwear is shown in accordance with some embodiments.

[0026] Figure 4 A perspective view of a sole for an article of footwear is shown in accordance with some embodiments.

[0027] Figure 5 A side view of an article of footwear is shown in accordance with some embodiments.

[0028] Figure 6 A perspective view of Figure 3 A cross-sectional view along line 6-6 of a sole for an article of footwear is shown in accordance with some embodiments.

[0029] Figure 7 A bottom perspective view of a sole for an article of footwear is shown in accordance with some embodiments.

[0030] Figure 8 A perspective view of a sole for an article of footwear is shown in accordance with some embodiments.

[0031] Figure 9 A perspective view of a sole for an article of footwear is shown in accordance with some embodiments.

[0032] Figure 10 A perspective view of a sole for an article of footwear is shown in accordance with some embodiments.

[0033] Figure 11 A top view of a sole for an article of footwear is shown in accordance with some embodiments.

[0034] Figure 12 A perspective view of a sole for an article of footwear is shown in accordance with some embodiments.

[0035] Figure 13 A top view of a sole for an article of footwear is shown in accordance with some embodiments.

[0036] Figure 14 A side view of an article of footwear is shown in accordance with some embodiments.

[0037] Figure 15 A bottom perspective view of a sole for an article of footwear is shown in accordance with some embodiments.

[0038] Figure 16A bottom view of a sole for an article of footwear is shown in accordance with some embodiments.

[0039] Figure 17 A bottom view of a sole for an article of footwear is shown in accordance with some embodiments.

[0040] Figure 18 A side view of a sole for an article of footwear is shown in accordance with some embodiments.

[0041] Figure 19 A top view of a sole for an article of footwear is shown in accordance with some embodiments.

[0042] Figure 20 A side view of a sole for an article of footwear is shown in accordance with some embodiments.

[0043] Figure 21 A perspective view of a mold for manufacturing a midsole is shown in accordance with some embodiments.

[0044] Figure 22 A perspective view of a cooling jig used in a manufacturing process is shown in accordance with some embodiments.

[0045] Figure 23 A side view of an article of footwear is shown in accordance with some embodiments, showing the lateral side of the article of footwear.

[0046] Figure 24 A side view of an article of footwear is shown in accordance with some embodiments, showing the medial side of the article of footwear.

[0047] Figure 25 A bottom view of a sole for an article of footwear is shown in accordance with some embodiments. DETAILED DESCRIPTION

[0048] Reference will now be made in detail to representative embodiments, including those illustrated in the accompanying drawings. References to some embodiments suggest that the described embodiments can include a particular feature, structure, or characteristic, but every embodiment can not necessarily include the particular feature, structure, or characteristic. Furthermore, when a particular feature, structure, or characteristic is described in connection with some embodiments, it is submitted that

[0049] The following examples are illustrative, but not limiting. Additional suitable modifications and adaptations of various conditions and parameters will be apparent to those skilled in the art or of ordinary skill in the art with the benefit of this disclosure. Such modifications and adaptations of the various conditions and parameters are intended to come within the spirit and scope of the disclosure.

[0050] Footwear articles are used to enhance the walking and / or running experience of a wearer. For example, a midsole can provide cushioning, support, and stability. The midsole can also improve aspects of the gait cycle. Adding more structure and support to the midsole can increase the weight of the footwear article. To offset this increased weight, a hollow midsole defining a hole therethrough reduces the weight of the shoe, but can also reduce stability. The geometry of the hollow midsole can be configured to provide the desired support and stability without adding weight. A hollow midsole that provides sufficient cushioning, support, and stability is described below.

[0051] The disclosed embodiments provide footwear articles having a hollow midsole with a diagonal geometry. The diagonal geometry helps achieve an optimal level of cushioning and maximum comfort by adjusting the midsole's ability to collapse during athletic activities. The midsole can also be configured in a way that facilitates rocking (e.g., from back to front, from side to side, or both). For example, the forefoot and rearfoot regions can be curved at the bottom of the sole, and / or the height of the sole can be greatest at the midfoot region and decrease toward the forefoot and rearfoot regions. Thus, the footwear article can facilitate a faster transition to the forefoot, thereby enhancing the propulsion phase of the wearer's movement.

[0052] In some embodiments, the hollow midsole defines a hole disposed within the midsole. For example, the hollow midsole can include a hole from the rearfoot region to the forefoot region. The hole can extend the height of the midsole (from the bottom surface of the midsole to the top surface of the midsole). Increasing the aggregate area of the hole at the bottom surface (e.g., by adding more holes or making the holes larger) reduces the total surface area of the bottom surface of the midsole that is engaged. The ratio between the surface area engaged and the hole size affects the stiffness, flex, and weight of the shoe. This ratio can vary across the sole such that it is different in various regions of the sole, thereby providing specific stiffness and flex for each region.

[0053] In some embodiments, footwear article 10, e.g., as shown in Figure 1 The footwear article 10 includes a footwear upper 12 and a sole 14. Any suitable upper can be used as the footwear upper 12. In some embodiments, the upper can be made of a woven single or multiple layer portion, or other suitable material. In some embodiments, the upper 12 can be a knit material. The upper can include a tongue and laces, or the upper can be tongueless. Other fastening systems can also be used in addition to laces. Although these examples are given, any other upper can be used.

[0054] The sole 14 can include an outsole 16 and a midsole 18. In some embodiments, the upper 12 is coupled to the midsole 18. For example, the upper 12 can be stitched, glued, or adhered to the midsole 18. In some embodiments, the midsole 18 is coupled to the outsole 16. For example, the midsole 18 can be directly glued to the outsole 16.

[0055] The midsole 18 provides support and cushioning to the footwear article 10. In some embodiments, the midsole 18 is made of a foam material. For example, the midsole 18 may be made of expanded thermoplastic polyurethane granular foam (e-TPU). In some embodiments, ethylene-vinyl acetate (EVA) foam is used for the midsole 18. Other foam or non-foam materials may also be used for the midsole 18. In some embodiments, the midsole 18 may be made of a combination of different materials (e.g., e-TPU granular foam and EVA foam).

[0056] like Figure 2 As shown, the midsole 18 defines a top surface 32, a bottom surface 34, and a peripheral surface 36. In some embodiments, the top surface 32 of the midsole 18 is attached to the upper 12, and the bottom surface 34 is attached to the outsole 16. In some embodiments, for example, as... Figure 2 As shown in the heel portion of the midsole 18, the peripheral surface 36 can be raised above the inner portion of the top surface 32. In some embodiments, this configuration allows the midsole 18 to accommodate the upper 12 within the concave top surface 32, such that the top of the peripheral surface 36 can overlap with the upper 12.

[0057] The midsole 18 may be a hollow midsole 18 defining a plurality of holes 24. In some embodiments, the hollow midsole 18 includes holes 24 disposed throughout the midsole 18. For example, the hollow midsole 18 may include more than 10, more than 20, or more than 30 holes. In some embodiments, the hollow midsole may include about 15-30 holes. In some embodiments, the hollow midsole 18 may include 24 holes. The holes extend from the top surface 32 to the bottom surface 34. Figure 3 As shown, the upper 12 (or some other component disposed above the midsole 18, such as the reinforcing member 19 discussed below) is visible through the hole 24. In some embodiments, the hole extends obliquely along the entire height of the midsole 18. In some embodiments, the hole 24 extends obliquely toward the rearfoot region as it extends from the top surface 32 of the hollow midsole 18 to the bottom surface 34. In some embodiments, the hole 24 is positioned at an angle θ relative to the bottom surface 34 of the midsole, the angle θ ranging from 55 to 81 degrees (see [link to relevant documentation]). Figure 6 In some embodiments, the angle θ ranges from 55 to 70 degrees. In some embodiments, the angle θ ranges from 70 to 81 degrees. In some embodiments, the angle θ is 72 degrees. In some embodiments, the angle θ is 81 degrees. This angle helps to prevent the collapse of the hollow insole during impact and provides the user with increased cushioning and comfort during exercise.

[0058] In some embodiments, such as Figure 2As shown, the midsole 18 includes a plurality of walls 50 that define diagonal holes 24 extending from the top surface 32 to the bottom surface 34 of the hollow midsole 18. The walls 50 can use a thickness that provides a desired stiffness, flex, and weight of the midsole. In some embodiments, the walls 50 have a thickness between 5 mm and 10 mm. Other thicknesses can also be used. In some embodiments, the walls 50 can have different thicknesses in different regions of the midsole 18. Further, the walls 50 can have different thicknesses at different locations along the vertical direction of the midsole 18. In some embodiments, the walls 50 can span the height of the midsole 18. The walls 50 can be configured in various forms. In some embodiments, the walls can be configured in a zigzag shape such that triangular holes 24 are defined between intersecting walls 50. In some embodiments, the walls 50 can be configured in an arc shape such that circular holes are defined between intersecting walls 50. In some embodiments, the walls 50 can be configured in a grid shape such that square or polygonal holes are defined between intersecting walls 50. The walls 50 can include a perimeter wall 50 that creates the closed geometry of the midsole 18 and forms the perimeter surface 36. In some embodiments, the perimeter wall 50 can extend past the upper 12 and overlap with the upper 12.

[0059] The bottom surface of the walls 50 forms a surface engagement area 60 of the midsole 18. In some embodiments, the surface area of the surface engagement area 60 is less than the combined area of the plurality of holes 24 at the bottom surface 34 of the midsole 18. Thus, the midsole 18 can be a highly hollow midsole. This configuration reduces the overall weight of the midsole 18. While a smaller ratio between the surface engagement area and the hole area (i.e., the surface engagement ratio) generally results in a weaker structure, i.e., a weaker or more flexible shoe, the configuration of the walls 50 and the shape and diagonal geometry of the holes 24 compensate for the reduced surface engagement area 60 and thus result in a lightweight shoe with sufficient stiffness. Further, the holes 24 allow for increased vertical compression during activity while maintaining sufficient stiffness and reduced weight. Further, the holes 24 (and walls 50) provide horizontal displacement (e.g., the top surface 32 moves horizontally forward relative to the bottom surface 34) during compression. Thus, the size and corresponding angle of the holes can provide controlled collapse and assist in forward movement.

[0060] As Figure 4As shown, the midsole 18 may include three regions: a forefoot region 26, a midfoot region 28, and a rearfoot region 30. In some embodiments, a plurality of holes 24 are provided in each region of the midsole 18. In some embodiments, the holes 24 are provided throughout the midsole 18. For example, the holes 24 may be provided from the peripheral wall 50 at the medial edge 52 of the midsole 18 to the peripheral wall 50 at the lateral edge 54 of the midsole 18. Similarly, the holes 24 may be provided from the peripheral wall 50 at the heel of the midsole 18 to the peripheral wall 50 at the toe of the midsole 18. In some embodiments, the holes 24 are provided only in some regions of the midsole 18 (e.g., only in the forefoot region 26, or only in the forefoot region 26 and the midfoot region 28).

[0061] Various hole arrangements can be used. In some embodiments, for example, such as Figure 3 As shown, holes 24 can extend from the hind foot region 30 to the forefoot region 26 in approximately two columns c1 and c2, wherein the holes 24 within columns c1 and c2 are offset from each other in the lateral and longitudinal directions, such that the holes from c1 are not collinear with the holes from c2. Therefore, the holes 24 can be arranged in an alternating pattern, such that the center of one of the holes 24 is not aligned with the center of the adjacent hole 24 in either the lateral or longitudinal direction. In some embodiments, the forefoot region 26 may have additional columns of holes 24 to accommodate a larger width of the forefoot region 26. For example, in some embodiments, such as Figures 15-17 As shown, the holes 24 can be arranged in two, three, or four columns. In some embodiments, the hole size is not affected by the number of columns. In some embodiments, the hole size depends on the number of columns. For example, a larger number of columns can result in a smaller overall hole size. This can be achieved by comparison. Figure 15 Hole size and Figure 17 The larger hole size of hole 24 is shown in the figure. Figure 17 There are fewer columns. In some embodiments, a hole 24 may extend across the entire width of the footwear 10. In some embodiments, the holes may be arranged in a grid, wherein a plurality of holes 24 are collinear across the width of the midsole 18.

[0062] The size and shape of the hole 24 can help control the stiffness of the bottom in this area. In some embodiments, the hole 24 can be shaped to have three or four sides, such as a triangle, a square, or a rhombus, as... Figure 13 and 15 As shown in Figure 17. In some embodiments, the hole 24 may be shaped such that the hole has more than four sides, such as a pentagon, hexagon, octagon or some other shape.

[0063] The size and shape of the holes 24 can vary depending on which area they are set in. For example, as Figure 3As shown, in forefoot region 26, three to four holes 24 can fit side by side, while in midfoot region 28 and hindfoot region 30, only one to two holes 24 can fit side by side. In some embodiments, the hole size ranges between 32 mm 2 in area to 1200 mm 2 in area. Other hole sizes can also be used. In some embodiments, the smallest hole 24 has an area of 32 mm 2 . For example, the smallest hole 24 can be a diamond shape with a width of 10 mm and a height of 4 mm for an area of 32 mm 2 . In some embodiments, the holes 24 can be about 55 mm wide x 25 mm for an area of about 800 mm 2 . In some embodiments, the holes 24 can be about 80 mm wide x 40 mm for an area of greater than 1200 mm 2 .

[0064] Smaller hole sizes can provide greater stiffness due to increased resistance to collapse under forces of athletic activity. Conversely, larger hole sizes will provide more flexibility due to lack of resistance to collapse under forces of athletic activity. In some embodiments, the size of the holes 24 in the hindfoot region 30 and the midfoot region 28 are larger than the size of the holes 24 in the forefoot region 26. In some embodiments, the average size of the holes 24 disposed in the forefoot region 26 of the voided midsole 18 is different than the average size of the holes 24 disposed in the hindfoot region 30 of the voided midsole 18. In some embodiments, the size of the holes 24 within each region can also vary.

[0065] In some embodiments, the size of the holes 24 can vary from the medial side 120 to the lateral side 130 of the voided midsole 18, for example, as Figure 11 shown. The size of the holes can vary in a gradient from the medial side 120 to the lateral side 130. For example, in some embodiments, the holes on the medial side 120 can be larger than the holes 24 on the lateral side 130, and the size of the holes 24 can decrease as their location gets closer to the lateral side edge 54. This provides more cushioning on the medial side 120 and more stiffness and support on the lateral side 130. The smaller holes 24 on the lateral side 130 enable the banking effect of the midsole 18 to reduce underpronation due to the stiffer lateral side function. The variation in hole size can be customized for a particular wearer.

[0066] In some embodiments, the lateral gradient in hole size is only present in some regions of the sole 18. For example, the size of the holes 24 in the rearfoot region can be the same on the medial side 120 and the lateral side 130, while the hole size in the forefoot region 26 is larger on the medial side 120 than on the lateral side 130. This configuration can provide forefoot tilt and horizontal heel displacement (e.g., controlled collapse during forward motion).

[0067] In some embodiments, the shape of the holes 24 can contribute to the stiffness of the article of footwear 10. Various shapes can be used. For example, in some embodiments, the shape of the holes 24 can be circular, oval, square, diamond, arcuate, or some other polygonal or non-polygonal shape. In some embodiments, the shape of the holes 24 can be triangular. In some embodiments, for example, as shown in FIG. 2, the orientation of the triangular holes 24 is such that the apex 25 (i.e., the point of the triangle) is closest to the toe 90 of the article of footwear 10. This configuration contributes to the collapse of the hollow midsole during athletic activities. Figure 3

[0068] In some embodiments, all of the holes 24 have the same shape. In some embodiments, the holes 24 can have different shapes in different regions 26, 28, 30. In some embodiments, the shape of the holes 24 remains the same throughout the height of the midsole 18 (as shown in FIG. 2). In some embodiments, the holes 24 have a uniform shape along their height. In some embodiments, the shape of the holes 24 varies along the height of the midsole 18. In some embodiments, for example, as shown in FIG. 3, the holes 24 have a shape with a lateral length greater than a longitudinal length (i.e., the base of the triangle is greater than the height). Depending on the desired stiffness, a particular hole size and shape can be selected. These variations in hole size and shape change the configuration of the holes and, thus, the desired stiffness. Figure 6 Figure 3

[0069] In some embodiments, the holes of the hollow midsole (e.g., the holes 24 of the midsole 18) are hollow portions of the midsole. For example, the holes can be hollow cylinders extending from a bottom surface to a top surface of the midsole structure. In some embodiments, the holes are channels through the midsole (e.g., from a bottom surface to a top surface). The holes can also be openings or cavities in or through the midsole structure. As discussed above, the holes can be defined by a plurality of walls (e.g., the walls 50). In some embodiments, the walls form tubular elements that surround the holes. Thus, the hollow midsole can include tubular elements that form a plurality of holes. In some embodiments, the walls form partitions between adjacent holes. In some embodiments, the walls form boundary elements that surround the holes to form the sides of the holes.

[0070] ​​​In addition to helping the stiffness of the midsole 18, the holes 24 also reduce the overall weight of the article of footwear 10. This configuration results in a lightweight yet resilient midsole 18, which promotes an optimal toe-off experience during athletic activities.

[0071] To further promote an optimal toe-off experience, the midsole 18 can also include an arcuate rocker shape, such that the article of footwear 10 provides a softer ground contact and smoother ride experience for the user during athletic activities. As shown in Figure 4 the longitudinal direction 100. In some embodiments, the rocking in the lateral direction 110 is produced by the forefoot region 26 and the hindfoot region 30 having a curved shape. In some embodiments, the forefoot region 26 and the hindfoot region 30 have a convex shape. In some embodiments, the rocking in the lateral direction 110 is produced by the forefoot region 26 and the hindfoot region 30 having a curved shape. In some embodiments, the forefoot region 26 and the hindfoot region 30 have a convex shape. In some embodiments, the height of the midsole 18 varies at different regions of the foot. For example, as shown in Figure 5 the midsole 18 is higher in the midfoot region 28 than in the forefoot region 26 and the hindfoot region 30 (e.g., h2 in the midfoot region 28 is greater than hi in the forefoot region 26 and h3 in the hindfoot region 30). In some embodiments, the height of the midsole 18 continuously decreases in the forefoot region 26 near the front of the midsole 18. In some embodiments, the height of the midsole 18 continuously decreases in the hindfoot region 30 near the back of the midsole 18. This configuration helps the rocking function, which promotes a faster transition to the forefoot, thus enhancing the propulsion phase of the wearer’s movement. The arcuate rocker shape naturally promotes displacement from an unstable curve apex to a more neutral (resting) position, thus helping the wearer reach the toe-off phase.

[0072] In some embodiments, as shown in Figure 5 the peripheral surface 36 can include protrusions 40 extending outwardly from the peripheral surface 36. In some embodiments, the shape of the protrusions 40 can vary. In some embodiments, the protrusions 40 can be circular, angular, pointed, arcuate, or a combination thereof. In some embodiments, as shown in Figure 5In the midsole, the protrusion 40 has a pointed shape. The protrusion 40 increases the total surface area of ​​the midsole and helps to create a wider support base for the footwear 10, making the footwear more stable. The protrusion may extend 10 mm to 20 mm in the lateral direction away from the remainder of the peripheral surface 36. In some embodiments, the protrusion 40 may extend obliquely from the top surface 32 of the hollow midsole 18 to the bottom surface 34 of the hollow midsole 18. In some embodiments, the peripheral surface 36 may include the same number of protrusions 40 on the medial and lateral sides of the midsole 18. In some embodiments, the footwear 10 may have a different number of protrusions 40 on the medial side of the foot than on the lateral side. In some embodiments, the footwear 10 may include five protrusions 40 on the medial side of the foot and six protrusions 40 on the lateral side of the foot. The protrusions 40 may be provided in any or all areas of the midsole 18. For example, in some embodiments, the protrusions 40 may be provided in the midfoot area 28 and the rearfoot area 30.

[0073] In some embodiments, the protrusion 40 extends obliquely along the height of the midsole 18. For example... Figure 5 As shown, angle θ' represents the angle at which the protrusion 40 extends over the entire height of the midsole 18. Angle θ' is measured relative to the bottom surface 34 of the midsole 18. Angle θ' can range from approximately 55 to 81 degrees. In some embodiments, angle θ' ranges from 55 to 70 degrees. In some embodiments, angle θ' ranges from 70 to 81 degrees. In some embodiments, angle θ' is 72 degrees. In some embodiments, angle θ' is 81 degrees. As discussed above, in some embodiments, the midsole 18 may be becored at an angle relative to the bottom surface 34 of the midsole 18 (i.e., beveled holes 24). In some embodiments, the angle of the protrusion 40 and the angle of the hollow midsole 18 (holes 24) are the same. In some embodiments, the angle of the protrusion 40 and the angle of the hollow midsole 18 (holes 24) are different. This range of angles and beveled geometry allows the midsole 18 to collapse during impact, thereby providing increased cushioning and comfort for the user. The slanted positioning of the 40 protrusions, 18 midsole, and 24 triangular holes provides optimal toe-off experience during sports activities.

[0074] The protrusion 40 provides an articulated structure on the sidewall (i.e., peripheral surface 36), which can enhance the collapse effect of the bore 24 and allow shear movement during the collapse of the midsole 18. In some embodiments, the articulated structure closely conforms to the shape (e.g., angle) of the bore 24. In some embodiments, the articulated structure (e.g., protrusion 40) conforms to the shape of the bore 24 and thus provides a uniform thickness for the wall 50 at the peripheral surface 36. In some embodiments, such as... Figure 12As shown, the protrusions 40 are only located in the hindfoot region 30 and the midfoot region 28. This allows the hindfoot region 30 and the midfoot region 28 to shear and provide a collapsing motion when these portions of the article of footwear contact the ground. Conversely, the forefoot region 26, which lacks protrusions 40, provides a smoother sidewall (i.e., perimeter surface 36). This smoother sidewall is more rigid than the articulating sidewall and reduces the articulation of the void 24, which can allow for a more rigid toe-off when the forefoot region 26 contacts the ground. In some embodiments, the protrusions 40 can extend from the hindfoot 30 to the forefoot 26. This configuration would allow the article of footwear 10 to shear during motion and provide the greatest degree of comfort during motion.

[0075] In some embodiments, for example as Figure 12 shown, the protrusions 40 include a horizontal void 23 that extends laterally toward the center of the midsole 18. In some embodiments, the horizontal void 23 is disposed within the hindfoot region 30. In some embodiments, the horizontal void 23 is disposed within the hindfoot region 30, the midfoot region 28, and the forefoot region 26. In some embodiments, the void 23 is disposed on any wall 50 that forms the perimeter surface 36. In some embodiments, there are 2-8 horizontal voids 23 disposed in the midsole 18. In some embodiments, as Figure 23 and Figure 24 shown, there are 4 horizontal voids 23, preferably these 4 horizontal voids 23 are disposed in the midfoot region 28. These lateral voids 23 allow for a unique visual effect. Additionally, the orientation of the horizontal voids 23 that extend laterally through the midsole can allow for additional cushioning in the respective region in which the horizontal void 23 is located. For example, there can be additional cushioning due to the increased ratio of cored portions that include the horizontal voids 23 as compared to solid portions. In some embodiments, the horizontal voids 23 aid in midsole ventilation.

[0076] In some embodiments, the sole 14 can include an outsole 16. As Figure 7 shown, the outsole 16 is disposed on the bottom surface 34 of the midsole 18. In some embodiments, the outsole 16 extends across the entire bottom surface of the midsole 18. In some embodiments, the outsole 16 extends across the bottom surface of the midsole 18 such that each wall 50 is covered by the outsole 16. In some embodiments, the outsole 16 can only cover portions of the walls 50. For example, as Figure 7 shown, the outsole 16 can cover all of the walls 50 disposed in the forefoot region 26, but only cover portions of the walls 50 in other regions of the midsole 18. Thus, the outsole 16 can be disposed in some or all regions of the midsole 18.

[0077] In some embodiments, the outsole 16 is composed of one piece (as Figure 3 shown). In some embodiments, the outsole 16 is composed of multiple pieces, for example, strips 17. As Figure 7As shown, the outsole 16 may include a plurality of strips 17 that only cover a portion of the wall 50. The strips 17 do not obstruct the holes 24 disposed within the midsole 18. Therefore, the outsole 16 does not cover the holes 24. Instead, the strips 17 are attached to the bottom surface 34 of the wall 50 of the midsole 18. Figure 25 As shown, the outsole 16 may include multiple components (e.g., three components) covering almost all portions of the wall 50. These components do not obstruct the hole 24 disposed within the midsole 18. Therefore, the outsole 16 does not cover the hole 24. And these components are attached to the bottom surface 34 of the wall 50 of the midsole 18.

[0078] In some embodiments, the outsole 16 may be selectively configured to cover only the portions of the midsole 18 that will experience the greatest force during athletic activity, such as the forefoot region 26 and the rearfoot region 30. Within each region, the outsole 16 may be further selectively configured to cover the most frequently worn areas within each region for a particular type of runner. For runners who overpronate during running, the outsole 16 may be positioned on the medial side of the area. For runners who underpronate during running, the outsole 16 may be positioned on the lateral side of the area within each region. And for runners with a normal running gait, the outsole 16 may be positioned within the center of the area. In some embodiments, the sole 14 does not include the outsole 16.

[0079] The sole 14 may also include one or more reinforcing members 19. The reinforcing members 19 may be of various forms, such as plates, bars, or fabric. The reinforcing members 19 may be located in various positions (e.g., above the midsole, inside the midsole, below the midsole). In some embodiments, the reinforcing members 19 may be disposed in any or all areas of the midsole (e.g., forefoot, midfoot, rearfoot). The reinforcing members 19 provide additional stiffness to the footwear article 10. Exemplary constructions of the reinforcing members 19 are provided below.

[0080] In some embodiments, such as Figure 8 As shown, the reinforcing member 19 may be disposed within the forefoot region 26 and extend into the midfoot region 28. In some embodiments, the reinforcing member 19 is disposed in the center of the region and does not extend to the periphery 36. In some embodiments, the reinforcing member 19 at least partially covers some of the holes 24. In some embodiments, the reinforcing member 19 is a carbon plate 70.

[0081] In some embodiments, such as Figure 9As shown, the stiffening member 19 can be provided in some or all areas of the midsole 18. In some embodiments, the stiffening member 19 can be provided in the forefoot region 26. In some embodiments, the stiffening member 19 can extend to the perimeter surface 36 and cover the aperture 24. In some embodiments, the stiffening member 19 is a non-elastic fabric 80. The non-elastic fabric 80 can be a mesh fabric. The amount of additional stiffness provided to the stiffening member depends on the type of stiffening member 19 and the thickness of the stiffening member 19. A carbon plate stiffening member 70 can promote more stiffness in the forefoot, while a non-elastic fabric stiffening member 80 can modulate the bending stiffness.

[0082] In some embodiments, the sole 14 can include a stiffening member 19 provided on the top surface 32 of the midsole 18. In some embodiments, the stiffening member 19 can be provided in any or all areas of the midsole 18. For example, in Figure 7 some embodiments, the stiffening member 19 can be provided in the forefoot region 26. In some embodiments, the stiffening member 19 can be provided in the midfoot region 28 and / or the heel region 30. In some embodiments, the stiffening member 19 can be provided in the forefoot region 26 and the midfoot region 28. In some embodiments, the stiffening member 19 can be provided in the forefoot region 26 and the heel region 30. In some embodiments, the stiffening member 19 can be provided in the forefoot region 26, the midfoot region 28, and the heel region 30.

[0083] In some embodiments, as shown in FIG. 1, the sole 14 can include a stiffening member 19 provided on the top surface 32 of the midsole 18. In some embodiments, the stiffening member 19 can be provided in some or all areas of the midsole 18. In some embodiments, the stiffening member 19 can be provided in the forefoot region 26. In some embodiments, the stiffening member 19 can extend through the forefoot, midfoot, and heel regions of the midsole 18. The stiffening member 19 provides additional stiffness to the midsole 18, and its configuration on the top surface 32 of the midsole 18 helps to reduce any interference with the collapse of the aperture 24 during athletic activities. The stiffening member 19 can be a rigid plastic plate or a non-elastic fabric. Figure 18 In some embodiments, as shown in FIG. 2, the sole 14 can include more than one stiffening member 19 formed as a plate. For example, the sole 14 can include a plate 72 provided between the midsole 18 and the outsole 16 and a plate 71 provided between the midsole 18 and the upper 12. In some embodiments, the plates 71 and 72 only partially overlap. For example, the plate 71 extends from the forefoot region 26 to the heel region 30, and the plate 72 is provided only in the forefoot region 26. This location of the plate 72 can help to provide a more rigid toe-off. The plates 71 and 72 can be made of carbon (or injected carbon), nylon, carbon-infused nylon, thermoplastic polyurethane (TPU), or some other material.

[0084] Figure 13 In some embodiments, the shoe can have multiple rod-shaped stiffening members 19 (see FIGS. 3, 19 In some embodiments, the rod-shaped stiffening members 19 can be carbon, injected carbon, nylon, carbon-infused nylon, or TPU.

[0085] Figure 13 In some embodiments, for example, as shown in FIG. 4, the rod-shaped stiffening members 19 are embedded within the midsole 18. The embedded rod-shaped stiffening members 19 can extend from the heel region 30 to the forefoot region 26, or from the midfoot region 28 to the forefoot region 26. For example, in Figure 13 ​​In some embodiments, five rod-like reinforcing members 19 extend from the midfoot region 28 to the forefoot region 26. More or fewer rod-like reinforcing members 19 can be used. In some embodiments, the reinforcing members 19 are equally spaced apart from each other. In some embodiments, the reinforcing members 19 can be closer to each other in the midfoot region 28 and further apart from each other as they extend in the forefoot region 26. In some embodiments, as shown in FIG. 1, the rod-like reinforcing members 19 extend through the apertures 24 such that they are visible through the apertures 24. In some embodiments, the rod-like reinforcing members 19 can be visible through the horizontal apertures 23. Figure 13 In some embodiments, as shown in FIG. 1, the rod-like reinforcing members 19 extend through the apertures 24 such that they are visible through the apertures 24. In some embodiments, the rod-like reinforcing members 19 can be visible through the horizontal apertures 23.

[0086] In some embodiments, as shown in FIG. 1, the rod-like reinforcing members 19 extend through the apertures 24 such that they are visible through the apertures 24. In some embodiments, the rod-like reinforcing members 19 can be visible through the horizontal apertures 23. Figure 19 and 20 In some embodiments, as shown in FIG. 1, the rod-like reinforcing members 19 extend through the apertures 24 such that they are visible through the apertures 24. In some embodiments, the rod-like reinforcing members 19 can be visible through the horizontal apertures 23. Figure 20 In some embodiments, as shown in FIG. 1, the rod-like reinforcing members 19 extend through the apertures 24 such that they are visible through the apertures 24. In some embodiments, the rod-like reinforcing members 19 can be visible through the horizontal apertures 23.

[0087] In some embodiments, as shown in FIG. 1, the rod-like reinforcing members 19 extend through the apertures 24 such that they are visible through the apertures 24. In some embodiments, the rod-like reinforcing members 19 can be visible through the horizontal apertures 23.

[0088] In some embodiments, the rod-like reinforcing members 73 and 74 can be cylindrical, triangular, or square. In some embodiments, the rod-like reinforcing members 73 and 74 can have a width in a range of about 2 mm to 8 mm and a height in a range of about 2 mm to 9 mm. In some embodiments, the height and / or width can vary along the length of the rod. In some embodiments, the width or height of the rod-like reinforcing members decreases as they extend from the forefoot region 26 to the rearfoot region 30. For example, the rod-like reinforcing members 73 and 74 can have a height of 9 mm in the forefoot region 26 and decrease to 2 mm as the rod-like reinforcing members extend to the rearfoot region 30. In some embodiments, the width and height of the rod-like reinforcing members are uniform throughout their length. For example, the rod-like reinforcing members 73 and / or 74 can have a width of 4 mm.

[0089] In some embodiments, such as Figure 10 As shown, one or more grooves 20 may be provided on the bottom surface 34 of the midsole 18 and / or the outsole 16. In some embodiments, the groove 20 is provided in the peripheral wall 50 at the bottom surface of the midsole, wherein the groove extends from the peripheral surface of the hollow midsole to one of the holes. The groove 20 is a recess in the midsole (and / or outsole) that allows air to escape upon impact with a flat surface. The recess of the groove 20 forms a basin or notch that is not coplanar with the bottom surface 34 of the midsole 18. Without such a groove, the footwear 10 may cause squeaking or impact noise during sports activities. For example, without the groove, when the footwear 10 contacts the ground during sports activities, all bottom surfaces of the midsole 18 may contact the ground, and the midsole 18 will begin to collapse. As the midsole 18 collapses, the air trapped in the collapse hole 24 will be forced out of the midsole 18, but trapped between the bottom surface 34 of the midsole 18 and the ground. During sporting activities, this trapping and forced air out of the footwear 10 causes squeaking or impact noise.

[0090] To reduce impact noise and squeaking, the groove 20 is recessed into the wall 50 of the midsole 18, and this recess extends into the hole 24 or the peripheral surface 36. In some embodiments, the groove 20 does not contact the ground and forms a gap between the ground and the bottom of the midsole 18, allowing air to escape from within the hole 24 through the groove 20. The groove 20 can extend from the peripheral surface 36 of the hollow midsole 18 to one of the holes 24. Because air is no longer trapped and has an escape path, this construction reduces squeaking or impact noise that typically occurs during athletic activities. In some embodiments, the groove 20 may contact the ground. For example, the groove may contact the ground when the midsole 18 collapses as the wearer runs. Thus, in some cases, the groove 20 may allow air to escape during the initial contact between the shoe and the ground and when the midsole 18 collapses, but if the midsole 18 collapses beyond a certain point, the groove 20 or a portion of the groove 20 may contact the ground.

[0091] In some embodiments, such as Figure 10 As shown, the groove 20 can be located in the hindfoot region 30 of the midsole 18. Other configurations are also possible. For example, the groove 20 can be located in the forefoot region 26 or the midfoot region 28. In some embodiments, each hole 24 adjacent to the peripheral surface 36 has a groove connecting the hole 24 to the peripheral surface 36. The groove 20 can be 5 mm to 10 mm wide and about 2 mm to 5 mm deep.

[0092] In some embodiments, such as Figure 14As shown, the midsole is a layered structure. For example, in some embodiments, as described above, the midsole is composed of a top non-cored solid portion 140 and a bottom cored midsole 150 with holes 24 and jointed sidewalls or protrusions 40. In various embodiments, the ratio of the non-cored solid portion 140 to the cored portion 150 can vary. In some embodiments, the ratio of the non-cored solid portion 140 to the cored portion 150 is between 80:20 and 20:80. For example, in some embodiments, the ratio of the non-cored solid portion 140 to the cored portion 150 is 50:50. In some embodiments, the non-cored solid portion 140 and the cored portion 150 are made of the same material. In some embodiments, each layer of the layered midsole is made of a different material.

[0093] Various embodiments described herein provide an article of footwear with a lightweight and highly cored midsole. The configuration of the size and shape of the holes rigidifies the midsole at the forefoot, midfoot, and hindfoot regions where the holes are located. The convex shape and curvature of the hindfoot and forefoot regions also creates a geometry that facilitates rocking (i.e., from back to front). Thus, the article of footwear can facilitate a faster transition to the forefoot, thereby enhancing the propulsion phase of the wearer’s movement. In some embodiments, the midsole can be customized for a particular wearer. For example, a scan can be taken to measure a user’s foot size, and a midsole customized to the configuration of the scan can be created.

[0094] Various manufacturing processes can be used to manufacture the midsole 18 as described above. In some embodiments, the midsole can be manufactured through ethylene-vinyl acetate (EVA) injection molding. In EVA injection molding, a mold can be used on a smaller scale than other molding techniques. For example, in some embodiments, the EVA injection mold can be about 40% of the size of the finished midsole. Figure 21 An example mold 200 is shown. In some embodiments, EVA material is added to the mold 200 through an injection path 205. The mold 200 can include one or more injection paths 205. Although smaller than the finished product, the mold 200 is similar in shape to the midsole 18. The mold 200 defines a space 215 that holds the EVA material, and includes a plurality of protrusions 210 arranged to form the holes 24 in the midsole 18. Upon injection, the EVA material fills the space 215 around the protrusions 210. Once the material is within the mold, heat and pressure are applied to cause the material to form into the shape of the mold 200. After the material has formed the desired shape, the pressure is released, causing the material to expand.

[0095] In some embodiments, a cooling clamp 250 is used to maintain the shape and size of the finished part. For example, as shown in FIG. 6, the cooling clamp 250 is placed around the midsole 18 to maintain the shape and size of the midsole 18. In some embodiments, the cooling clamp 250 is placed around the midsole 18 while the midsole 18 is still in the mold 200. In some embodiments, the cooling clamp 250 is placed around the midsole 18 after the midsole 18 has been removed from the mold 200. Figure 22The cooling fixture 250 shown includes a plurality of protrusions 252 that are inserted into the holes 24 of the newly formed midsole 18. In some embodiments, the cooling fixture 250 includes fewer protrusions 252 than the number of holes 24 in the midsole 18. In some embodiments, the cooling fixture 250 includes the same number of protrusions 252 as the number of holes 24 in the midsole 18. The cooling fixture 250 holds the shape of the injected midsole 18 as the material cools.

[0096] Other manufacturing methods can alternatively be used. In some embodiments, the midsole 18 can be manufactured using polyurethane casting or molding, water jet cutting from an oversized midsole shape, milling, or machining.

[0097] The foregoing description of specific embodiments will so fully reveal the general nature of the present application that others can modify and / or adapt for various applications such specific embodiments without the exercise of inventive faculty and without the necessity of doing further testing, as those skilled in the art will appreciate. Therefore, it is intended that this written description serve as a base and a fundamental teaching of the application. Consequently, while the application has been shown as embodied in specific embodiments, there is no intent to limit the application to these specific embodiments. On the contrary, the intent is to cover all modifications and alternatives falling within the scope of the application as disclosed herein. It is to be understood that the foregoing description is not exhaustive of the scope of the present application. While this application has been shown and described with references to particular embodiments thereof, it will be understood by those skilled in the art that various changes in form and details can be made therein without departing from the spirit and scope of the application. Accordingly, the disclosed application is intended to be broadly construed, and the specification is to be interpreted to be illustrative and not restrictive. Changes and modifications can be made in the design, voltage and current applied, and the number of layers, without departing from the scope and spirit of the application.

[0098] The breadth and scope of the present application should not be limited by any of the above-described exemplary embodiments, but should be defined in accordance with the following claims and their equivalents.

Claims

1. A sole for footwear products, the sole comprising: a) A hollow insole, the hollow insole comprising a plurality of walls and defining a top surface, a bottom surface, and a peripheral surface extending from the top surface to the bottom surface, the hollow insole including holes configured to be distributed throughout the insole, wherein the walls of the hollow insole define the holes extending obliquely from the top surface of the hollow insole to the bottom surface of the hollow insole. The bottom surface of the wall forms a surface bonding area for the hollow bottom, and the surface area of ​​the surface bonding area is smaller than the total area of ​​the holes on the bottom surface of the hollow bottom. The hollow bottom is made of foam material; b) Outer bottom, the outer bottom being disposed on the bottom surface of the hollow insole, wherein the outer bottom does not cover the hole.

2. The sole according to claim 1, wherein, The hole extends at an angle between 55 and 81 degrees relative to the bottom surface of the hollow inlet.

3. The sole according to claim 1, further comprising a forefoot region, a midfoot region, and a rearfoot region, wherein, The holes are disposed in the forefoot region, the midfoot region, and the hindfoot region, wherein the average size of the holes in the forefoot region is different from the average size of the holes in the hindfoot region.

4. The sole according to claim 1, wherein, The height of the hollow insole increases from the forefoot region to the midfoot region and decreases from the midfoot region to the hindfoot region.

5. The sole according to claim 1, further comprising a non-elastic fabric disposed on the bottom surface of the hollow insole.

6. The sole according to claim 1, further comprising a groove disposed in the bottom surface of the hollow insole, wherein, The groove extends from the peripheral surface of the bottom of the hollow cavity to one of the holes.

7. The sole according to claim 1, wherein, The peripheral surface includes a protrusion that extends obliquely from the top surface of the hollow bottom to the bottom surface of the hollow bottom.

8. The sole according to claim 7, wherein, The protrusions are provided in the rearfoot and midfoot regions of the sole, and there are no protrusions in the forefoot region of the sole.

9. The sole according to claim 7, wherein, The protrusion maintains a consistent wall thickness between the peripheral surface and adjacent holes.

10. A footwear product comprising: a) Shoe upper; and b) A hollow midsole, connected to the upper and including a plurality of walls and perforations arranged throughout the midsole, the plurality of walls defining the oblique perforations extending from the top surface of the hollow midsole to the bottom surface. Wherein, the surface area of ​​the wall at the bottom surface of the hollow bottom is less than the total area of ​​the holes at the bottom surface of the hollow bottom. The hollow bottom is made of foam material; c) Outer bottom, the outer bottom being disposed on the bottom surface of the hollow insole, wherein the outer bottom does not cover the hole.

11. The footwear article according to claim 10, wherein, As the hole extends from the top surface of the hollow bottom to the bottom surface, the hole extends obliquely toward the hind foot region.

12. The footwear article according to claim 10, wherein, The holes are arranged in an alternating pattern, such that the center of one of the holes is not aligned with the center of the adjacent hole in the lateral direction.

13. The footwear article according to claim 10, wherein the outsole is composed of a single component.

14. The footwear article according to claim 10, wherein, The outsole comprises multiple components.

15. The footwear article according to claim 10, wherein, The outsole extends through the bottom surface of the hollow insole, such that each wall on the bottom surface is covered by the outsole.

16. The footwear article according to claim 10, wherein, The average size of the holes in the forefoot region of the hollow sole is different from the average size of the holes in the hindfoot region of the hollow sole.

17. The footwear article of claim 10, further comprising a reinforcing member connected to the bottom surface of the midsole and disposed in the forefoot region of the hollow midsole.

18. The footwear article according to claim 17, wherein, The reinforcing member comprises a non-elastic fabric.

19. The footwear article of claim 10, wherein the wall comprises a peripheral wall, and wherein, The hollow insole includes a groove disposed in the peripheral wall at the bottom surface of the insole, wherein the groove extends from the peripheral surface of the hollow insole to one of the holes.

20. The footwear article according to claim 10, wherein, The wall includes a peripheral wall, wherein the peripheral wall includes protrusions that extend obliquely from the top surface of the hollow insole to the bottom surface of the hollow insole, wherein the protrusions are disposed in the hind foot region and the midfoot region of the hollow insole, and wherein there are no protrusions in the forefoot region of the hollow insole.

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