Article of footwear with stacked forefoot bladders

Abstract

An article of footwear having a sole structure that includes a foam midsole layer. A first forefoot cushioning member is secured to a foot-facing surface of the foam midsole layer in a forefoot region, a second forefoot cushioning member overlies the first forefoot cushioning member, and a midsole fabric extends at least in the forefoot and midfoot regions and over the second forefoot cushioning member. One or more of the forefoot cushioning component, the second forefoot cushioning component, and the midsole fabric may include a bladder and a tensile component. The bladder encloses the lumen and retains gas within the lumen. The stretching component is arranged in the inner cavity.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of priority to U.S. Provisional Application No. 63 / 403,027, filed on September 1, 2022, the entire contents of which are incorporated herein by reference. Technical Field

[0003] The present disclosure generally relates to an article of footwear that includes a sole structure having a stacked forefoot cushioning component including a bladder. Background Art

[0004] Sole structures for articles of footwear are generally configured to provide cushioning, motion control, and / or resiliency. Some sole structures include cushioning components that include a bladder that forms a sealed interior cavity filled with a fluid, such as a gas, that elastically reacts to compressive loads. A tensile component may be disposed within the interior cavity and may limit outward expansion of the bladder. BRIEF DESCRIPTION OF THE DRAWINGS

[0005] The drawings described herein are for illustration purposes only, are schematic in nature, and are intended to be exemplary rather than limiting the scope of the present disclosure.

[0006] Figure 1 is an exploded view of an article of footwear within the scope of the teachings of the present disclosure, including an upper and a sole structure.

[0007] Figure 2 It is intercepted at line 2-2 Figure 1 A cross-sectional view of a footwear article.

[0008] Figure 3 yes Figure 2 A partial close-up view of a portion of.

[0009] Figure 4 is a cross-sectional view of an alternative embodiment of an article of footwear.

[0010] Figure 5 is a cross-sectional view of another alternative embodiment of an article of footwear. DETAILED DESCRIPTION

[0011] The present disclosure generally relates to a footwear article that utilizes stacked forefoot cushioning components that may each include a bladder having a gas retaining cavity that accommodates a stretch component. The forefoot cushioning components may be stacked on top of one another on a foam midsole layer to provide desired cushioning and impact protection. For example, a first forefoot cushioning component may be at a surface of the foam midsole layer that faces the foot, and a second forefoot cushioning component may overlap the first forefoot cushioning component. A midsole fabric may overlap the second forefoot cushioning component. A plate may be included in the midfoot region of the sole structure. These and other features provide responsiveness and motion control as discussed herein.

[0012] In an example, a footwear article includes a sole structure having a forefoot region, a midfoot region, and a heel region. The sole structure may include a midsole, a first forefoot cushioning component, a second forefoot cushioning component, and a midsole fabric. The foam midsole may have a foot-facing surface extending in each of the forefoot region and the midfoot region and a ground-facing surface extending in each of the forefoot region and the midfoot region. The first forefoot cushioning component may be fixed to the foot-facing surface of the foam midsole in the forefoot region. The second forefoot cushioning component may be stacked on the first forefoot cushioning component. The midsole fabric may extend at least in the forefoot region and the midfoot region and on the second forefoot cushioning component. In some embodiments, the foam midsole and the midsole fabric may also extend in the heel region.

[0013] Each of the first forefoot cushioning component, the second forefoot cushioning component and the midsole fabric includes a bladder that surrounds the inner cavity and holds the gas in the inner cavity. Thus, in the forefoot area, in addition to the midsole layer, three top-loaded bladders are effectively provided to affect the cushioning profile.

[0014] In one or more embodiments, at least one of the first forefoot cushioning component, the second forefoot cushioning component, and the midsole fabric may include a stretch component disposed in the inner cavity. The stretch component may include a stretch layer and a plurality of tethers connecting the stretch layer. The stretch layer may be connected to the inner surface of the bladder so that the tethers span the inner cavity. Optionally, each of the first forefoot cushioning component, the second forefoot cushioning component, and the midsole fabric may include such a stretch component.

[0015] In an example, the bladder of each of the first forefoot cushioning component, the second forefoot cushioning component, and the midsole fabric may include a first polymer sheet and a second polymer sheet bonded to the first polymer sheet to surround the interior cavity.

[0016] In one or more embodiments, the mid-bottom layer may have a top depression in the foot-facing surface in the forefoot region. The first forefoot cushioning component may be disposed within the top depression. The second forefoot cushioning component may interface with the top surface of the first forefoot cushioning component and also interface with the foot-facing surface of the mid-bottom layer forward of the first forefoot cushioning component. The top depression helps position the first forefoot cushioning component and allows it to be at least partially nested in the foam mid-bottom layer.

[0017] Similarly, the second forefoot cushioning component may interface with the first forefoot cushioning component and extend further forward than the first forefoot cushioning component such that a forward extent of the second forefoot cushioning component interfaces with a foot-facing surface of the foam midsole forward of the first forefoot cushioning component.

[0018] In one or more embodiments, the sole structure may include a plate disposed at the foam midsole layer in the midfoot region. In some embodiments, the plate may be a shank and may be disposed only in the midfoot region. The plate may overlap the foot-facing surface of the midsole layer. The foam midsole layer may include a depression at the foot-facing surface or the ground-facing surface and in which the plate is disposed. In embodiments where the plate is disposed at the foot-facing surface of the foam midsole layer, the midsole fabric may overlap the plate. The plate may be relatively rigid compared to the foam midsole layer and may therefore serve to stabilize the sole structure to aid in jumping motions, preventing the sole structure from excessively bending at the plate.

[0019] The sole structure may also include an outsole that underlying the foam midsole and forming the ground engaging surface of the article of footwear.

[0020] In an example, a footwear article includes a sole structure having a forefoot region, a midfoot region, and a heel region. The sole structure includes a foam midsole having a foot-facing surface extending in each of the forefoot region, the midfoot region, and the heel region and a ground-facing surface extending in each of the forefoot region, the midfoot region, and the heel region. The sole structure also includes a plate disposed at the midsole only in the midfoot region, a first forefoot cushioning component fixed to the foot-facing surface of the foam midsole in the forefoot region, and a second forefoot cushioning component stacked on the first forefoot cushioning component. Each of the first forefoot cushioning component and the second forefoot cushioning component includes a bladder that surrounds an inner cavity and holds gas in the inner cavity, and each of the first forefoot cushioning component and the second forefoot cushioning component also includes a stretching component disposed in the inner cavity. The stretching component includes a stretching layer and a plurality of tethers connecting the stretching layer. The stretching layer is connected to the inner surface of the bladder so that the tethers span the inner cavity.

[0021] In one or more embodiments, the plate is completely behind the first forefoot cushioning component and the second forefoot cushioning component.

[0022] In one or more embodiments, the midsole fabric extends in each of the forefoot region, the midfoot region, and the heel region, and extends over both the second forefoot cushioning component and the plate. The midsole fabric also includes a bladder and a stretch component, the bladder enclosing an inner cavity and retaining gas in the inner cavity, and the stretch component is disposed in the inner cavity. The stretch component includes a stretch layer and a plurality of tethers connecting the stretch layer. The stretch layer is connected to the inner surface of the bladder so that the tethers span the inner cavity.

[0023] The above features and advantages and other features and advantages of the teachings of the present disclosure will be apparent from the following detailed description of the modes for carrying out the teachings of the present disclosure when considered in conjunction with the accompanying drawings. It should be understood that although embodiments may be described separately in the following drawings, their individual features may be combined into additional embodiments.

[0024] Figure 1 1 is an exploded view of an article of footwear 10 including an upper 12 and a sole structure 14. Figure 2 As shown, upper 12 is secured to sole structure 14 to define a foot-receiving cavity 16, wherein a foot may be received through an ankle opening 18 (see FIG. Figure 1 ) is received and supported on sole structure 14. Upper 12 is shown to include body 20 and tongue 25, body 20 having eyelets 22 defining throat opening 24. Upper 12 is also shown to include tensioning elements, such as elastic laces 26, to adjust body 20 on the foot. However, upper 12 is merely exemplary, and other configurations of uppers may be used within the scope of the present disclosure, such as an upper configured as a sock or bootie, an upper having a "high-top" configuration with an ankle portion extending higher on the wearer's leg, etc.

[0025] The upper 12 may be made of a variety of materials, such as leather, fabric, polymer, cotton, foam, composite material, or a combination of these materials. For example, the body 20 may be a polymer material that provides elasticity, and may be a braided, knitted (e.g., warp knitted) or woven construction. The lower portion of the body 20 of the upper 12 is fixed to the periphery of the sole structure 14, such as Figure 2 shown.

[0026] refer to Figure 2, the article of footwear 10, along with the upper 12 and sole structure 14, can be divided into a forefoot region 30, a midfoot region 32, and a heel region 34. The forefoot region 30 generally includes portions of the article of footwear 10 corresponding to the toes and the metatarsophalangeal joints (which may be referred to as MPT or MPJ ​​joints), which connect the metatarsal bones of the foot with the proximal phalanges of the toes. The midfoot region 32 generally includes portions of the article of footwear 10 corresponding to the arch area and the instep of the foot, and the heel region 34 corresponds to the rear portion of the foot, including the calcaneus. The forefoot region 30, the midfoot region 32, and the heel region 34 are not intended to delineate precise areas of the article of footwear 10, but are intended to represent general areas of the article of footwear 10 to aid in the following discussion.

[0027] like Figure 1 As indicated, the article of footwear 10 has a lateral side 36 and a medial side 38. The lateral side 36 and the medial side 38 extend through each of the forefoot region 30, the midfoot region 32, and the heel region 34 and correspond to opposite sides of the article of footwear 10, each falling on opposite sides of the longitudinal midline (LM) of the article of footwear 10, as also shown in FIG. Figure 1 Therefore, the lateral side 36 is considered to be opposite to the medial side 38. The illustrated article of footwear 10 is configured for a right foot. The article of footwear configured for a left foot may be a mirror image of the article of footwear 10.

[0028] The sole structure 14 includes a foam midsole 40, a first forefoot cushioning component 42, a second forefoot cushioning component 44, a plate 46, a midsole fabric 48, and an outsole 50, all of which will be discussed further herein. Figure 2 , the foam midsole layer 40 is an integral, one-piece component that supports each of the forefoot cushioning components 42 and 44, as well as the plate 46 and the midsole fabric 48. Thus, the foam midsole layer 40 establishes the relative positions of the forefoot cushioning components 42 and 44, the plate 46 and the midsole fabric 48, ensuring that these components function as a midsole system having the various beneficial properties discussed herein.

[0029] The foam mid-layer 40 may be at least partially polyurethane foam, or polyurethane ethylene-vinyl acetate (EVA) foam, and may include heat-expanded and molded EVA foam pellets. The foam mid-layer 40 may generally include phylon (ethylene vinyl acetate or "EVA") and / or polyurethane ("PU") base resins. For example, in one embodiment, the foam mid-layer 40 may be compression molded phylon. If EVA is used, it may have a vinyl acetate (VA) level of between about 9% and about 40%. Suitable EVA resins include, for example, EVA resins provided by EI du Pont de Nemours and Company. and Engage by Dow Chemical Company TM . In certain embodiments, EVA can be formed from a combination of high melt index and low melt index materials. For example, EVA can have a melt index from about 1 to about 50. EVA resins can be compounded to include various components, including blowing agents and curing / cross-linking agents. The blowing agent can have a weight percentage between about 10% and about 20%. The blowing agent can be thermally decomposable and selected from common organic and inorganic chemical blowing agents. The nature of the blowing agent is not particularly limited as long as it decomposes under the temperature conditions when the foam is incorporated into the original resin. Suitable blowing agents include, for example, azodicarbonamide. In certain embodiments, peroxide-based curing agents such as diisopropylbenzene peroxide can be used. The amount of curing agent can be between about 0.6% and about 1.5%. EVA can also include homogenizers, processing aids, and waxes. For example, a mixture of light aliphatic hydrocarbons such as those available from Schill+Seilacher "Struktol" GmbH can be included. 60NS, to allow other materials or waste EVA to be more easily incorporated into the resin. EVA may also include other ingredients, such as a release agent (e.g., stearic acid), an activator (e.g., zinc oxide), a filler (e.g., magnesium carbonate), a pigment, and clay. In an embodiment combining multiple materials, each material may be formed of a material that is compatible with and easily combined with another material. For example, the materials may each be formed of an EVA resin with a suitable blowing agent, a cross-linking agent and other auxiliary components, a pigment, a filler, and the like. With the benefit of this disclosure, other suitable materials will become apparent to those skilled in the art.

[0030] like Figures 2 to 3 As shown, the foam midsole layer 40 has a foot-facing surface 51 and a ground-facing surface 52. The foot-facing surface 51 and the ground-facing surface 52 extend in each of the forefoot region 30, the midfoot region 32, and the heel region 34.

[0031] Figure 1 The outsole 50 is shown as an integral, unitary, one-piece component. The outsole 50 is positioned below the foam midsole 40 and is secured to its bottom surface 52 to form a ground engaging surface 53 of the sole structure 14, as shown in FIG. Figure 2 Outsole 50 has a foot-facing surface 49 (also referred to as an inner surface or top surface) on which a ground-facing surface 52 of foam midsole 40 rests and is secured, such as by heat bonding and / or with an adhesive or other means. Outsole has a bottom surface 53, which is also the ground-engaging surface of sole structure 14 and article of footwear 10.

[0032] Outsole 50 may be formed of materials that generally include natural or synthetic rubber or other suitable durable materials. One or more materials for outsole 50 may be selected to provide a desired combination of durability and flexibility. Synthetic rubbers that may be used include polybutadiene rubber, ethylene propylene rubber (EPR), styrene isoprene styrene (SIS) copolymer rubber, and styrene butadiene rubber.

[0033] The foam midsole 40 has a top depression 54 in the foot-facing surface 51 in the forefoot region 30, such as Figure 1 The first forefoot cushioning component 42 is disposed within the top recess 54 and is supported by the foam mid-layer 40 therein, as shown in FIG. Figure 2 The top depression 54 may be shaped to follow the perimeter P1 of the first forefoot cushioning component 42, as shown in FIG. Figure 1 The top depression 54 helps position the first forefoot cushioning component 42 relative to the foam midsole layer 40 and allows it to be at least partially nested within the foam midsole layer 40 .

[0034] First forefoot cushioning component 42 is disposed within top recess 54 and secured to foot-facing surface 51 of foam midbase layer 40 at bottom surface 57 of first forefoot cushioning component 42 in top recess 54, such as by heat bonding and / or with an adhesive or other means.

[0035] Although not shown, in some embodiments, the top recess 54 can have an undercut at its perimeter so that when the first forefoot cushioning component 42 is received in the top recess 54, at least a portion of the perimeter P1 can be folded into the undercut, wherein the outer top edge of the recess 54 extends over the first forefoot cushioning component 42 and the portion of the perimeter P1 is therefore not exposed at the foot-facing surface 51.

[0036] The second forefoot cushioning component 44 overlies and is stacked directly on the first forefoot cushioning component 42. More specifically, in the illustrated embodiment, the bottom surface 58 of the second forefoot cushioning component 44 is in contact with the top surface 56 of the first forefoot cushioning component and is in contact with the foot-facing surface 51 of the foam midsole layer 40 in front of the first forefoot cushioning component 42. In other words, the second forefoot cushioning component 44 is in contact with the first forefoot cushioning component 42 and extends further forward than the first forefoot cushioning component 42, so that the front extent 44A of the second forefoot cushioning component 44 is in contact with the foot-facing surface 51 of the foam midsole layer 40 in front of the first forefoot cushioning component 42.

[0037] Midsole fabric 48 is shown as a "full length" midsole fabric, meaning that, like foam midsole layer 40, it extends in each of forefoot region 30, midfoot region 32, and heel region 34. In other embodiments, midsole fabric 48 may extend only in forefoot region 30 and midfoot region 32. As shown, midsole fabric 48 extends over second forefoot cushioning component 44 and foam midsole layer 40. For example, bottom surface 60 of midsole fabric 48 may be bonded to each of top surface 62 of second forefoot cushioning component 44 and foot-facing surface 51 of foam midsole layer 40.

[0038] As such, the stacked first forefoot cushioning component 42 and second forefoot cushioning component 44 can be referred to as being top loaded because compressive forces thereon (such as loading by the foot) will load the forefoot cushioning components 42 and 44 through the midsole fabric 48 without the presence of the foam midsole layer 40. In other words, at least at the depression 54, the first forefoot cushioning component 42 and second forefoot cushioning component 44 are closer to the foot than the foam midsole layer 40.

[0039] The depth of the top depression 54 can be less than or equal to the inflated height of the portion of the stacked first forefoot cushioning component 42 and the second forefoot cushioning component 44, so that the stacked first forefoot cushioning component 42 and the second forefoot cushioning component 44 largely fill the top depression 54, and the top surface 62 of the second forefoot cushioning component 44 is generally flush with or extends slightly above the surrounding portion of the foot-facing surface 51 of the foam midsole layer 40. The midsole fabric 48 covers the second forefoot cushioning component 44 to support a portion of the foot on its top surface 64. The top surface 64 of the midsole fabric 48 is the foot-receiving surface of the sole structure 14. Alternatively, a sockliner or other component can extend over the midsole fabric 48 and define the foot-facing surface of the sole structure 14. In the illustrated embodiment, the forefoot cushioning components 42, 44 are not exposed at the lateral side 36 or medial side 38 of the footwear article 10. For example, only the upper 12, the foam midsole layer 40, and the outsole 50 are visible from a vantage point outside the footwear article.

[0040] Each of the first forefoot cushioning component 42, the second forefoot cushioning component 44, and the midsole fabric 48 includes a corresponding bladder that surrounds the inner cavity and retains the gas in the inner cavity. More specifically, each of the first forefoot cushioning component 42, the second forefoot cushioning component 44, and the midsole fabric 48 includes a separate bladder that can be formed from two polymer sheets as discussed herein. Therefore, in the forefoot area 30, in addition to the foam midsole 40, three top-loaded bladders are effectively provided to affect the cushioning profile. In an example, the bladder of each of the first forefoot cushioning component 42, the second forefoot cushioning component 44, and the midsole fabric 48 can include a first polymer sheet and a second polymer sheet that is bonded to the first polymer sheet to surround the inner cavity.

[0041] For example, refer to Figure 3 The first forefoot cushioning component 42 includes a peripheral flange 74A (at Figure 1 The first polymer sheet 70A and the second polymer sheet 72A are bonded to each other at a position best indicated in FIG. 7 to enclose the inner cavity 76A. The peripheral flange 74A can extend around the entire perimeter of the first forefoot cushioning component 42 and define its outer perimeter P1, as shown in FIG. Figure 1 The first polymer sheet 70A may be referred to as a top sheet and defines a top surface 56. The second polymer sheet 72A may be referred to as a bottom sheet and defines a bottom surface 57. The combined polymer sheets 70A, 72A may be referred to as a first bladder or simply a bladder.

[0042] The second forefoot cushioning component 44 also includes a first polymer sheet 70B and a second polymer sheet 72B joined to each other at a peripheral flange 74B to surround the inner cavity 76B. The peripheral flange 74B can extend around the entire perimeter of the second forefoot cushioning component 44 and define its outer perimeter P2, such as Figure 1 The first polymer sheet 70B may be referred to as a top sheet and defines the top surface 62. The second polymer sheet 72B may be referred to as a bottom sheet and defines the bottom surface 58. The combined sheets 70B, 72B may be referred to as a second bladder or simply a bladder.

[0043] Similarly, the midsole fabric 48 includes a peripheral flange 74C (see Figure 1 ) to enclose the inner cavity 76C. The peripheral flange 74C can extend around the entire periphery of the midsole fabric 48 and define its outer perimeter P3, as shown in FIG. Figure 1 The first polymer sheet 70C may be referred to as a top sheet and defines a top surface 64. The second polymer sheet 72C may be referred to as a bottom sheet and defines a bottom surface 60. The combined polymer sheets 70C, 72C may be referred to as a third bladder or simply a bladder.

[0044] Each of the first forefoot cushioning component 42, the second forefoot cushioning component 44, and the midsole fabric 48 surrounds the inner chambers 76A, 76B, and 76C, respectively, and retains gas in the corresponding inner chambers 76A, 76B, and 76C. When the polymer sheets 70A, 72A are bonded to each other at the peripheral flange 74A and any inflation ports are sealed, the polymer sheets 70A, 72A define a first bladder that retains fluid (e.g., gas) in the inner chamber 76A. When the polymer sheets 70B, 72B are bonded to each other at the peripheral flange 74B and any inflation ports are sealed, the polymer sheets 70B, 72B define a second bladder that retains fluid (e.g., gas) in the inner chamber 76B. When the polymer sheets 70C, 72C are bonded to each other at the peripheral flange 74C and any inflation ports are sealed, the polymer sheets 70C, 72C define a third bladder that retains fluid (e.g., gas) in the inner chamber 76C. Inner chambers 76A, 76B and 76C are not in fluid communication with each other. This enables inner chambers 76A, 76B and 76C to hold gas at different inflation pressures. Alternatively, one or more of inner chambers 76A, 76B and 76C can be at ambient pressure. In yet another alternative, inner chambers 76A, 76B and 76C can be at the same inflation pressure.

[0045] As used herein, the "fluid" filling each inner cavity 76A, 76B and 76C can be a gas, such as air, nitrogen, another gas or a combination thereof. The first and second polymer sheets 70A, 72A, 70B, 72B and 70C, 72C of the first forefoot cushioning component 42, the second forefoot cushioning component 44 and the midsole fabric 48 can be various polymer materials that can elastically retain fluids (such as nitrogen, air or another gas). Examples of polymer materials for the first and second polymer sheets 70A, 72A, 70B, 72B and 70C, 72C include thermoplastic polyurethane, polyurethane, polyester, polyester polyurethane and polyether polyurethane. In addition, any one or all of the first and second polymer sheets 70A, 72A, 70B, 72B and 70C, 72C can each be formed by a layer of different materials including a polymer material. In one embodiment, each of the first and second polymer sheets 70A, 72A, 70B, 72B and 70C, 72C is formed of a film having one or more thermoplastic polyurethane layers having one or more barrier layers of ethylene and vinyl alcohol copolymer (EVOH) that are impermeable to the pressurized fluid contained therein, such as a flexible microlayer film including alternating layers of gas barrier material and elastomeric material, as disclosed in U.S. Pat. Nos. 6,082,025 and 6,127,026 to Bonk et al., the entire contents of which are incorporated herein by reference. Alternatively, the layers may include ethylene-vinyl alcohol copolymer, thermoplastic polyurethane, and regrind material of ethylene-vinyl alcohol copolymer and thermoplastic polyurethane. Additional suitable materials for the first and second polymer sheets 70A, 72A, 70B, 72B and 70C, 72C are disclosed in U.S. Pat. Nos. 4,183,156 and 4,219,945 to Rudy, the entire contents of which are incorporated herein by reference. Other suitable materials for the first and second polymer sheets 70A, 72A, 70B, 72B and 70C, 72C include thermoplastic films containing crystalline materials (such as disclosed in U.S. Pat. Nos. 4,936,029 and 5,042,176 to Rudy) and polyurethanes including polyester polyols (such as disclosed in U.S. Pat. Nos. 6,013,340, 6,203,868 and 6,321,465 to Bonk et al., the entire contents of which are incorporated herein by reference. In selecting materials for the first and second forefoot cushioning components 42 and 44 and for the midsole fabric 48, engineering properties such as tensile strength, stretch characteristics, fatigue characteristics, dynamic modulus, and loss tangent can be considered. For example, the thickness of the first and second polymer sheets 70A, 72A, 70B, 72B and 70C, 72C used to form the first and second forefoot cushioning components 42 and 44 and the midsole fabric 48, respectively, can be selected to provide these characteristics.

[0046] Any one or more of the first forefoot cushioning component 42, the second forefoot cushioning component 44, and the midsole fabric 48 may include a stretching component 78 disposed in the corresponding inner chambers 76A, 76B, and 76C. Figures 1 to 3 In the embodiment of FIG. 5 , each of the lumens 76A, 76B, and 76C has a corresponding tensile member 78 disposed therein.

[0047] refer to Figure 3 , each stretch component 78 includes a stretch layer 80, 82 and a plurality of tethers 84 connecting the stretch layers 80, 82. The stretch layers 80, 82 are connected to the top and bottom portions of the inner surface of the corresponding bladder formed by the polymer sheets 70A, 72A, 70B, 72B and 70C, 72C, respectively, so that the tethers 84 span the corresponding inner chambers 76A, 76B and 76C. In the first forefoot cushioning component 42, the stretch layer 80 is bonded to the inner surface 86 of the top polymer sheet (the first polymer sheet 70A), and the stretch layer 82 is bonded to the inner surface 87 of the bottom polymer sheet (the second polymer sheet 72A). In Figure 3 8, only some of the tethers 84 are indicated with reference numerals. The tethers 84 may also be referred to as fabric stretch members or threads, and may be in the form of dropped warp threads connecting the first stretch layer 80 and the second stretch layer 82. The stretch component 78 may be formed as an integral, one-piece fabric element having a spacer knit fabric.

[0048] At a given gas inflation pressure in lumen 76A, tether 84 limits the separation of first polymer sheet 70A and second polymer sheet 72A to Figure 3 The maximum separation position shown. The outward force of the pressurized gas in the inner cavity 76A places the tether 84 in tension, and the tether 84 prevents the stretch layers 80, 82 and the polymer sheets 70A, 72A from moving further outwardly away from each other. However, when under a compressive load, the tether 84 does not exhibit compression resistance. When pressure is applied to the first forefoot cushioning component 42, such as due to dynamic impact forces of the wearer during running or other movement, the first forefoot cushioning component 42 is compressed and the polymer sheets 70A, 72A move closer together, while the tether 84 collapses (i.e., becomes relaxed) in proportion to the pressure applied to the first and second polymer sheets 70A, 72A adjacent to the particular tether 84, and then, when the dynamic load is removed and the first and second polymer sheets 70A, 72A move away from each other, the tether 84 collapses (i.e., becomes relaxed). Figure 3 When they are in the position shown, they resume their extended length.

[0049] With respect to the stretch component 78 disposed in the inner cavity 76B of the second forefoot cushioning component 44, the stretch layer 80 is bonded to the inner surface 89 of the top polymer sheet (first polymer sheet 70B), and the stretch layer 82 is bonded to the inner surface 91 of the bottom polymer sheet (second polymer sheet 72B). With respect to the stretch component 78 disposed in the inner cavity 76C of the midsole fabric 48, the stretch layer 80 is bonded to the inner surface 93 of the top polymer sheet (first polymer sheet 70C), and the stretch layer 82 is bonded to the inner surface 95 of the bottom polymer sheet (second polymer sheet 72C).

[0050] refer to Figure 2 , plate 46 is disposed at the foam midsole layer 40 in the midfoot region 32. As shown, plate 46 is a shank and is disposed only in the midfoot region 32. The plate is completely behind the first forefoot cushioning component 42 and the second forefoot cushioning component 44. Plate 46 overlies the foot-facing surface 51 of the foam midsole layer 40, and the midsole fabric 48 overlies plate 46. Plate 46 is relatively flat. Plate 46 can generally be configured to extend substantially across the width of the foot-facing surface 51 of the foam midsole layer 40 in the midfoot region 32. In another example, such as in Figure 5 In the embodiment of the present invention, plate 46 may be positioned beneath foam midsole layer 40 and may be configured to extend substantially across a width of a bottom surface 52 of foam midsole layer 40 in midfoot region 32 .

[0051] Plate 46 is secured to foam midsole 40 in midfoot region 32, such as by heat bonding and / or with an adhesive or other means. Plate 46 may be a thermoplastic polyurethane. In an example, plate 46 may be polyether block amide PEBAX Rnew 63R53SP 01, which is a thermoplastic elastomer made of a flexible polyether and a rigid polyamide based on renewable resources and has an instantaneous hardness of 58 on the Shore D durometer test scale using the ISO 868 test method and is available from Arkema, Inc. of King of Prussia, Pennsylvania USA. In another example, plate 46 may be Rnew 55R53 SP 01, which is also a thermoplastic elastomer made from a flexible polyether and a rigid polyamide based on renewable resources and has an instantaneous hardness of 50 on the Shore D durometer test scale using the ISO 868 test method, is also available from Arkema, King of Prussia, Pennsylvania, USA.

[0052] Plate 46 has a greater bending stiffness than foam midsole 40 and is positioned in midfoot region 32 to limit twisting and folding in this region and provide rigidity to support take-off of vertical jumps. In other words, plate 46 increases the bending stiffness of sole structure 14 in midfoot region 32.

[0053] Figure 4 Another embodiment of an article of footwear 110 is shown that is similar in all respects to article of footwear 10, but foam midsole layer 40 is replaced by foam midsole layer 140 having a depression 154 in foot-facing surface 51 in midfoot region 32 in addition to depression 54 in foot-facing surface 51 in forefoot region 30. Depression 54 may be referred to as a first top depression, and depression 154 may be referred to as a second top depression. Plate 46 is disposed in depression 154, and midsole fabric 48 overlaps plate 46 at foot-facing surface 51 of foam midsole layer 40. Foam midsole layer 140 is otherwise identical to foam midsole layer 40, and the description of foam midsole layer 40 herein applies equally to foam midsole layer 140. The sole structure 114 of the article of footwear 110 includes the first forefoot cushioning component 42 , the second forefoot cushioning component 44 , the midsole fabric 48 , the plate 46 , and the outsole 50 as described with respect to the sole structure 14 , and a foam midsole layer 140 .

[0054] Figure 5 Another embodiment of an article of footwear 210 is shown, which is similar in all respects to article of footwear 10, but foam midsole 40 is replaced by foam midsole 240 having depressions 254 in ground-facing surface 52 in midfoot region 32 in addition to depressions 54 in forefoot region 30 at foot-facing surface 51. Plate 46 is disposed in depressions 254 and overlies outsole 50. Plate 46 may be secured to foam midsole 240 at depressions 254 and to foot-facing surface 49 of outsole 50. Foam midsole 240 is otherwise identical to foam midsole 40, and the description of foam midsole 40 herein applies equally to foam midsole 240. Sole structure 214 of article of footwear 210 includes first forefoot cushioning component 42, second forefoot cushioning component 44, midsole fabric 48, plate 46, and outsole 50 as described with respect to sole structure 14, as well as foam midsole 240. In some embodiments, the panel 46 may wrap upward from the ground-facing surface 52 to the inside wall of the foam midsole layer 240 .

[0055] The following clauses provide example configurations of the articles of footwear disclosed herein.

[0056] Item 1. A footwear article comprising: a sole structure having a forefoot region, a midfoot region, and a heel region, and the sole structure includes: a foam midsole layer having a foot-facing surface extending in each of the forefoot region and the midfoot region and a ground-facing surface extending in each of the forefoot region and the midfoot region; a first forefoot cushioning component, the first forefoot cushioning component being fixed to the foot-facing surface of the foam midsole layer in the forefoot region; a second forefoot cushioning component, the second forefoot cushioning component being stacked on the first forefoot cushioning component; and a midsole fabric, the midsole fabric extending at least in the forefoot region and the midfoot region; wherein the midsole fabric extends over the second forefoot cushioning component; and wherein each of the first forefoot cushioning component, the second forefoot cushioning component, and the midsole fabric includes a bladder that surrounds an inner cavity and retains gas in the inner cavity.

[0057] Clause 2. The article of footwear according to clause 1, wherein: at least one of the first forefoot cushioning component, the second forefoot cushioning component and the midsole fabric includes a stretch component disposed in the inner cavity; and the stretch component includes a stretch layer and a plurality of tethers connecting the stretch layer, the stretch layer being connected to the inner surface of the bladder so that the tethers span the inner cavity.

[0058] Clause 3. An article of footwear according to any one of the preceding clauses, wherein: each of the first forefoot cushioning component, the second forefoot cushioning component and the midsole fabric includes a stretch component disposed in the inner cavity; and the stretch component includes a stretch layer and a plurality of tethers connecting the stretch layer, the stretch layer being connected to the inner surface of the bladder so that the tethers span the inner cavity.

[0059] Clause 4. The article of footwear as recited in any preceding clause, wherein: the foam midsole layer has a top depression in the foot-facing surface in the forefoot region; and the first forefoot cushioning component is disposed within the top depression.

[0060] Clause 5. The article of footwear as recited in any preceding clause, wherein the second forefoot cushioning component is contiguous with a top surface of the first forefoot cushioning component and is contiguous with the foot-facing surface of the midsole layer forward of the first forefoot cushioning component.

[0061] Clause 6. The article of footwear as recited in any preceding clause, the sole structure further comprising: a plate disposed at the midsole layer in the midfoot region.

[0062] Clause 7. The article of footwear according to any of the preceding clauses, wherein the plate is a shank and is provided only in the midfoot region.

[0063] Clause 8. The article of footwear as recited in any preceding clause, wherein the foam midsole layer includes a depression at one of the foot-facing surface and the ground-facing surface, and wherein the plate is disposed in the depression.

[0064] Clause 9. The article of footwear as recited in any preceding clause, wherein the plate overlies the foot-facing surface of the foam midsole.

[0065] Clause 10. The article of footwear of any preceding clause, wherein the midsole fabric overlies the plate.

[0066] Item 11. A footwear article according to any of the preceding items, wherein the second forefoot cushioning component is connected to the first forefoot cushioning component and extends further forward than the first forefoot cushioning component, so that the front range of the second forefoot cushioning component is connected to the foot-facing surface of the foam midsole in front of the first forefoot cushioning component.

[0067] Clause 12. The article of footwear of any of the preceding clauses, the sole structure further comprising: an outsole underlying the foam midsole and forming a ground engaging surface of the article of footwear.

[0068] Clause 13. The article of footwear of any of the preceding clauses, wherein the bladder of each of the first forefoot cushioning component, the second forefoot cushioning component, and the midsole fabric comprises a first polymer sheet and a second polymer sheet bonded to the first polymer sheet to enclose the interior cavity.

[0069] Clause 14. The article of footwear according to any of the preceding clauses, wherein the foam midsole layer and the midsole fabric extend in the heel region.

[0070] Clause 15. The article of footwear according to any of the preceding clauses, wherein the midsole layer is a one-piece component extending in each of the forefoot region, the midfoot region, and the heel region.

[0071] Clause 16. A footwear article according to any of the preceding clauses, comprising: a sole structure having a forefoot region, a midfoot region and a heel region, and the sole structure includes: a foam midsole layer, the foam midsole layer having a foot-facing surface extending in each of the forefoot region, the midfoot region and the heel region and a ground-facing surface extending in each of the forefoot region, the midfoot region and the heel region; a plate, the plate being arranged at the foam midsole layer only in the midfoot region; a first forefoot cushioning component, the first forefoot cushioning component being fixed to the foot-facing surface of the midsole layer in the forefoot region; a second forefoot cushioning component, the second forefoot cushioning component being stacked on the first forefoot cushioning component; wherein each of the first forefoot cushioning component and the second forefoot cushioning component includes: a bladder, the bladder surrounding an inner cavity and retaining gas in the inner cavity; and a stretch component, the stretch component being arranged in the inner cavity; wherein the stretch component includes a stretch layer and a plurality of tethers connecting the stretch layer, the stretch layer being connected to the inner surface of the bladder so that the tethers span the inner cavity.

[0072] Clause 17. The article of footwear as recited in any preceding clause, wherein the plate is completely behind the first forefoot cushioning component and the second forefoot cushioning component.

[0073] Clause 18. The footwear article of any of the preceding clauses, wherein the sole structure further comprises: a midsole fabric extending in each of the forefoot region, the midfoot region, and the heel region, and extending over the second forefoot cushioning component and the plate; wherein the midsole fabric comprises a bladder surrounding an interior cavity and retaining gas in the interior cavity.

[0074] Clause 19. The article of footwear of any of the preceding clauses, wherein the midsole fabric comprises a stretch component disposed in the inner cavity; wherein the stretch component comprises a stretch layer and a plurality of tethers connecting the stretch layer, the stretch layer being connected to the inner surface of the bladder such that the tethers span the inner cavity.

[0075] Clause 20. The article of footwear according to any of the preceding clauses, wherein the midsole layer is a one-piece component.

[0076] To assist and clarify the description of various embodiments, various terms are defined herein. Unless otherwise indicated, the following definitions apply to the entire specification (including claims). Additionally, all references cited are incorporated herein by reference in their entirety.

[0077] "Articles of footwear," "articles of footwear manufacture," and "footwear" may be considered to be machines and articles of manufacture. Assembled finished articles of footwear (e.g., shoes, sandals, boots, etc.) and discrete components of articles of footwear (such as midsoles, outsoles, upper components, etc.) prior to final assembly into finished articles of footwear are considered herein and are alternatively referred to in the singular or plural as "articles of footwear."

[0078] "One", "a kind", "the", "at least one" and "one or more" are used interchangeably to indicate that there is at least one of the items. Unless the context clearly indicates otherwise, there may be multiple such items. Unless otherwise clearly or clearly indicated in the context (including the appended claims), all numerical values ​​of parameters (e.g., amounts or conditions) in this specification should be understood to be modified by the term "about" in all cases, regardless of whether "about" actually appears before the numerical value. "About" indicates that the stated numerical value allows some slight imprecision (close to exact in value; close to or quite close to the value; almost). If the imprecision provided by "about" is not understood in the art with this ordinary meaning, "about" as used herein at least indicates the changes that may be caused by the ordinary methods of measuring and using such parameters. In addition, the disclosure of a range should be understood to specifically disclose all values ​​within the range and the range further divided.

[0079] The terms "comprising", "including" and "having" are inclusive and therefore specify the presence of the stated features, steps, operations, elements or components, but do not exclude the presence or addition of one or more other features, steps, operations, elements or components. When possible, the order of steps, processes and operations can be changed, and additional or alternative steps can be adopted. As used in this specification, the term "or" includes any and all combinations of the associated listed items. The term "any of..." should be understood to include any possible combination of the referenced items, including "any of" the referenced items. The term "any of..." should be understood to include any possible combination of the referenced claims in the appended claims, including "any of" the referenced claims.

[0080] For consistency and convenience, directional adjectives may be employed throughout the detailed description corresponding to the illustrated embodiments. One of ordinary skill in the art will recognize that terms such as "above," "below," "upwardly," "downwardly," "top," "bottom," etc. may be used descriptively with respect to the drawings without implying a limitation on the scope of the invention as defined by the claims.

[0081] The term "longitudinal" particularly refers to a direction extending the length of a component. For example, the longitudinal direction of a shoe extends between a forefoot region and a heel region of the shoe. The terms "forward" or "front" are particularly used to refer to a general direction from the heel region towards the forefoot region, and the terms "rearward" or "rear" are particularly used to refer to the opposite direction, i.e., the direction from the forefoot region towards the heel region. In some cases, a component may be identified as having a longitudinal axis and a front-to-back longitudinal direction along the axis. The longitudinal direction or axis may also be referred to as the front-to-back direction or axis.

[0082] The term "lateral" refers in particular to a direction extending the width of a component. For example, the lateral direction of a shoe extends between the lateral side and the medial side of the shoe. The lateral direction or axis may also be referred to as the lateral direction or axis or the medial-lateral direction or axis.

[0083] The term "vertical" particularly refers to a direction that is substantially perpendicular to both the lateral direction and the longitudinal direction. For example, in the case where the sole structure is lying flat on a ground surface, the vertical direction may extend upward from the ground surface. It should be understood that each of these directional adjectives may be applied to individual components of the sole structure. The term "upward" or "upwardly" particularly refers to a vertical direction directed toward the top of a component, which may include the instep of the upper, the fastening area and / or the throat. The term "downward" or "downwardly" particularly refers to a vertical direction directed toward the bottom of a component opposite to the upward direction, and may generally be directed toward the bottom of the sole structure of an article of footwear.

[0084] The "interior" of a footwear article (such as a shoe) refers in particular to the portion at the space occupied by the wearer's foot when the shoe is worn. The "inside" of a component refers in particular to the side or surface of the component that is oriented toward (or will be oriented toward) the interior of the component or footwear article in the assembled footwear article. The "outside" or "exterior" of a component refers in particular to the side or surface of the component that is oriented away from (or will be away from) the interior of the shoe in the assembled shoe. In some cases, other components may be between the inside of the component and the interior of the assembled footwear article. Similarly, other components may be between the outside of the component and the space outside the assembled footwear article. In addition, the terms "inward" and "inwardly" refer in particular to the direction toward the interior of a component or footwear article (such as a shoe), and the terms "outward" and "outwardly" refer in particular to the direction toward the exterior of a component or footwear article (such as a shoe). In addition, the term "proximal" refers in particular to the direction closer to the center of the footwear component or closer to the foot when the user inserts the foot into the footwear article while wearing the footwear article. Likewise, the term "distal" specifically refers to a relative position farther from the center of the footwear component or farther from the foot when the user inserts the foot into the footwear when wearing the footwear. Therefore, the terms proximal and distal can be understood as generally relative terms that provide descriptions of relative spatial positions.

[0085] Although various embodiments have been described, the description is intended to be illustrative rather than restrictive, and it will be apparent to those of ordinary skill in the art that there may be more embodiments and implementations within the scope of these embodiments. Unless expressly limited, any feature of any embodiment may be used in combination with any other feature or element in any other embodiment or replace any other feature or element in any other embodiment. Therefore, these embodiments are not limited except in accordance with the appended claims and their equivalents. Moreover, various modifications and changes may be made within the scope of the appended claims.

[0086] Although several modes for implementing various aspects of the teachings of the present disclosure have been described in detail, those skilled in the art to which these teachings relate will recognize various alternative aspects for practicing the teachings of the present disclosure within the scope of the appended claims. It is intended that all content contained in the above description or shown in the accompanying drawings be interpreted as describing and illustrating the entire scope of alternative embodiments, which will be recognized by those of ordinary skill in the art as being implied by the included content, structurally and / or functionally equivalent, or otherwise presented as obvious based on the included content, and are not limited to those explicitly depicted and / or described embodiments.

Claims

1. A footwear product comprising: A sole structure having a forefoot region, a midfoot region and a heel region, and comprising: a foam midsole layer having a foot-facing surface extending in each of the forefoot region and the midfoot region and a ground-facing surface extending in each of the forefoot region and the midfoot region; a first forefoot cushioning component secured to the foot-facing surface of the foam midsole layer in the forefoot region; a second forefoot cushioning component, the second forefoot cushioning component being stacked on the first forefoot cushioning component; and a midsole fabric extending at least in the forefoot region and the midfoot region; wherein the midsole fabric extends over the second forefoot cushioning component; and Each of the first forefoot cushioning component, the second forefoot cushioning component, and the midsole fabric includes a bladder that surrounds an inner cavity and retains gas in the inner cavity.

2. The article of footwear according to claim 1, wherein: At least one of the first forefoot cushioning component, the second forefoot cushioning component, and the midsole fabric includes a stretch component disposed in the inner cavity; and The stretch member includes a stretch layer and a plurality of tethers connecting the stretch layer, the stretch layer being connected to an inner surface of the bladder such that the tethers span the inner cavity.

3. The article of footwear according to any one of claims 1 to 2, wherein: Each of the first forefoot cushioning component, the second forefoot cushioning component, and the midsole fabric includes a stretch component disposed in the inner cavity; and The stretch member includes a stretch layer and a plurality of tethers connecting the stretch layer, the stretch layer being connected to an inner surface of the bladder such that the tethers span the inner cavity.

4. The article of footwear according to any one of claims 1 to 2, wherein: the foam midsole layer having a top depression in the foot-facing surface in the forefoot region; and The first forefoot cushioning component is disposed within the top recess.

5. The article of footwear of claim 4, wherein the second forefoot cushioning component is contiguous with a top surface of the first forefoot cushioning component and is contiguous with the foot-facing surface of the foam midsole layer forward of the first forefoot cushioning component.

6. The footwear article according to any one of claims 1 to 2, wherein the sole structure further comprises: A plate is disposed at the foam midsole layer in the midfoot region.

7. The article of footwear according to claim 6, wherein the plate is a shank and is provided only in the midfoot area.

8. The article of footwear of claim 6, wherein the foam midsole layer includes a depression at one of the foot-facing surface and the ground-facing surface, and the plate is disposed in the depression.

9. The article of footwear of claim 6, wherein the plate overlies the foot-facing surface of the foam midsole.

10. The article of footwear of claim 6, wherein the midsole fabric overlays the plate.

11. The footwear article according to any one of claims 1 to 2, wherein the second forefoot cushioning component is connected to the first forefoot cushioning component and extends further forward than the first forefoot cushioning component, so that the front range of the second forefoot cushioning component is connected to the foot-facing surface of the foam midsole layer in front of the first forefoot cushioning component.

12. The article of footwear according to any one of claims 1 to 2, wherein the sole structure further comprises: An outsole is positioned beneath the foam midsole and forms a ground engaging surface of the article of footwear.

13. The footwear article according to any one of claims 1 to 2, wherein the bladder of each of the first forefoot cushioning component, the second forefoot cushioning component, and the midsole fabric comprises a first polymer sheet and a second polymer sheet bonded to the first polymer sheet to surround the interior cavity.

14. The article of footwear according to any one of claims 1 to 2, wherein the foam midsole layer and the midsole fabric extend in the heel area.

15. The article of footwear according to any one of claims 1-2, wherein the foam midsole layer is a one-piece component extending in each of the forefoot region, the midfoot region, and the heel region.

16. A footwear article comprising: A sole structure having a forefoot region, a midfoot region and a heel region, and comprising: a foam midsole layer having a foot-facing surface extending in each of the forefoot region, the midfoot region, and the heel region and a ground-facing surface extending in each of the forefoot region, the midfoot region, and the heel region; a plate disposed at the foam midsole layer only in the midfoot region; a first forefoot cushioning component secured to the foot-facing surface of the midsole layer in the forefoot region; a second forefoot cushioning component, the second forefoot cushioning component being stacked on the first forefoot cushioning component; wherein each of the first forefoot cushioning component and the second forefoot cushioning component comprises: a bladder surrounding the lumen and retaining gas within the lumen; and A stretch member is disposed in the inner cavity; wherein the stretch member comprises a stretch layer and a plurality of tethers connecting the stretch layer, the stretch layer being connected to the inner surface of the bladder such that the tethers span the inner cavity.

17. The article of footwear of claim 16, wherein the plate is completely behind the first forefoot cushioning component and the second forefoot cushioning component.

18. The article of footwear according to any one of claims 16 to 17, wherein the sole structure further comprises: a midsole fabric extending in each of the forefoot region, the midfoot region, and the heel region and extending over the second forefoot cushioning component and the plate; The midsole fabric includes a bladder that surrounds an inner cavity and holds gas in the inner cavity.

19. The article of footwear of claim 18, wherein the midsole fabric includes a stretch member disposed in the interior cavity; wherein the stretch member includes a stretch layer and a plurality of tethers connecting the stretch layer, the stretch layer being connected to the inner surface of the bladder such that the tethers span the interior cavity.

20. The article of footwear according to any one of claims 16 to 17, wherein the midsole layer is a one-piece component.

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