Cushioning member for article of footwear

Abstract

The invention relates to a cushioning member for an article of footwear. A method of manufacturing a cushioning member is provided. The method includes forming a first barrier member from a first material, the first barrier member including a first compartment and a second compartment. The method further includes forming a second barrier member from a second material different from the first material. The first compartment is provided with a first number of particulates and the second compartment is provided with a second number of particulates. The method further includes covering the first compartment with a second barrier member and covering the second compartment with a second barrier member.

Description

[0001] This application is a divisional application of an application filed on July 20, 2020, with application number 202080062877.7 and invention name “Buffering component for footwear articles”.

[0002] CROSS-REFERENCE TO RELATED APPLICATIONS

[0003] This application claims priority to non-provisional U.S. patent application No. 16 / 933,687, filed on July 20, 2020, which claims priority under 35 U.S.C. §119(e) to U.S. Provisional Application No. 62 / 878,706, filed on July 25, 2019, and U.S. Provisional Application No. 62 / 923,661, filed on October 21, 2019, the disclosures of which are hereby incorporated by reference in their entireties.

[0004] field

[0005] The present disclosure relates to cushioning members incorporating particulate matter for use with articles of footwear, and more particularly to methods of making cushioning members incorporating particulate matter for use with articles of footwear.

[0006] background

[0007] This section provides background information related to the present disclosure which is not necessarily prior art.

[0008] Articles of footwear conventionally include an upper and a sole structure. The upper may be formed of any suitable material to receive, secure, and support the foot on the sole structure. The upper may cooperate with laces, straps, or other fasteners to adjust the fit of the upper around the foot. A bottom portion of the upper, proximate the bottom surface of the foot, is attached to the sole structure.

[0009] The sole structure generally includes a layered arrangement extending between a ground surface and an upper. One layer of the sole structure includes an outsole that provides wear resistance and traction to the ground surface. The outsole may be formed of rubber or other materials that impart durability and wear resistance and enhance traction to the ground surface. Another layer of the sole structure includes a midsole disposed between the outsole and the upper. The midsole provides cushioning for the foot and is generally at least partially formed of a polymer foam material that elastically compresses under an applied load to cushion the foot by attenuating ground reaction forces. The midsole may define a bottom surface on a side opposite the outsole and a footbed on an opposite side, the contour of which may be set to conform to the contour of the bottom surface of the foot. The sole structure may also include an insole or sockliner for enhanced comfort, which is located within the cavity near the bottom portion of the upper.

[0010] Midsoles using polymer foam materials are typically constructed as a single slab that compresses elastically under an applied load, such as during a walking or running motion. Typically, the design of a single slab of polymer foam focuses on balancing cushioning properties, which are related to the softness and responsiveness of the slab when compressed under a gradient load. A polymer foam that provides too soft cushioning will reduce compressibility and the ability of the midsole to attenuate ground reaction forces after repeated compression. In contrast, a polymer foam that is too hard and therefore very responsive will sacrifice softness, resulting in a loss of comfort. Although different areas of a slab of polymer foam can vary in density, hardness, energy return, and material selection to balance the softness and responsiveness of the slab as a whole, it is difficult to achieve to produce a single slab of polymer foam that is loaded in a gradient manner from soft to responsive.

[0011] Attached photos

[0012] The drawings described herein are for illustrative purposes only of selected configurations and are not intended to limit the scope of the present disclosure.

[0013] Figure 1 is a perspective view of an article of footwear in accordance with the principles of the present disclosure;

[0014] Figure 2 yes Figure 1 An exploded view of the footwear item;

[0015] Figure 3 It is along Figure 1 The line 3-3 is intercepted Figure 1 a cross-sectional view of a cushioning member of an article of footwear;

[0016] Figure 4is a bottom perspective view of an article of footwear in accordance with the principles of the present disclosure;

[0017] Figure 5 is a partial perspective cross-sectional view of an article of footwear in accordance with the principles of the present disclosure;

[0018] Figure 6 yes Figure 4 A top view of a midsole of an article of footwear;

[0019] Fig. 7A is taken along the longitudinal axis of the article of footwear Figure 4 An exploded cross-sectional view of a sole structure of an article of footwear;

[0020] Figure 7B is taken across the heel area of ​​the footwear Figure 4 A cross-sectional view of a sole structure of an article of footwear;

[0021] Figure 8 is used to form Figure 3 A cross-sectional view of a tool used in a buffer member;

[0022] Fig. 9 yes Figure 8 A cross-sectional view of a tool showing the formation of Figure 3 a sheet of material of a buffer member and a barrier member;

[0023] Fig.10 yes Figure 8 Tools and Fig. 9 A cross-sectional view of a barrier member showing the barrier member receiving a certain amount of particulate matter;

[0024] Fig.11 yes Figure 8 A cross-sectional view of the tool, showing Fig. 9 The barrier member is fixed to another barrier member;

[0025] Fig.12 is a cross-sectional view of a cushioning member formed according to the principles of the present disclosure;

[0026] Fig.13 yes Fig.12 A perspective view of a buffer member;

[0027] Fig.14 is used to form Figure 3 A cross-sectional view of a tool for use in a cushioning member of the present invention, wherein the two halves of the tool are open and receive a sheet of material;

[0028] Fig.15 yes Fig.10a cross-sectional view of a tool showing a partially formed barrier member in a closed state and forming a sheet of material into a cushioning member;

[0029] Fig.16 yes Fig.15 a cross-sectional view of a partially formed barrier member;

[0030] Fig.17 is an exploded view of another barrier member shown in conjunction with a sheet of adhesive material and a barrier member;

[0031] Fig.18 is used to Fig.16 The barrier component is connected to Fig.17 a cross-sectional view of a tool used in another barrier member;

[0032] Fig.19 is a cross-sectional view of a partially formed pre-filled cushioning member;

[0033] Fig. 20 is used to Fig.19 a cross-sectional view of a die cutting tool forming a partially formed pre-filled cushioning member into a desired shape;

[0034] Fig.21 yes Fig.19 A top view of a pre-filled cushioning member showing a port for receiving an injection nozzle;

[0035] Fig. 22 yes Fig.19 A top view of a pre-filled cushioning member showing Fig.21 The port receives a corresponding nozzle of a filling device;

[0036] Fig.23 yes Fig.19 A top view of a pre-filled cushioning member showing Fig. 22 A nozzle is used to add particles into a chamber of a pre-filled cushioning member;

[0037] Fig.24 is a top view of a cushioning member filled with granules and sealed via a welding process;

[0038] Fig.25 yes Fig.24 a cross-sectional view of a filled cushioning member;

[0039] Fig.26 yes Fig.25 A perspective view of a cushioning member of FIG.

[0040] Fig. 27 is included Fig.26 A cross-sectional view of a sole structure of a cushioning member.

[0041] Corresponding reference numerals indicate corresponding parts throughout the drawings.

[0042] Detailed Description

[0043] Example configurations will now be described more fully with reference to the accompanying drawings. Example configurations are provided so that the present disclosure will be thorough and will fully convey the scope of the present disclosure to those of ordinary skill in the art. Specific details, such as examples of specific components, devices, and methods, are set forth to provide a thorough understanding of the configurations of the present disclosure. It will be apparent to those of ordinary skill in the art that specific details need not be employed, that example configurations may be implemented in many different forms, and that specific details and example configurations should not be construed as limiting the scope of the present disclosure.

[0044] The terms used herein are only for the purpose of describing specific exemplary configurations, and are not intended to be restrictive. As used herein, unless the context clearly indicates otherwise, the singular articles "a", "an" and "the" may also be intended to include plural forms. The terms "comprises", "comprising", "including" and "having" are inclusive, and thus specify the presence of features, steps, operations, elements and / or parts, but do not exclude the presence or addition of one or more other features, steps, operations, elements, parts and / or groups thereof. Unless specifically identified as an order of execution, the method steps, processes and operations described herein should not be interpreted as necessarily requiring them to be performed in the specific order discussed or shown. Additional or alternative steps may be adopted.

[0045] When an element or layer is referred to as being "on another element or layer," "engaged to," "connected to," "attached to," or "coupled to" another element or layer, it may be directly on, engaged, connected, attached to, or coupled to another element or layer, or there may be intervening elements or layers. Conversely, when an element is referred to as being "directly on another element or layer," "directly engaged to," "directly connected to," "directly attached to," or "directly coupled to" another element or layer, there may be no intervening elements or layers. Other words used to describe the relationship between elements should be interpreted in a similar manner (e.g., "between" versus "directly between," "adjacent" versus "directly adjacent," etc.). As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items.

[0046] The terms first, second, third, etc. can be used in this article to describe a variety of elements, components, regions, layers and / or sections. These elements, components, regions, layers and / or sections should not be limited by these terms. These terms can only be used to distinguish an element, component, region, layer or section from another region, layer or section. Terms such as "first", "second" and other numerical terms do not imply sequence or order unless the context clearly indicates. Therefore, the first element, first component, first region, first layer or first section discussed below can be referred to as the second element, second component, second region, second layer or second section, without departing from the teaching of the example configuration.

[0047] One aspect of the present disclosure provides a method for manufacturing a buffer member. The method includes forming a first barrier member from a first material, the first barrier member including a first compartment and a second compartment. The method also includes forming a second barrier member from a second material different from the first material. The first compartment is provided with a first quantity of particulate matter and the second compartment is provided with a second quantity of particulate matter. The method also includes covering the first compartment with a second barrier member and covering the second compartment with a second barrier member.

[0048] Embodiments of the present disclosure may include one or more of the following optional features. In some embodiments, forming the first barrier member includes forming a sheet of the first material into a shape that defines the first compartment and the second compartment. Forming the first barrier member from the first material may include forming the first barrier member from a polymer. In some examples, forming the first barrier member from the first material includes forming the first barrier member from thermoplastic polyurethane (TPU). Forming the second barrier member from the second material may include forming the second barrier member from spandex.

[0049] Providing the first quantity of particulate matter to the first compartment may include providing the first compartment with a quantity of particulate matter that is substantially the same as the second quantity of particulate matter. In some examples, providing the first quantity of particulate matter to the first compartment includes providing the first compartment with a quantity of particulate matter that is different from the second quantity of particulate matter. Providing the first quantity of particulate matter to the first compartment and providing the second quantity of particulate matter to the second compartment may include providing foam beads to the first compartment and the second compartment.

[0050] In some examples, providing the foam beads to the first compartment and the second compartment includes providing foam beads having a substantially spherical shape. Providing the foam beads to the first compartment and the second compartment may include providing foam beads having approximately the same size and shape. Alternatively, providing the foam beads to the first compartment and the second compartment may include providing foam beads having different sizes and shapes.

[0051] In some embodiments, forming the first barrier member by the first material and forming the second barrier member by the second material includes forming one of the first barrier member and the second barrier member by a permeable material, and forming the other of the first barrier member and the second barrier member by an impermeable material. For example, forming the first barrier member by the first material and forming the second barrier member by the second material may include forming the first barrier member by an impermeable material and forming the second barrier member by a permeable material. In some examples, providing a first quantity of particulate matter to the first compartment and providing a second quantity of particulate matter to the second compartment is performed before the first compartment and the second compartment are covered by the second barrier member. Alternatively, providing a first quantity of particulate matter to the first compartment and providing a second quantity of particulate matter to the second compartment is performed after the first compartment and the second compartment are covered by the second barrier member.

[0052] In some embodiments, the method includes attaching a second barrier member to a first barrier member. Attaching the second barrier member to the first barrier member may include attaching the second barrier member to the first barrier member at a first attachment location surrounding the first compartment, and may include attaching the second barrier member to the first barrier member at a second attachment location surrounding the second compartment. In some examples, attaching the second barrier member to the first barrier member includes attaching the second barrier member to the first barrier member via an adhesive. Attaching the second barrier member to the first barrier member via an adhesive may include attaching the second barrier member to the first barrier member via a hot melt adhesive. Forming the first barrier member from a first material may include applying heat and vacuum to a sheet of the first material. Additionally or alternatively, forming the first barrier member from a first material may include compression molding a sheet of the first material in a die.

[0053] In some examples, providing a first quantity of particulate matter to a first compartment and providing a second quantity of particulate matter to a second compartment includes injecting the first quantity of particulate matter between a first barrier member and a second barrier member at a first port in fluid communication with the first compartment. The method also includes injecting the second quantity of particulate matter between the first barrier member and the second barrier member at a second port in fluid communication with the second compartment. The first port and the second port may be sealed after the first quantity of particulate matter is injected into the first compartment and after the second quantity of particulate matter is injected into the second compartment. Sealing the first port and the second port may include attaching the first barrier member to the second barrier member using radio frequency (RF) welding.

[0054] Another aspect of the present disclosure provides a method for manufacturing a sole structure for an article of footwear. The method includes providing a first cavity and a second cavity to a midsole. A first barrier member is formed of a first material and includes a first compartment and a second compartment, and the second barrier member is formed of a second material. The method also includes providing a first quantity of particulate matter to the first compartment, providing a second quantity of particulate matter to the second compartment, and covering the first compartment with a second barrier member. The method also includes covering the second compartment with a second barrier member, positioning the first compartment in the first cavity, and positioning the second compartment in the second cavity.

[0055] Embodiments of the present disclosure may include one or more of the following optional features. In some embodiments, forming the first barrier member from a first material includes forming the first barrier member from a material different from a second material. Forming the first barrier member may include forming a sheet of the first material into a shape that defines a first compartment and a second compartment. Forming the first barrier member from a first material may also include forming the first barrier member from a polymer. Forming the first barrier member from a first material may also include forming the first barrier member from a thermoplastic polyurethane (TPU). In some examples, forming the second barrier member from a second material includes forming the second barrier member from a stretch fiber.

[0056] In some embodiments, providing the first quantity of particles to the first compartment includes providing the first compartment with a quantity of particles that is substantially the same as the second quantity of particles. Alternatively, providing the first quantity of particles to the first compartment may include providing the first compartment with a quantity of particles that is different from the second quantity of particles. Providing the first quantity of particles to the first compartment and providing the second quantity of particles to the second compartment may also include providing foam beads to the first compartment and the second compartment.

[0057] In some examples, providing the foam beads to the first compartment and the second compartment includes providing foam beads having a substantially spherical shape. In addition, providing the foam beads to the first compartment and the second compartment may include providing foam beads having approximately the same size and shape. Providing the foam beads to the first compartment and the second compartment may alternatively include providing foam beads having different sizes and shapes.

[0058] In some embodiments, forming the first barrier member by the first material and forming the second barrier member by the second material includes forming one of the first barrier member and the second barrier member by a permeable material, and forming the other of the first barrier member and the second barrier member by an impermeable material. For example, forming the first barrier member by the first material and forming the second barrier member by the second material may include forming the first barrier member by an impermeable material and forming the second barrier member by a permeable material. Providing a first quantity of particulate matter to the first compartment and providing a second quantity of particulate matter to the second compartment are performed before the first compartment and the second compartment are covered by the second barrier member. Alternatively, and in some examples, providing a first quantity of particulate matter to the first compartment and providing a second quantity of particulate matter to the second compartment are performed after the first compartment and the second compartment are covered by the second barrier member.

[0059] In some examples, the method includes attaching a second barrier member to a first barrier member. Attaching the second barrier member to the first barrier member may include attaching the second barrier member to the first barrier member at a first attachment location surrounding the first compartment, and may include attaching the second barrier member to the first barrier member at a second attachment location surrounding the second compartment. Attaching the second barrier member to the first barrier member may also include attaching the second barrier member to the first barrier member via an adhesive. Attaching the second barrier member to the first barrier member via an adhesive may include attaching the second barrier member to the first barrier member via a hot melt adhesive. Forming the first barrier member from the first material may include applying heat and vacuum to a sheet of the first material. Forming the first barrier member from the first material may alternatively include compression molding the sheet of the first material in a mold.

[0060] In some embodiments, providing a first quantity of particulate matter to the first compartment and providing a second quantity of particulate matter to the second compartment includes injecting the first quantity of particulate matter between the first barrier member and the second barrier member at a first port that is in fluid communication with the first compartment. The method may also include injecting the second quantity of particulate matter between the first barrier member and the second barrier member at a second port that is in fluid communication with the second compartment. The method may also include sealing the first port and the second port after injecting the first quantity of particulate matter into the first compartment and after injecting the second quantity of particulate matter into the second compartment. Sealing the first port and the second port may include attaching the first barrier member to the second barrier member using radio frequency (RF) welding. Finally, providing a midsole may include forming the midsole from a foamed polymer material.

[0061] Another aspect of the present disclosure provides a method of manufacturing a sole structure for an article of footwear. The method includes providing an outsole, providing a midsole, and positioning a cushioning member. The midsole includes a first cavity, a first hole formed in a first surface of the midsole and in fluid communication with the first cavity, and a second hole formed in a second surface of the midsole and in fluid communication with the first cavity. The second surface is disposed on a side of the midsole opposite the first surface and opposite the outsole. The cushioning member includes a first compartment, the first compartment containing a first quantity of particulate matter in the first cavity, whereby the first quantity of particulate matter is visible at the outsole through the second hole.

[0062] This aspect may include one or more of the following optional features. In some embodiments, positioning the buffer member within the first cavity includes positioning a buffer member having a first barrier member and a second barrier member, the first barrier member and the second barrier member cooperating to contain a first quantity of particulate matter within the first compartment. The method also includes forming the first barrier member to define the first compartment, and attaching the second barrier member to the first barrier member. In some examples, the method includes positioning an adhesive between the first barrier member and the second barrier member. Positioning the adhesive between the first barrier member and the second barrier member may include surrounding the first compartment with the adhesive. Positioning the adhesive between the first barrier member and the second barrier member may include positioning a hot melt adhesive.

[0063] In some examples, the method includes a first compartment that tapers in a direction away from the second barrier member. The method may also include covering the first compartment with the second barrier member to define a first internal cavity, and a first number of particulates are disposed in the first internal cavity. The method may also include forming the first barrier member from a first material, and forming the second barrier member from a second material different from the first material. Forming the first barrier member from the first material may include forming the first barrier member from a polymer. Forming the first barrier member from the first material may include forming the first barrier member from thermoplastic polyurethane (TPU). Forming the second barrier member from the second material may include forming the second barrier member from spandex.

[0064] In some examples, forming the first barrier member from a first material and forming the second barrier member from a second material includes forming one of the first material and the second material from a permeable material, and forming the other of the first material and the second material from an impermeable material. For example, forming the first barrier member from a first material and forming the second barrier member from a second material may include forming the first material from an impermeable material and forming the second material from a permeable material.

[0065] In some embodiments, positioning a cushioning member including a first compartment includes positioning a cushioning member including foam beads, wherein the first compartment includes a first quantity of particulate matter. Positioning the cushioning member including foam beads may include providing foam beads having a substantially spherical shape. Positioning the cushioning member including foam beads may include providing foam beads having substantially the same size and shape. Alternatively, positioning the cushioning member including foam beads may include providing foam beads having at least one of different sizes and different shapes.

[0066] In some examples, the method includes forming an outsole from one of a transparent material and a translucent material, the first quantity of particulate matter being visible through the material of the outsole at the second aperture. The method may also include providing a second cavity, a third aperture, and a fourth aperture to the midsole, the third aperture being formed in a first surface of the midsole and in fluid communication with the second cavity, the fourth aperture being formed in a second surface of the midsole and in fluid communication with the second cavity.

[0067] In some embodiments, the method includes providing a second compartment to the cushioning member, the second compartment being received by the second cavity of the midsole and containing a second amount of particulate matter, the second amount of particulate matter being visible at the outsole through the fourth hole. Positioning the cushioning member in the first cavity may also include positioning the outer surface of the cushioning member substantially flush with the first surface of the midsole. Positioning the cushioning member in the first cavity may also include extending the outer surface of the cushioning member from the first surface of the midsole to form at least one bulge. Forming at least one bulge may include forming at least one bulge at the first compartment.

[0068] refer to Figure 1 and Figure 2 , a footwear article 10 is provided. Figure 1 , article of footwear 10 includes an upper 12 and a sole structure 14 attached to upper 12. Article of footwear 10 may be divided into one or more portions. These portions may include a forefoot region 16, a midfoot region 18, and a heel region 20. Forefoot region 16 may correspond to the toes and the joints connecting the metatarsal bones and phalanges of the foot. Midfoot region 18 may correspond to the arch area of ​​the foot, and heel region 20 may correspond to the rear portion of the foot (including the calcaneus).

[0069] The upper 12 includes an inner surface defining an interior cavity 22 that receives and secures a foot for support on the sole structure 14. An ankle opening 24 located in the heel region 20 may provide access to the interior cavity 22. For example, the ankle opening 24 may receive a foot to secure the foot within the cavity 22 and facilitate entry and removal of the foot from the interior cavity 22. In some examples, one or more fasteners 26 extend along the upper 12 to adjust the fit of the interior cavity 22 around the foot while accommodating entry and removal of the foot from the interior cavity 22. The upper 12 may include holes 28, such as eyelets and / or other engagement features that receive fasteners 26, such as fabric or mesh loops. The fasteners 26 may include laces, straps, cords, hooks and loops, or any other suitable type of fasteners.

[0070] Upper 12 may additionally include a tongue portion 30 extending between interior cavity 22 and fastener 26. Upper 12 may be formed of one or more materials stitched or adhesively bonded together to form interior cavity 22. Suitable materials for the upper may include, but are not limited to, textiles, foams, leather, and synthetic leather. These materials may be selected and positioned to impart durability, breathability, wear resistance, flexibility, and comfort to the foot when the foot is disposed within interior cavity 22.

[0071] Continue to refer Figure 1 and Figure 2 , sole structure 14 is shown to include a midsole 32, an outsole 34, and a cushioning member 36. Figure 2 As shown, the midsole 32 is generally disposed between the outsole 34 and the upper 12 and supports the cushioning member 36 relative to the upper 12. That is, the midsole 32 can support the cushioning member 36 between the outsole 34 and the lower base 38 of the upper 12. The base 38 can be connected to the upper 12 via the stitching 40 ( Figure 2 ) is attached to upper 12, or, alternatively, may be integrally formed with the material of upper 12. For example, if upper 12 or a portion of upper 12 is formed of a knitted material, the knitted material may also form base 38, and, thus, base 38 opposite midsole 32 and cushioning member 36 may be integrally formed with upper 12.

[0072] If base 38 is formed separately from upper 12, base 38 may be attached to upper 12 via stitching 40. Regardless of whether base 38 is formed integrally with upper 12, or alternatively, is a separate component attached to upper 12, base 38 is generally disposed between midsole 32 and upper 12 and is formed of a flexible material. Forming base 38 from a flexible material allows base 38 to stretch and move when loaded by a wearer's foot during use. Allowing base 38 to flex and move in response to loads received by a wearer's foot during use allows the wearer's foot to compress midsole 32 and / or cushioning member 36, thereby providing a degree of comfort and cushioning to the wearer during use of article of footwear 10, as will be described in more detail below.

[0073] The midsole 32 may be formed of a polymer material such as, for example, a foamed polymer material. That is, the foamed polymer material may be ethyl vinyl acetate or polyurethane. Regardless of the specific construction of the midsole 32, the midsole 32 generally extends from a front end 42 of the upper 12 to a rear end 44 of the upper 12. In addition, the midsole 32 may extend between a medial side 46 of the upper 12 and a lateral side 48 of the upper 12. In this way, a portion of the midsole 32 may extend onto an outer surface 50 of the upper 12 near the junction of the upper 12 and the midsole 32. For example, the midsole 32 may include a protrusion 52 that extends at least partially around the periphery of the midsole 32 and extends from the midsole 32 to cover a portion of the outer surface 50 of the upper 12. When the material of the midsole is formed as Figure 2 When the shape is shown in FIG. 5 , the protrusion 52 can be formed integrally with the midsole 32 .

[0074] Special References Figure 2 and Figure 3 , the midsole 32 is shown to include a forefoot cavity 54, a midsole cavity 56, and a heel cavity 58. Figure 2 and Figure 3As shown, cavities 54, 56, 58 are arranged along the length of sole structure 14, such that forefoot cavity 54 is arranged in forefoot region 16, midfoot cavity 56 is arranged in midfoot region 18, and heel cavity 58 is arranged in heel region 20. Cavities 54, 56, 58 are formed in a first surface 60 of midsole 32, which is opposite base 38 of upper 12. First surface 60 is recessed from upper surface 62 of midsole 32 to provide clearance for a portion of cushioning member 36 when cushioning member 36 is arranged within midsole 32, as will be described in greater detail below. In the illustrated example, forefoot cavity 54 has a front end arranged between a ball portion and a toe portion in the forefoot region.

[0075] Midsole 32 additionally includes a second surface 64 located on a side of midsole 32 opposite first surface 60. Second surface 64 is opposite outsole 34 and provides a surface to which outsole 34 may be attached.

[0076] The cavities 54, 56, 58 are each associated with a first hole and a second hole of the midsole 32, which respectively allow for insertion of the cushioning member 36 into the midsole 32 and for visibility of the cushioning member 36 at the outsole 34 once the cushioning member 36 is inserted into the midsole 32. Specifically, the forefoot cavity 54 defines a first hole 66 at the junction of the forefoot cavity 54 and the first surface 60. The first hole 66 defines an opening of the forefoot cavity 54 at the first surface 60 and generally defines a shape of the forefoot cavity 54 at the first surface 60. The forefoot cavity 54 additionally includes a second hole 68 disposed at an end of the forefoot cavity 54 opposite the first hole 66 and formed through a bottom wall 70 of the midsole 32 within the forefoot cavity 54. In one configuration, the bottom wall 70, and therefore the second hole 68, may extend in a plane that is substantially parallel to the plane defined by the first surface 60.

[0077] As described, the opening of forefoot cavity 54 at first surface 60 is generally defined by the shape and size of first aperture 66, and further, a bottom portion of forefoot cavity 54 disposed at an end of forefoot cavity 54 opposite first aperture 66 is generally defined by bottom wall 70. Forefoot cavity 54 is further defined by a series of side surfaces 72 extending from bottom wall 70 around the perimeter of forefoot cavity 54 to the junction of first aperture 66 and first surface 60. Thus, side surfaces 72 cooperate with one another to surround forefoot cavity 54 between bottom wall 70 and first aperture 66 and define the shape of forefoot cavity 54.

[0078] The midfoot cavity 56 is disposed generally along the longitudinal axis (F) of the sole structure 14 between the forefoot cavity 54 and the heel cavity 58 ( Figure 3). Midshoe cavity 56 includes a first hole 74 that defines an opening of midshoe cavity 56 at first surface 60. Midshoe cavity 56 also includes a second hole 76 that is disposed at an end of midshoe cavity 56 opposite first hole 74 and formed through bottom wall 78 of midsole 32. Like bottom wall 70 associated with forefoot cavity 54, bottom wall 78 associated with midshoe cavity 56 defines a bottom of midshoe cavity 56 and, therefore, a bottom surface of midshoe cavity 56. Side surface 80 extends between first hole 74 and bottom wall 78 to define the overall shape of midshoe cavity 56. As such, side surface 80 cooperates with bottom wall 78 to define the overall shape of midshoe cavity 56 between first hole 74 and bottom wall 78.

[0079] The heel cavity 58 is disposed closer to the rear end 44 than the forefoot cavity 54 and the midfoot cavity 56, and includes a first aperture 82 formed in the first surface 60 of the midsole 32. The first aperture 82 defines an opening of the heel cavity 58 and generally defines the shape of a perimeter of the heel cavity 58 at the first surface 60. The heel cavity 58 additionally includes a second aperture 84 disposed at an end of the heel cavity 58 opposite the first aperture 82 and formed through a bottom wall 86 of the heel cavity of the midsole 32. As with the forefoot cavity 54 and the midfoot cavity 56, the bottom wall 86 is disposed at an end of the heel cavity 58 opposite the first aperture 82 and serves to define a bottom surface of the heel cavity 58. A side surface 88 extends from the bottom wall 86 to the first aperture 82 and cooperates to define a perimeter of the heel cavity 58.

[0080] As depicted, each of the forefoot cavity 54, the midfoot cavity 56, and the heel cavity 58 includes respective side surfaces 72, 80, 88 that define the shape of each cavity 54, 56, 58. Figure 3 As shown, one or more of the side surfaces 72, 80, 88 may be tapered in a direction from the respective first aperture 66, 74, 82 to the respective bottom wall 70, 78, 86. By providing the side surfaces 72, 80, 88 with a taper extending from the respective first aperture 66, 74, 82 to the respective bottom wall 70, 78, 86, the cross-sectional area of ​​the cavity 54, 56, 58 generally decreases in a direction extending from the first surface 60 of the midsole 32 to the second surface 64 of the midsole 32. Figure 3 As shown, the degree to which the side surfaces 72, 80, 88 taper in a direction extending from the first surface 62 to the second surface 64 may vary between the cavities 54, 56, 58. For example, the forefoot cavity 54 may include a side surface 72 that has a more gradual taper than any of the side surfaces 80, 88, respectively, of the midfoot cavity 56 and the heel cavity 58. Additionally, the side surface 88 of the heel cavity 58 may include a lesser taper than any of the side surfaces 72, 80, respectively, of the forefoot cavity 54 and the midfoot cavity 56.

[0081] Special References Figure 3 , the forefoot cavity 54, the midfoot cavity 56, and the heel cavity 58 are shown as being formed into the material of the midsole 32 at spaced-apart locations along the longitudinal axis (F) of the sole structure 14. Thus, a first wall 90 of the midsole 32 may extend between the forefoot cavity 54 and the midfoot cavity 56, and a second wall 92 may extend between the midfoot cavity 56 and the heel cavity 58. Thus, the first wall 90 may be used to separate the forefoot cavity 54 from the midfoot cavity 56, while the second wall 92 may be used to separate the midfoot cavity 56 from the heel cavity 58 in a direction extending along the longitudinal axis (F) of the sole structure 14. As will be described in more detail below, the walls 90, 92 help maintain a desired position of the cushioning member 36 relative to the midsole 32, and thus help provide a desired cushioning effect to the wearer's foot during use of the article of footwear 10.

[0082] Special References Figure 2 and Figure 3 , the cushioning member 36 is shown to include a first barrier member 94, a second barrier member 96, and a quantity of particulate matter 98 contained within the cushioning member 36. In one configuration, the second barrier member 96 is attached to the first barrier member 94 to contain the particulate matter 98 generally between the second barrier member 96 and the first barrier member 94. For example, the cushioning member 36 may include a first compartment 100, a second compartment 102, and a third compartment 104, each compartment containing a first quantity of particulate matter 98, a second quantity of particulate matter 98, and a third quantity of particulate matter 98, respectively.

[0083] First barrier member 94 and second barrier member 96 may be formed of a flexible material that allows first barrier member 94 and second barrier member 96 to stretch and move during use of article of footwear 10 when sole structure 14 is subjected to forces from the wearer's foot. In one configuration, first barrier member 94 and second barrier member 96 are formed of different materials. For example, first barrier member 94 may be formed of a polymer material such as thermoplastic polyurethane (TPU). Forming first barrier member 94 from TPU allows first barrier member 94 to be formed of an impermeable material and, in some configurations, allows first barrier member 94 to be formed of an optically transparent and / or translucent material.

[0084] The second barrier member 96 can be formed of a flexible material such as, for example, spandex. Forming the second barrier member 96 of a flexible material such as spandex also allows the second barrier member 96 to be permeable. Forming the second barrier member 96 of a permeable material allows fluid to pass through the second barrier member 96 to communicate with the first compartment 100, the second compartment 102, and the third compartment 104, thereby allowing air circulation from the area outside the cushioning member 36 to enter the compartments 100, 102, 104.

[0085] The second barrier member 96 can be attached to the first barrier member 94 via an adhesive 106. The adhesive 106 can be a hot melt adhesive and can surround the perimeter of each of the first compartment 100, the second compartment 102, and the third compartment 104. In this way, the adhesive 106 bonds the material of the second barrier member 96 to the material of the first barrier member 94 between each of the compartments 100, 102, 104, thereby defining an internal cavity within each compartment 100, 102, 104 between the second barrier member 96 and the first barrier member 94.

[0086] Attaching the second barrier member 96 to the first barrier member 94 around the perimeter of each compartment 100, 102, 104 such that the adhesive 106 completely surrounds each compartment 100, 102, 104 creates a web member 108 in the area where the second barrier member 96 is attached to the first barrier member 94. The web member 108 can extend between each compartment 100, 102, 104 and around the outer perimeter of the cushioning member 36, as shown. Fig. 9 32. The web member 108 may include a thickness that is substantially equal to the depth of the first surface 60 of the midsole 32 relative to the upper surface 62 of the midsole 32. In addition, the overall shape of the cushioning member 36 defined by the web member 108 at the perimeter of the cushioning member 36 may include a shape that is substantially equal to the shape of the first surface 60 formed in the upper surface 62. Therefore, when the cushioning member 36 is inserted into the midsole, the upper surface 110 of the cushioning member 36 is substantially flush with the upper surface 62 of the midsole 32, thereby providing a uniform surface for receiving the base 38. Providing a uniform surface opposite the base 38 provides a degree of comfort to the wearer's foot by preventing the wearer from feeling the transition or junction between the midsole 32 and the cushioning member 36.

[0087] Special References Figure 3, the cushioning member 36 is shown as including different amounts of particulate matter 98 disposed within the compartments 100, 102, 104. For example, the first compartment 100, the second compartment 102, and the third compartment 104 are each shown as including different amounts of particulate matter 98. That is, the first compartment 100 disposed with the forefoot cavity 54 and, therefore, with the forefoot region 16 of the sole structure 14 includes less particulate matter 98 than the second compartment 102 and the third compartment 104. Conversely, the third compartment 104 received by the heel cavity 58 of the midsole 32 and, therefore, located in the heel portion 20 of the sole structure 14 receives a greater amount of particulate matter 98 than the second compartment 102 and the first compartment 100. Although the compartments 100, 102, 104 are described and shown as receiving different amounts of particulate matter 98, each compartment 100, 102, 104 may receive approximately the same amount of particulate matter 98. Additionally, one or more of the compartments 100, 102, 104 may receive a volume of particulate matter 98 that creates a protrusion 112 ( Fig. 9 ). For example, the second compartment 102 and the third compartment 104 of the cushioning member 36 may each include a protrusion 112 extending from a nominal plane defined by the second barrier member 96 at the location of the second compartment 102 and the third compartment 104. That is, the protrusion 112 extends from a nominal plane defined by the web member 108.

[0088] Regardless of the amount of particulate matter 98 disposed within the respective compartments 100, 102, 104, the particulate matter 98 can be used to enhance the functionality and cushioning properties provided by the material of the midsole 32. For example, the particulate matter 98 contained within the compartments 100, 102, 104 can include foam beads having a substantially spherical shape. In addition, the foam beads defining the particulate matter 98 can have substantially the same size and shape, or, alternatively, can have at least one of different sizes and different shapes. Regardless of the specific size and shape of the particulate matter 98, the particulate matter 98 cooperates with the outsole 34 and the midsole 32 to provide cushioning and responsiveness to the article of footwear 10 during use.

[0089] Cushioning member 36 may be inserted into midsole 32 such that first compartment 100 is received by forefoot cavity 54, second compartment 102 is received by midfoot cavity 56, and third compartment 104 is received by heel cavity 58. Once cushioning member 36 is disposed within midsole 32, surface 110 of cushioning member 36 is substantially flush with upper surface 62 of midsole 32 at web member 108 that defines the perimeter of cushioning member 36. In this manner, second barrier member 96 cooperates with the material of midsole 32 at upper surface 62 of midsole 32 to provide a generally uniform surface against which base 38 rests when sole structure 14 is attached to upper 12.

[0090] The outsole 34 may be formed of a transparent or translucent material and may include one or more discrete portions that are separated from one another. The outsole 34 may be formed of a durable material (such as, for example, rubber) and may be attached to the second surface 64 of the midsole 32. Individual portions of the outsole 34 may be attached to the second surface 64 of the midsole 32 near the second holes 68, 76, 84 associated with the forefoot cavity 54, the midsole cavity 56, and the heel cavity 58, respectively. These portions of the outsole 34 may be separated from one another along the length of the sole structure 14 in a direction substantially parallel to the longitudinal axis (L). Although the outsole 34 is described and shown as including individual portions spaced apart from one another, the outsole 34 may alternatively have an integral construction that generally extends across the entire second surface 64 of the midsole 32 so that the outsole 34 extends continuously between the front end 42 and the rear end 44 and between the medial side 46 and the lateral side 48. Regardless of the specific configuration of outsole 34 (ie, integral or discrete portions), outsole 34 may include a tread 35 extending from outsole 34 to provide increased traction with a ground surface during use of article of footwear 10 .

[0091] Forming the outsole 34 from a transparent or translucent material allows the cavities 54, 56, 58 to be viewed from the outsole 34 when the outsole 34 is attached to the midsole 32 at the second surface 64. Furthermore, because the compartments 100, 102, 104 substantially fill the respective cavities 54, 56, 58 of the midsole 32, the compartments 100, 102, 104, and thus the particulate matter 98 disposed therein, are likewise visible through the material of the outsole 34 at the second apertures 68, 76, 84 of the midsole 32. Thus, the particulate matter 98 residing within the respective compartments 100, 102, 104 of the cushioning member 36 are visible through the outsole 34 at the second apertures 68, 76, 84 associated with the respective cavities 54, 56, 58.

[0092] The sole structure 14 may be attached to the upper 12 via a suitable adhesive 114 ( Figure 3 ). For example, adhesive 114 may extend between protrusion 52 of midsole 32 and exterior surface 50 of upper 12 and attach protrusion 52 of midsole 32 to exterior surface 50 of upper 12. Additionally, adhesive 114 may attach web member 108 of cushioning member 36 to midsole 32 at the junction of web member 108 and first surface 60 of midsole 32.

[0093] refer to Figure 4-7B, an article of footwear 10a is provided and includes an upper 12 and a sole structure 14a attached to the upper 12. Given that the structure and function of components associated with the article of footwear 10a are substantially similar relative to the article of footwear 10a, the same reference numerals are used below and in the accompanying drawings to identify the same components, while the same reference numerals with letter extensions are used to identify those components that have been modified.

[0094] Continue to refer Figure 4 , sole structure 14a is shown to include a midsole 32a, an outsole 34a, and a cushioning member 36a. Figure 5 As shown, midsole 32a is generally disposed between outsole 34a and upper 12 and supports cushioning member 36a relative to upper 12. That is, midsole 32a can support cushioning member 36a between outsole 34a and lower base 38 of upper 12.

[0095] As in the above example, Figure 4-7B The midsole 32a is shown to include a ball cavity 54a, a midsole cavity 56a, and a heel cavity 58a. Here, the midsole 32a also includes a T The toe cavity 116 in the shoe. Figure 5-7B As shown, chambers 54a, 56a, 58a, 116 are arranged along the length of sole structure 14a, such that toe chamber 116 is arranged in the toe region 16 of forefoot region 16 adjacent to the front end 42 of upper 12. T In the embodiment of the present invention, the ball chamber 54a is disposed in the ball region 16 of the forefoot region 16 adjacent to the toe chamber 116. B 1, midsole cavity 56a is disposed in midsole region 18, and heel cavity 58a is disposed in heel region 20 adjacent rear end 44. Cavities 54a, 56a, 58a, 116 are formed in a first surface 60 of midsole 32a that is opposite base 38 of upper 12. First surface 60 is recessed from upper surface 62 of midsole 32a to provide clearance for a portion of cushioning member 36a when cushioning member 36a is disposed within midsole 32a, as will be described in greater detail below.

[0096] Cavities 54a, 56a, 58a, 116 are each associated with a first aperture and a second aperture of midsole 32a that respectively permit insertion of cushioning member 36a into midsole 32a and visibility of cushioning member 36a at outsole 34a after insertion of cushioning member 36a into midsole 32a.

[0097] Specifically, the ball cavity 54a defines a first aperture 66a at the junction of the ball cavity 54a and the first surface 60. The first aperture 66a defines an opening of the ball cavity 54a at the first surface 60 and generally defines a shape of the ball cavity 54a at the first surface 60. The ball cavity 54a also includes a second aperture 68a disposed at an end of the ball cavity 54a opposite the first aperture 66a and formed through a bottom wall 70a of the midsole 32a.

[0098] As described, the opening of the ball cavity 54a at the first surface 60 is generally defined by the shape and size of the first aperture 66a, and further, the bottom portion of the ball cavity 54a disposed at an end of the ball cavity 54a opposite the first aperture 66a is generally defined by the bottom wall 70a. The ball cavity 54a is also defined by a series of side surfaces 72a extending from the bottom wall 70a around the perimeter of the ball cavity 54a to the junction of the first aperture 66a and the first surface 60. Thus, the side surfaces 72a cooperate with each other to define the shape of the ball cavity 54a between the bottom wall 70a and the first aperture 66a.

[0099] The midfoot cavity 56a is generally disposed along the longitudinal axis (F) of the sole structure 14a between the ball cavity 54a and the heel cavity 58a. Figure 6 ). The mid-shoe cavity 56a includes a first hole 74a that defines an opening of the mid-shoe cavity 56a at the first surface 60. However, unlike the above examples, the bottom end of the mid-shoe cavity 56a is enclosed by the bottom wall 78a of the midsole 32a, so that the mid-shoe cavity 56a ends. The side surface 80a extends between the first hole 74a and the bottom wall 78a to define the overall shape of the mid-shoe cavity 56a. In this way, the side surface 80a cooperates with the bottom wall 78a to define the overall shape of the mid-shoe cavity 56a between the first hole 74a and the bottom wall 78a.

[0100] The heel cavity 58a is disposed closer to the rear end 44 than the ball cavity 54a and the midsole cavity 56a and includes a first aperture 82a formed in the first surface 60 of the midsole 32a. The first aperture 82a defines an opening of the heel cavity 58a and generally defines the shape of the perimeter of the heel cavity 58a at the first surface 60. The heel cavity 58a additionally includes a second aperture 84a disposed at an end of the heel cavity 58a opposite the first aperture 82a and formed through a bottom wall 86 of a third cavity of the midsole 32a. As with the ball cavity 54a and the midsole cavity 56a, the bottom wall 86 is disposed at an end of the heel cavity 58a opposite the first aperture 82a and serves to define a bottom surface of the heel cavity 58a. A side surface 88a extends from the bottom wall 86 to the first aperture 82a and cooperates to define the perimeter of the heel cavity 58a.

[0101] The toe cavity 116 is disposed in the toe region 16 between the ball cavity 54a and the front end 42.T 1 and includes a first hole 118 formed in the first surface 60 of the midsole 32a. The first hole 118 defines an opening of the toe cavity 116 and generally defines the shape of the perimeter of the toe cavity 116 at the first surface 60. The toe cavity 116 additionally includes a second hole 120 disposed at an end of the toe cavity 116 opposite the first hole 118 and formed through a bottom wall 122 of the toe cavity 116 of the midsole 32a. The bottom wall 122 is disposed at an end of the toe cavity 116 opposite the first hole 118 and is used to define a bottom surface of the toe cavity 116. The side surface 124a extends from the bottom wall 122 to the first hole 118 and cooperates to define the perimeter of the toe cavity.

[0102] As described above, each of the ball cavity 54a, midfoot cavity 56a, heel cavity 58a, and toe cavity 116 includes respective side surfaces 72a, 80a, 88a, 124 that define the shape of each cavity 54a, 56a, 58a, 116. Fig. 7A As shown, one or more of the side surfaces 72a, 80a, 88a, 124 may be tapered in a direction from the respective first aperture 66a, 74a, 82a, 118 to the respective bottom wall 70a, 78a, 86a, 122. By providing the side surfaces 72a, 80a, 88a, 124 with a taper extending from the respective first aperture 66a, 74a, 82a to the respective bottom wall 70a, 78a, 86a, the cross-sectional area of ​​the cavity 54a, 56a, 58a, 116 generally decreases in a direction extending from the first surface 60 of the midsole 32a to the second surface 64 of the midsole 32a.

[0103] Special References Fig. 7A and Figure 7B , a toe cavity 116, a ball cavity 54a, a midsole cavity 56a, and a heel cavity 58a are shown as being formed in the material of the midsole 32a at spaced locations along the longitudinal axis (F) of the sole structure 14a. Thus, a first wall 90a of the midsole 32a may extend between the toe cavity 116 and the ball cavity 54a, a second wall 92a may extend between the ball cavity 54a and the midsole cavity 56a, and a third wall 93a may extend between the midsole cavity 56a and the heel cavity 58a.

[0104] One or more of the cavities 54a, 56a, 58a, 116 may include structural features configured to change the physical properties of the midsole 32a. For example, in the illustrated example, the heel cavity 58a is surrounded by one or more struts 126 that project downwardly around the rear end 44. Adjacent ones of the struts 126 are spaced apart from one another and are configured to interface with the outsole 34a when the sole structure 14a is assembled, thereby providing support for the article of footwear 10a in the heel region 20. Figure 5 As shown, the particulate matter 98 can migrate from the heel cavity 58a and into the peripheral region 127 surrounding the stud 126 to provide cushioning between the outsole 34a and the midsole 32a at the rear end 44.

[0105] Continue to refer Figure 5 and Figure 7B , the cushioning member 36a is shown to include a first barrier member 94a, a second barrier member 96a, and a certain amount of particulate matter 98 contained within the cushioning member 36a. In one configuration, the second barrier member 96a is attached to the first barrier member 94a to generally contain the particulate matter 98 between the second barrier member 96a and the first barrier member 94a. For example, the cushioning member 36a may include a first compartment 100a, a second compartment 102a, and a third compartment 104a, each compartment containing a first amount of particulate matter 98, a second amount of particulate matter 98, and a third amount of particulate matter 98, respectively.

[0106] All the particles 98 are distributed in the three compartments 100, 102, 104. Figure 1-Figure 3 Unlike the example Figure 4-7B In the example of FIG. 3 , the cushioning member 36a is configured as a hybrid cushioning member 36a, wherein a first portion of the particulate matter 98 is contained within the compartments 100a, 102a, 104a formed by joining the first barrier layer 94a and the second barrier layer 96a, and a second portion of the particulate matter is directly disposed within one of the cavities 54a, 56a, 58a, 116 and is sealed within the cavity by the second barrier layer 96a. For example, Figure 4-7B As shown in the example of FIG. 1 , the cushioning member 36 a may be provided in the toe area 16 T , ball area 16 B A series of three compartments are formed in the midfoot region 18, while the particulate matter in the heel region 20 is disposed directly within the heel cavity 58a formed in the heel region 20. Here, the second barrier layer 96a extends over the heel cavity 58a to enclose the particulate matter 98 therein.

[0107] Although the shape and configuration of the cushioning member 36a may be different from Figure 1-Figure 3104a, 102a, 104a, but cushioning member 36a may be formed using materials and methods similar to those described above with respect to cushioning member 36. That is, first barrier member 94a and second barrier member 96a may be formed from a flexible material that allows first barrier member 94a and second barrier member 96a to stretch and move during use of article of footwear 10a when sole structure 14a is subjected to forces from the wearer's foot. Second barrier member 96a may be attached to first barrier member 94a via adhesive 106. Attaching second barrier member 96a to first barrier member 94a around the perimeter of each compartment 100a, 102a, 104a such that adhesive 106 completely surrounds each compartment 100a, 102a, 104a creates web member 108 in the area where second barrier member 96a is attached to first barrier member 94a.

[0108] Special References Fig. 7A and Figure 7B , cushioning member 36a is shown as including different amounts of particulate matter 98 disposed within compartments 100a, 102a, 104a. For example, first compartment 100a, second compartment 102a, and third compartment 104a are each shown as including different amounts of particulate matter 98. That is, disposed with toe cavity 116 and thus with toe region 16 of sole structure 14a. T The first compartment 100a, which is arranged together, includes less particulate matter 98 than the second compartment 102a and the third compartment 104a. In contrast, the third compartment 104a, which is received by the midsole cavity 56a of the midsole 32a and is therefore located in the midsole region 18 of the sole structure 14a, receives a greater amount of particulate matter 98 than the second compartment 102a and the first compartment 100a. Although the compartments 100a, 102a, 104a are described and shown as receiving different amounts of particulate matter 98, each compartment 100a, 102a, 104a may receive approximately the same amount of particulate matter 98. In addition, one or more of the compartments 100a, 102a, 104a may receive a volume of particulate matter 98 that creates a protrusion 112 ( Figure 5 ). For example, the second compartment 102a and the third compartment 104a of the cushioning member 36a may each include a protrusion 112 that extends from a nominal plane defined by the second barrier member 96a at the location of the second compartment 102a and the third compartment 104a. That is, the protrusion 112 extends from a nominal plane defined by the web member 108.

[0109] As described above, the compartments 100a, 102a, 104a are configured to be received within each of the toe cavity 116, the ball cavity 54a, and the mid-shoe cavity 56a. However, the heel cavity 58a does not receive a corresponding cavity of the cushioning member 36a. Instead, the particulate matter 98 is provided directly to the heel cavity 58a. Here, the particulate matter 98 is accommodated by the side surface 88 of the heel cavity 58a in the lateral direction, while the second hole 84a on the bottom of the heel cavity 58a is enclosed by a portion of the outsole 34a, and the first hole 82a on the top of the heel cavity 58a is enclosed by a portion of the second barrier member 96a.

[0110] refer to Figure 5 and Fig. 7A , cushioning member 36a includes a first barrier layer 94a forming a lower portion of cushioning member 36a, cushioning member 36a includes compartments 100a, 102a, 104a. Second barrier member 96a includes a first portion 128 extending over each of compartments 100a, 102a, 104a and joined to first barrier member 94a to form a web member 108 in forefoot region 16 and midfoot region 18. In addition, second barrier member 96a includes a second portion 130 extending beyond first barrier member 94a and through heel region 20 to cover heel cavity 58a. Thus, unlike first portion 128 attached to first barrier member 94a along web member 108, second portion 130 of second barrier member 96a is directly attached to midsole 32a and surrounds the periphery of first aperture 82a of heel cavity 58a. In some examples, second portion 130 is attached to first surface 60 of midsole 32a such that the portion of upper surface 110 of cushioning member 36a formed by second portion 130 is substantially flush with upper surface 62 of midsole 32a.

[0111] The outsole 34a may be formed of a transparent or translucent material and may include one or more discrete portions that are separated from each other. The outsole 34a may be formed of a durable material (such as, for example, rubber) and may be attached to the second surface 64 of the midsole 32a. Individual portions of the outsole 34a may be attached to the second surface 64 of the midsole 32a near the second holes 120, 68a, 84a associated with the toe cavity 116, the ball cavity 54a, and the heel cavity 58a, respectively. These portions of the outsole 34a may be separated from each other along the length of the sole structure 14a in a direction substantially parallel to the longitudinal axis (F). Although the outsole 34a is described and shown as including individual portions spaced apart from each other, the outsole 34a may alternatively have an integral construction that generally extends across the entire second surface 64 of the midsole 32a so that the outsole 34a extends continuously between the front end 42 and the rear end 44 and between the medial side 46 and the lateral side 48. Regardless of the specific configuration of outsole 34a (ie, integral or discrete portions), outsole 34a may include tread 35 extending from outsole 34a to provide increased traction with a ground surface during use of article of footwear 10a.

[0112] Incorporating the cushioning member 36, 36a into the footwear article 10, 10a provides a degree of comfort and cushioning for the wearer's foot during use. For example, and as described above, the base 38, 38a and the second barrier member 96, 96a of the cushioning member 36, 36a are formed of a flexible material. Therefore, when a force is applied by the wearer's foot on the base 38, 38a during use of the footwear article 10, 10a, the force causes the material of the base 38, 38a and the second barrier member 96, 96a to bend and stretch, thereby allowing the wearer's foot to engage the particles 98 disposed in the cavity 54, 54a, 56, 56a, 58, 58a, 116 and displace the particles 98 disposed in the cavity 54, 54a, 56, 56a, 58, 58a, 116. In this way, the particles 98 exert a force on the material of the first barrier member 94, 94a, causing the first barrier member 94, 94a to bend and stretch as well. Such movement of the first barrier member 94, 94a compresses the material of the midsole 32, 32a generally surrounding the compartments 100, 100a, 102, 102a, 104, 104a or cavities 54, 54a, 56, 56a, 58, 58a, 116, which in turn absorbs forces associated with walking or running motions.

[0113] The bending and stretching of the materials of the base 38, 38a, the first barrier member 94, 94a and the second barrier member 96, 96a and the compression of the material of the midsole 32, 32a provide a certain degree of cushioning and comfort for the wearer when wearing the footwear 10, 10a. In addition, the interaction between the wearer's foot and the particles 98 - allowed by the generally flexible nature of the materials of the base 38, 38a and the second barrier member 96, 96a - also provides cushioning for the wearer's foot. In addition, since the particles 98 are allowed to move relative to each cavity 54, 54a, 56, 56a, 58, 58a, 116 and move within each cavity 54, 54a, 56, 56a, 58, 58a, 116, the particles 98 conform to the shape of the wearer's foot and thus provide a certain degree of customized cushioning specific to the shape of the wearer's foot. In addition, because the particulate matter 98 is allowed to move relative to and within the first compartment 100, 100a, the second compartment 102, 102a, and the third compartment 104, 104a, and / or the heel cavity 58a, the shape of the substrate 38, 38a and the second barrier member 96, 96a is dynamic and largely based on the load applied at the substrate 38, 38a at any given time. In other words, the support provided by the particulate matter 98 disposed within the cavity 54, 54a, 56, 56a, 58, 58a, 116 moves and shifts in response to the force applied at the substrate 38, 38a. In this way, as the wearer applies forces at different locations on the substrate 38, 38a, the effective shape of the substrate 38, 38a and the second barrier member 96, 96a continuously changes, thereby causing the particulate matter 98 to shift and move relative to and within the cavities 54, 54a, 56, 56a, 58, 58a, 116. In this way, the cushioning members 36, 36a provide cushioning and support to the sole structure 14, 14a, and thus the article of footwear 10, 10a, that dynamically responds to the applied forces and automatically conforms to the shape of the wearer's foot, thereby providing a customized and personal cushioning system for the wearer.

[0114] about Figure 4-7B In the example of sole structure 14a in FIG. 1 , providing particulate matter directly to one of the cavities (e.g., heel cavity 58a) provides particulate matter 98 with increased degrees of freedom compared to particulate matter 98 enclosed within a compartment of cushioning members 36, 36a. For example, where one of the cavities is formed with a structural feature (such as a post or cross member), particulate matter 98 will be unconstrained within the cavity and free to migrate around the internal structure.

[0115] Specific reference Figure 8-Figure 13, the method of manufacturing the buffer member 36 will be described in detail. Figure 1-Figure 3 The buffer member 36 provides a method for illustrating the diagram, but it should be understood that the method can also be applied to form Figure 4-7B As will be described in detail below, the buffer member 36a is formed Figure 8-Figure 11 The method of the cushioning member 36 shown in utilizes a thermoforming process to form the first barrier member 94, and further, after the particulate matter 98 is added to the first compartment 100, the second compartment 102, and the third compartment 104, a heat press is used to attach the second barrier member 96 to the first barrier member 94.

[0116] like Figure 8 As shown, tool 200 may be used to form a sheet of material 202 into a first barrier member 94. For example, and as described above, the first barrier member 94 may be formed of thermoplastic polyurethane (TPU). Thus, sheet of material 202 may be a sheet of TPU material. Tool 200 may include a forefoot cavity 204, a midfoot cavity 206, and a heel cavity 208. Forefoot cavity 204 may include a curved surface 210 that provides a first compartment 100 with ... Fig. 9 Similarly, the mid-shoe cavity 206 may correspond to the second compartment 102, and the heel cavity 208 may correspond to the third compartment 104, whereby the mid-shoe cavity 206 includes an arcuate surface 212 that conforms to the shape of the second compartment 102, and the heel cavity 208 includes an arcuate surface 214 that conforms to the shape of the third compartment 104. The tool 200 may additionally include a series of vacuum ports 216 ( Fig. 9 ).

[0117] In operation, the material piece 202 may be placed adjacent to the tool 200 such that the material piece 202 is opposite the forefoot cavity 204, the midfoot cavity 206, and the heel cavity 208. Heat may be applied to the material piece 202 prior to and / or during the application of the vacuum force to the material piece 202 via the vacuum port 216. For example, the material piece 202 may be heated by an external heat source (not shown) and / or via a heating element (not shown) disposed within the tool 200 to heat the material piece 202 while the material piece 202 is being drawn into the cavities 204, 206, 208 via the vacuum 218 and the vacuum port 216.

[0118] like Fig. 9, forming the sheet of material 202 such that the sheet of material 202 is drawn into the cavities 204, 206, 208 to form the respective compartments 100, 102, 104 of the cushioning member 36. Specifically, the material of the sheet of material 202 engages the arcuate surfaces 210, 212, 214 to form the sheet of material 202 into the respective compartments 100, 102, 104 of the cushioning member 36. Heat and pressure applied to the sheet of material 202 (i.e., by the vacuum (218) and the internal and / or external heat sources) causes the sheet of material 202 to substantially conform to the shape of the tool 200 at the cavities 204, 206, 208, thereby forming the first barrier member 94 of the cushioning member 36. Once sheet of material 202 is formed into the shape of first barrier member 94 , the material of first barrier member 94 is allowed to cool so that the material of first barrier member 94 retains the shape of tool 200 as defined by arcuate surfaces 210 , 212 , 214 of cavities 204 , 206 , 208 , respectively.

[0119] As described above, once sheet 202 is formed into the shape of first barrier member 94, compartments 100, 102, 104 may be filled with particulate matter 98. As described above, particulate matter 98 may include foam beads having the same and / or different shapes to provide cushioning member 36 with the ability to provide cushioning to article of footwear 10 after second barrier member 96 is attached to first barrier member 94 and cushioning member 36 is inserted into midsole 32.

[0120] The pellets 98 may be added to the compartments 100, 102, 104 by placing the pellets 98 into each compartment 100, 102, 104 via a series of hoppers. Fig.10 ). Specifically, the first hopper 220 can be aligned with the first compartment 100, the second hopper 222 can be aligned with the second compartment 102, and the third hopper 224 can be aligned with the third compartment 104, so that when the hoppers 220, 222, 224 release the particulate matter 98, the particulate matter 98 is received by the corresponding compartments 100, 102, 104. In one configuration, the hoppers 220, 222, 224 can be gravity fed, so that when a valve or other metering device (not shown) associated with the corresponding hopper 220, 222, 224 is opened, the particulate matter 98 disposed within the hoppers 220, 222, 224 is automatically dispensed from the hoppers 220, 222, 224 and received by the compartments 100, 102, 104 of the first barrier member 94. Once a predetermined amount of particulate matter 98 is received by the first, second, and third compartments 100 , 102 , 104 , valves associated with the hoppers 220 , 222 , 224 may be closed to prevent further particulate matter 98 from being received by any of the compartments 100 , 102 , 104 .

[0121] Special References Fig.11 , compartments 100, 102, 104 are shown as being substantially filled with particulate matter 98. At this point, adhesive 106 may be applied at the area surrounding compartments 100, 102, 104 to allow first barrier member 94 to be attached to second barrier member 96. As described above, and in one configuration, adhesive 106 may be a hot melt adhesive. The hot melt adhesive may be placed on first barrier member 94 at the area surrounding compartments 100, 102, 104 and at protrusion 226 of tool 200. Protrusion 226 may generally follow the shape of first wall 90 and second wall 92 of midsole 32 to allow cushioning member 36 to be attached to cavities 54, 56, 58 (e.g., Figure 3 shown in ) are accommodated in a matching manner.

[0122] Once the adhesive 106 is disposed on the first barrier member 94 in an area surrounding the first compartment 100, the second compartment 102, and the third compartment 104, the material sheet 228 can be placed between the first barrier member 94 and the heat source 230. The material sheet 228 can be positioned on the adhesive 106 so that the material sheet 228 is opposite to and covers the first compartment 100, the second compartment 102, and the third compartment 104. Once the material sheet 228 is appropriately positioned relative to the first barrier member 94, the heat source 230 can be activated, causing the adhesive 106 to bond with the material sheet 228 and seal the first compartment 100, the second compartment 102, and the third compartment 104.

[0123] Once the sheet of material 228 is attached to the first barrier member 94, the sheet of material 228 closes the first compartment 100, the second compartment 102, and the third compartment 104, and thus forms the second barrier member 96. Fig.12 , as described above, the second barrier member 96 can define the protrusions 112 according to the number of particles 98 disposed within the corresponding compartments 100, 102, 104. Regardless of the number of particles 98 received by the corresponding compartments 100, 102, 104, once the material sheet 228 is attached to the first barrier member 94, and thus forms the second barrier member 96, the cushioning member 36 can be inserted into the midsole 32 so that the first compartment 100 is received by the ball cavity 54 of the midsole 32, the second compartment 102 is received by the midsole cavity 56 of the midsole 32, and the third compartment 104 is received by the heel cavity 58 of the midsole 32.

[0124] As described above, cushioning member 36 may be formed via a thermoforming process. Thus, first compartment 100, second compartment 102, and third compartment 104 receive a predetermined amount of particulate matter 98, and further, once installed in article of footwear 10, first compartment 100, second compartment 102, and third compartment 104 may cause second barrier member 96 to form protrusions 112 at outer surface 110 opposite to base 38. Although the amount of particulate matter 98 disposed within first compartment 100, second compartment 102, and / or third compartment 104 may cause one or more protrusions 112 to be formed at second barrier member 96, protrusions 112 are limited by the amount of particulate matter 98 that can be placed in each compartment 100, 102, 104 via hoppers 220, 222, 224 without the particulate matter 98 overflowing over the edge of first barrier member 94. Thus, the extent to which the protrusions 112 extend from the cushioning member 36 is limited by the amount of particulate matter 98 that can accumulate in the compartments 100 , 102 , 104 without the particulate matter 98 spilling over the edge of the first barrier member 94 .

[0125] The projections 112 may be added by first attaching the second barrier member 96 to the first barrier member 94, thereby closing the compartments 100, 102, 104 before the particulate matter 98 is added to the compartments 100, 102, 104. Adding the particulate matter 98 to the compartments 100, 102, 104 after the second barrier member 96 is attached to the first barrier member 94 requires the use of a different process than the thermoforming process described above.

[0126] As will be described in more detail below, a compression molding process may be used instead of a thermoforming process in order to first attach the second barrier member 96 to the first barrier member 94 before adding the granules 98 to the compartments 100, 102, 104. Attaching the second barrier member 96 to the first barrier member 94 before filling the compartments 100, 102, 104 with granules 98 allows one or more of the compartments 100, 102, 104 to be overfilled with granules 98 relative to when the cushioning member 36 is formed as described above and in Figure 8-Figure 11 The thermoforming process shown in FIG. 1 is formed in terms of the amount of particulate matter 98 that can be added to the compartments 100 , 102 , 104 .

[0127] refer to Figure 14-Figure 24 , a compression molding process for use in manufacturing the cushioning member 36 will be described in detail.

[0128] The compression molding process may utilize a mold 300 that includes an upper mold half 302 and a lower mold half 304. Lower mold half 304 may include a ball cavity 308, a midsole cavity 310, and a heel cavity 312. Ball cavity 308 may include an arcuate surface 314 for forming first compartment 100 of first barrier member 94. Similarly, midsole cavity 310 may include an arcuate surface 316 for forming second compartment 102 of first barrier member 94, and heel cavity 312 may include an arcuate surface 318 for forming third compartment 104 of first barrier member 94. Cavities 308, 310, 312 and associated arcuate surfaces 314, 316, 318 may be the same as cavities 204, 206, 208 and arcuate surfaces 210, 212, 214, respectively, of tool 200 that is used to form a first barrier member 94 via Figure 8-11 The first barrier member 94 is formed by the thermoforming process shown in FIG.

[0129] The upper mold half 302 may include protrusions extending into the respective cavities 308, 310, 312. Specifically, the upper mold half 302 may include a first protrusion 320, a second protrusion 322, and a third protrusion 324 respectively received by the ball cavity 308, the midfoot cavity 310, and the heel cavity 312. The protrusions 320, 322, 324 may follow the shape of the respective arcuate surfaces 314, 316, 318 and may be spaced apart from the arcuate surfaces 314, 316, 318 by the thickness of the TPU material sheet used to form the first barrier member 94, as will be described in more detail below.

[0130] In operation, a sheet of material 306, such as a sheet of TPU material, may be inserted between upper mold half 302 and lower mold half 304. Sheet of material 306 may be attached to lower mold half 304 via a pair of posts 326 extending from lower mold half 304 and through a portion of sheet of material 306.

[0131] Once the sheet of material 306 is disposed between the upper mold half 302 and the lower mold half 304 ( Fig.14 ), the mold halves 302, 304 may be brought toward each other, or alternatively, one of the mold halves 302, 304 may be moved toward the other of the mold halves 302, 304 until the mold halves 302, 304 are moved into Fig.15 That is, the upper mold half 302 and / or the lower mold half 304 can be moved from Fig.14 Move to the position shown in Fig.15 , to change the material sheet 306 from a substantially planar shape ( Fig.14 ) is formed into the shape of the first barrier member 94 ( Fig.15 ). When the mold halves 302, 304 are positioned Fig.15, the posts 326 can be received within corresponding holes 328 of the upper mold half 302, thereby defining a relative spacing between the upper mold half 302 and the lower mold half 304. In one configuration, the spacing is approximately equal to the thickness of the sheet of material 306 to prevent the sheet of material 306 from being compressed between the protrusions 320, 322, 324 and the respective arcuate surfaces 314, 316, 318 of the cavities 308, 310, 312.

[0132] Engaging the sheet of material 306 with the post 326 maintains the position of the sheet of material 306 relative to the lower mold half 304 at the post 326. Thus, when the upper mold half 302 engages the sheet of material 306 at the protrusions 320, 322, 324, the material of the sheet of material 306 is stretched and formed into the shape defined by the arcuate surfaces 314, 316, 318. The sheet of material 306 is formed into the shape defined by the arcuate surfaces 314, 316, 318 by the deformation of the upper mold half 302. Fig.16 The shapes shown in .

[0133] like Fig.16 As shown in FIG. 1 , the sheet of material 306 is formed into a shape defining the compartments 100 , 102 , 104 , but relative to Fig. 9 The shape of the first barrier member 94 shown in FIG. 3 includes additional material at the location where the post 326 joins the sheet of material 306. Thus, Fig.16 The material sheet 306 depicted in FIG. 1 is a partially formed first barrier member 94. The additional material defines a flange 330 that extends generally around the perimeter of the material sheet 306 and surrounds the compartments 100, 102, 104 formed by the mold 300. The flange 330 may additionally include a pair of holes 332 that are formed into the material sheet 306. Fig.16 During the construction shown in FIG. 3 , the pair of holes 332 are formed through the posts 326. As will be described in more detail below, the flange along with the holes 332 can be removed from the sheet of material 306 to form the first barrier member 94, such as via a die cutting process.

[0134] Once the sheet of material 306 is formed into Fig.16 , the sheet of material 334 for forming the second barrier member 96 can be attached to the sheet of material 306. As described above, the second barrier member 96 can be formed of a flexible material such as spandex. In addition, the second barrier member 96 is described as being attached to the first barrier member 94 via the adhesive 106. Fig.17, adhesive 106 can be provided in the form of adhesive material sheet 336 (e.g., sheet of hot melt adhesive). Finally, barrier element 338 can be positioned between adhesive 106 and the material sheet 306 forming the first barrier member 94 to form an unattached region between adhesive 106 and the first barrier member 94. The unattached region between the adhesive 106 and the first barrier member 94 also forms an unattached region between the first barrier member 94 and the second barrier member 96. As will be described in more detail below, the region where the first barrier member 94 is separated from the second barrier member 96 via barrier element 338 provides a region allowing particulate matter 98 to be added to the first compartment 100, the second compartment 102, and the third compartment 104.

[0135] The sheet of material 306 may be placed on a tool 340 ( Fig.14 ), the tool 340 is substantially in accordance with the material sheet 306 formed into Fig.16 300. The tool 340 may be the same as the tool 200 described above with respect to the thermoforming process. Alternatively, the tool 340 may be the same as the tool 200, except that the tool 340 does not include the vacuum port 216 associated with the tool 200. Regardless of the specific configuration of the tool 340, the tool 340 may include a forefoot cavity 342, a midshoe cavity 344, and a heel cavity 346, which respectively receive the first compartment 100, the second compartment 102, and the third compartment 104 defined by the sheet of material 306 after being formed by the mold 300.

[0136] After sheet of material 306 is inserted into tool 340 such that first compartment 100 is received by forefoot cavity 342, second compartment 102 is received by midfoot cavity 344, and third compartment 104 is received by heel cavity 346, barrier element 338 may be positioned on sheet of material 306, adhesive sheet of material 336 may be placed on barrier element 338, and sheet of material 334 forming second barrier member 96 may be placed on top of adhesive sheet 336. Thus, barrier element 338 is disposed between adhesive sheet 336 and sheet of material 306 forming first barrier member 94, adhesive sheet 336 is disposed between sheet of material 334 forming second barrier member 96 and barrier element 338, and sheet of material 334 forming second barrier member 96 is disposed on adhesive sheet of material 336 and includes exposed outer surface 348.

[0137] Special References Fig.17, the adhesive sheet is shown to include a first hole 350, a second hole 352, and a third hole 354. The first hole 350 includes a shape corresponding to the shape of the first compartment 100 to allow the adhesive 106 to completely surround the first compartment 100. Similarly, the second hole 352 includes a shape corresponding to the shape of the second compartment 102 to allow the adhesive 106 of the adhesive material sheet 336 to completely surround the second compartment 102, and the third hole 354 includes a shape corresponding to the shape of the third compartment 104 to allow the adhesive 106 of the adhesive material sheet 336 to completely surround the third compartment 104.

[0138] The adhesive material sheet 336 may additionally include a fourth hole 356, a fifth hole 358, and a sixth hole 360. The fourth hole 356, the fifth hole 358, and the sixth hole 360 ​​may correspond to the first compartment 100, the second compartment 102, and the third compartment 104 of the first barrier member 94 of the additional cushioning member 36, respectively. For example, the adhesive material sheet 336 may be used to form a pair of cushioning members 36 at the same time. Fig.17 , the sheet of adhesive material 336 and the associated apertures 350, 352, 354, 356, 358, 360 are sized and positioned to accommodate cushioning members 36 for use with different articles of footwear 10. That is, the apertures 350, 352, 354 are used to form a cushioning member 36 for use with a right article of footwear 10, while the apertures 356, 358, 360 are used to form a cushioning member 36 for use with a left article of footwear 10. Although the sheet of adhesive material 336 and the associated apertures 350-360 are described and shown as being used to form a cushioning member 36 for use with a right article of footwear 10 and a cushioning member 36 for use with a left article of footwear 10, respectively, the apertures 350-360 may be formed through the sheet of adhesive material 336 and positioned so that a pair of cushioning members 36 having the same configuration are formed. That is, a pair of cushioning members 36 may be formed for use with a right article of footwear 10 , or, alternatively, a pair of cushioning members 36 may be formed for use with a left article of footwear 10 .

[0139] Finally, while a pair of cushioning members 36 are described as being simultaneously formed via the sheet of adhesive material 336, the sheet of adhesive material 336 may include only three apertures in total such that only one cushioning member 36 is formed. That is, the sheet of adhesive material 336 may include apertures 350, 352, 354 for use in manufacturing a cushioning member 36 for a right article of footwear 10, or alternatively, may include only apertures 356, 358, 360 for use in manufacturing a cushioning member 36 for use with a left article of footwear 10. While the sheet of adhesive material 336 may be used to form a pair of cushioning members 36 for articles of footwear for the same or different feet, or alternatively, may be configured to manufacture a single cushioning member 36, the sheet of adhesive material 336 will be described and illustrated below as including six apertures 350-360 for forming a pair of cushioning members 36 configured for use in a right article of footwear 10 and a left article of footwear 10, respectively.

[0140] Although not specifically shown, the tool 340 may include two sets of cavities 342, 344, 346 that receive portions of the same sheet of material 306 or separate sheets of material 306, respectively, to position the compartments 100, 102, 104 relative to the holes of the adhesive sheet of material 336. In this manner, the tool 340 may support a pair of first compartments 100, a pair of second compartments 102, and a pair of third compartments 104 of the same or different sheets of material 306 relative to the adhesive sheet of material 336 to simultaneously attach the pairs of compartments 100, 102, 104 to the sheet of material 334 via the adhesive 106.

[0141] The barrier element 338 may be formed of a material that resists the adhesive 106 that is bonded to the adhesive material sheet 336. For example, the barrier element 338 may be formed of form, Bonding between the adhesive 106 of the adhesive material sheet 336 and the material sheet 306 forming the first barrier member 94 is prevented.

[0142] Regardless of the material used to form barrier element 338, barrier element 338 may include a series of protrusions 362 extending from body 364. Protrusions 362 may be arranged along the length of body 364 such that each protrusion 362 is aligned with a corresponding aperture 350-360 of sheet 336 of adhesive material.

[0143] As described, the adhesive material sheet 336 is positioned so that the apertures 350-360 are aligned with the corresponding compartments 100, 102, 104 formed by one or more material sheets 306 to simultaneously form a pair of cushioning members 36. Thus, aligning the protrusions 362 with the apertures 350-360 aligns one protrusion 362 with each of the corresponding apertures 350-360 and also aligns the protrusions 362 with the compartments 100, 102, 104 of a pair of first barrier members 94 for forming a pair of cushioning members 36. Thus, when the barrier element 338 is disposed between the adhesive material sheet 336 and the material sheet 306 forming the first barrier member 94, the barrier element 338 is positioned so that the protrusions 362 are aligned with the compartments 100, 102, 104 of each barrier member 94, respectively.

[0144] Once barrier element 338, adhesive material sheet 336, and material sheet 334 forming second barrier member 96 are stacked on material sheet 306 forming first barrier member 94, heating device 366 may be used to apply heat to surface 348. Heating material sheet 334 forming second barrier member 96 activates adhesive 106 of adhesive material sheet 336, thereby bonding material sheet 334 forming second barrier member 96 to material sheet 306 forming first barrier member 94 at every location except the location of barrier element 338. That is, adhesive material sheet 336 is not bonded to material sheet 306 forming first barrier member 94 at the locations of protrusion 362 and body 364 of barrier element 338.

[0145] Once the sheet of material 334 forming the second barrier member 96 is attached to the sheet of material 306 forming the first barrier member 94, the assembly includes Fig.19 At this point, the sheet of material 334 forming the second barrier member 96 is attached to the sheet of material 306 forming the first barrier member 94, but does not include the particulate matter 98. Therefore, Fig.19 The configuration shown in FIG. 9 is a pre-filled barrier member without particulate matter 98 .

[0146] As mentioned above Fig.17 As depicted, adhesive material sheet 336 and barrier element 338 are used to form a pair of cushioning members 36. Fig. 20 As shown in FIG. 1 , by subjecting the material sheet 334 forming the pair of second barrier members 96 and the material sheet 306 forming the first barrier member 94 to a die cutting process, the pair of cushioning members 36 can be separated from each other and formed as described above with respect to Fig.13 The shape of the cushioning member 36 shown. That is, the connected material sheets 306, 334 can be inserted into a die cutting tool 368 having an upper die 370 and a lower die 372. Specifically, Fig.19The structure shown in the figure can be inserted into the cavity 374 of the lower mold 372 to properly position the joined material sheets 306, 334 relative to the cutting mechanism 376 associated with the upper mold 370. Although not specifically shown, the cutting mechanism 376 includes a defined Fig.13 The shape of the outer periphery of the buffer member 36 shown in FIG. Fig.19 Only one cutting mechanism 376 is shown in the cross-section in FIG. 3 , but a pair of cutting mechanisms 376 may be used if a pair of cushioning members 36 are cut simultaneously from the joined sheets of material 306 , 334 .

[0147] In operation, as the upper die 370, and therefore the cutting mechanism 376, translates toward the lower die 372, the cutting mechanism 376 engages the outer periphery of the joined material sheets 306, 334, thereby separating the pre-filled cushioning members 36 from one another and forming the pre-filled cushioning members 36 into Fig.13 At this point, the pair of pre-filled cushioning members 36 are separated from each other and can be filled with a predetermined amount of particulate matter 98 .

[0148] Special References Figure 17-19 , the compartments 100, 102, 104 are shown as receiving injection nozzles 378 at respective ports 380 associated with the compartments 100, 102, 104. The ports 380 are formed at the locations of the protrusions 362 of the blocking element 338. That is, and as described above, the protrusions 262 prevent the adhesive material 106 of the adhesive material sheet 336 from joining the second barrier member 96 to the first barrier member 94 at the locations of the protrusions 362. Thus, the ports 380 are formed at the locations of the protrusions 362 of the blocking element 338, thereby allowing the nozzles 378 to be inserted into the respective compartments 100, 102, 104.

[0149] In operation, the nozzle 378 is inserted into the corresponding port 380 of the compartment 100, 102, 104 and is in fluid communication with the interior of the compartment 100, 102, 104. Note that Figure 17-19 The view shown in FIG. 1 is a partial cross-sectional view whereby a portion of the second barrier member 96 is removed to show the first compartment 100 , the second compartment 102 , and the third compartment 104 of the first barrier member 94 .

[0150] Once the nozzle 378 is disposed within the port 380 such that the nozzle 378 is disposed between the second barrier member 96 and the first barrier member 94, the particulate matter 98 can be injected into the nozzle 378 via fluid pressure. For example, air pressure can be used to inject particulate matter 98 into the nozzle 378. Fig. 22) is introduced into the nozzle 378. Although the nozzle 378 is described and shown as being associated with the common hopper 382, ​​the nozzle 378 may alternatively be associated with a separate hopper that supplies the particulate matter 98 to the nozzle 378.

[0151] like Figure 17-19 As shown in , the nozzle 378 may include an inner diameter that is substantially equal to the outer diameter of the particulate matter 98 or, alternatively, slightly larger than the outer diameter of the particulate matter 98 to prevent the particulate matter 98 from aggregating and clogging within the nozzle 378. The particulate matter 98 may be injected into the compartments 100, 102, 104 via the nozzle 378, and further, because the particulate matter 98 is injected under fluid pressure (such as air pressure), the particulate matter 98 disposed within the compartments 100, 102, 104 may overfill one or more of the compartments 100, 102, 104. Thus, compared to when the compartments 100, 102, 104 are filled with particulate matter 98 (as described above with respect to Figure 8-11 Compartments 100, 102, 104 may include a greater number of particulate matter 98 than the number of particulate matter that can be accommodated within compartments 100, 102, 104 by the thermoforming process described herein. That is, because particulate matter 98 is injected into compartments 100, 102, 104 under fluid pressure, and further because second barrier member 96 is attached to first barrier member 94 and each barrier member 94, 96 is formed of a flexible material, particulate matter 98 may be overfilled in each of compartments 100, 102, 104, resulting in a larger protrusion 112 at one or more of compartments 100, 102, 104. The protrusion is Fig.25 and Fig.26 1 and 2 as extending from the surface of the second barrier member 96.

[0152] Once the desired amount of particulate matter is disposed within each compartment 100, 102, 104, the port 380 may be closed by joining the first barrier member 94 and the second barrier member 96 at the port 380. For example, the first barrier member 94 and the second barrier member 96 may be locally subjected to a welding process, such as radio frequency (RF) welding, at each port location. Fig.24 As shown in FIG. 3 , one or more welding devices 384 may be used to join the first barrier member 94 and the second barrier member 96 at the location of the port 380 , thereby closing the port 380 and containing the particulate matter 98 within the compartments 100 , 102 , 104 .

[0153] like Fig.25 and Fig.26 As shown in FIG. 1 , a formed and filled cushioning member 36 is shown and includes the same as that described above with reference to FIG. Figure 8-11 The thermoforming process described and shown forms a similar construction of the cushioning member 36. However, Fig.25and Fig.26 The cushioning member 36 shown in FIG. 1 may include a greater number of particles 98 in one or more of the compartments 100, 102, 104 and may therefore include a larger protrusion 112 at the second barrier member 96. Finally, when compared with Figure 8-11 When compared to the web member 108 formed by the thermoforming process, the location of the port 380 can be seen at the web member 108 where RF welding is used to join the first barrier member 94 and the second barrier member 96.

[0154] like Fig. 27 As shown in Figure 8-11 Thermoforming process or through Figure 14-24 The cushioning member 36 formed by the compression molding process of the present invention can be incorporated into the midsole 32. That is, the first compartment 100 can be aligned with the ball cavity 54 of the midsole 32, the second compartment 102 can be aligned with the midfoot cavity 56 of the midsole 32, and the third compartment 104 can be aligned with the heel cavity 58 of the midsole 32, so that the compartments 100, 102, 104 are received by the cavities 54, 56, 58, respectively. Once the cushioning member 36 is inserted into the midsole 32, the midsole 32 can be attached to the upper 12. At this point, the cushioning member 36 can be used to provide a certain degree of comfort and cushioning to the wearer's foot during use of the article of footwear 10.

[0155] The following clauses provide exemplary methods for making a cushioning member or sole structure for an article of footwear, as described above.

[0156] Item 1: A method for manufacturing a buffer member, comprising: forming a first barrier member from a first material, the first barrier member including a first compartment and a second compartment; forming a second barrier member from a second material different from the first material; providing a first quantity of particulate matter to the first compartment; providing a second quantity of particulate matter to the second compartment; covering the first compartment with the second barrier member; and covering the second compartment with the second barrier member.

[0157] Clause 2: The method of Clause 1, wherein forming the first barrier member comprises forming a sheet of the first material into a shape defining the first compartment and the second compartment.

[0158] Clause 3: The method of any of the preceding clauses, wherein forming the first barrier member from a first material comprises forming the first barrier member from a polymer.

[0159] Clause 4: The method of any of the preceding clauses, wherein forming the first barrier member from a first material comprises forming the first barrier member from thermoplastic polyurethane (TPU).

[0160] Clause 5: The method of any of the preceding clauses, wherein forming the second barrier member from a second material comprises forming the second barrier member from a spandex.

[0161] Clause 6: The method of Clause 1, wherein providing the first quantity of particulate matter to the first compartment comprises providing the first compartment with approximately the same quantity of particulate matter as the second quantity of particulate matter.

[0162] Clause 7: The method of Clause 1, wherein providing the first amount of particulate matter to the first compartment comprises providing an amount of particulate matter to the first compartment that is different than the second amount of particulate matter.

[0163] Clause 8: The method of any of the preceding clauses, wherein providing the first quantity of particulate matter to the first compartment and providing the second quantity of particulate matter to the second compartment comprises providing foam beads to the first compartment and the second compartment.

[0164] Clause 9: The method of Clause 8, wherein providing the foam beads to the first compartment and the second compartment comprises providing the foam beads having a substantially spherical shape.

[0165] Clause 10: The method of Clause 8, wherein providing the foam beads to the first compartment and the second compartment comprises providing foam beads having substantially the same size and shape.

[0166] Clause 11: The method of Clause 8, wherein providing the first compartment and the second compartment with foam beads comprises providing foam beads having different sizes and shapes.

[0167] Clause 12: The method of Clause 1, wherein forming the first barrier member from the first material and forming the second barrier member from the second material comprises forming one of the first barrier member and the second barrier member from a permeable material and forming the other of the first barrier member and the second barrier member from an impermeable material.

[0168] Clause 13: The method of Clause 1, wherein forming the first barrier member from a first material and forming the second barrier member from a second material comprises forming the first barrier member from an impermeable material and forming the second barrier member from a permeable material.

[0169] Clause 14: The method of Clause 1, wherein providing the first quantity of particulate matter to the first compartment and providing the second quantity of particulate matter to the second compartment is performed before the first compartment and the second compartment are covered by the second barrier member.

[0170] Clause 15: The method of Clause 1, wherein providing the first quantity of particulate matter to the first compartment and providing the second quantity of particulate matter to the second compartment is performed after the first compartment and the second compartment are covered by a second barrier member.

[0171] Clause 16: The method of any of the preceding clauses, further comprising attaching a second barrier member to the first barrier member.

[0172] Clause 17: The method of clause 16, wherein attaching the second barrier member to the first barrier member comprises attaching the second barrier member to the first barrier member at a first attachment location surrounding the first compartment, and comprises attaching the second barrier member to the first barrier member at a second attachment location surrounding the second compartment.

[0173] Clause 18: The method of Clause 16, wherein attaching the second barrier member to the first barrier member comprises attaching the second barrier member to the first barrier member via an adhesive.

[0174] Clause 19: The method of Clause 18, wherein attaching the second barrier member to the first barrier member via an adhesive comprises attaching the second barrier member to the first barrier member via a hot melt adhesive.

[0175] Clause 20: The method of Clause 1, wherein forming the first barrier member from the first material comprises applying heat and a vacuum to the sheet of the first material.

[0176] Clause 21: The method of Clause 1, wherein forming the first barrier member from the first material comprises compression molding a sheet of the first material within a mold.

[0177] Item 22: A method as described in Item 1, wherein providing a first quantity of particulate matter to the first compartment and providing a second quantity of particulate matter to the second compartment includes injecting the first quantity of particulate matter between the first barrier member and the second barrier member at a first port connected to the fluid of the first compartment, and includes injecting the second quantity of particulate matter between the first barrier member and the second barrier member at a second port connected to the fluid of the second compartment.

[0178] Clause 23: The method of Clause 22, further comprising sealing the first port and the second port after injecting the first quantity of particulate matter into the first compartment and after injecting the second quantity of particulate matter into the second compartment.

[0179] Clause 24: The method of Clause 23, wherein sealing the first port and the second port comprises attaching the first barrier member to the second barrier member using radio frequency (RF) welding.

[0180] Item 25: A method of manufacturing a sole structure for an article of footwear, comprising: providing a midsole having a first cavity and a second cavity; forming a first barrier member from a first material, the first barrier member including a first compartment and a second compartment; forming a second barrier member from a second material; providing a first quantity of particulate matter to the first compartment; providing a second quantity of particulate matter to the second compartment; covering the first compartment with the second barrier member; covering the second compartment with the second barrier member; positioning the first compartment within the first cavity; and positioning the second compartment within the second cavity.

[0181] Clause 26: The method of Clause 25, wherein forming the first barrier member from the first material comprises forming the first barrier member from a material different from the second material.

[0182] Clause 27: The method of Clause 25, wherein forming the first barrier member comprises forming a sheet of the first material into a shape defining the first compartment and the second compartment.

[0183] Clause 28: The method of any of the preceding clauses, wherein forming the first barrier member from a first material comprises forming the first barrier member from a polymer.

[0184] Clause 29: The method of any of the preceding clauses, wherein forming the first barrier member from a first material comprises forming the first barrier member from thermoplastic polyurethane (TPU).

[0185] Clause 30: The method of any of the preceding clauses, wherein forming the second barrier member from a second material comprises forming the second barrier member from a spandex.

[0186] Clause 31: The method of Clause 25, wherein providing the first quantity of particulate matter to the first compartment comprises providing the first compartment with approximately the same quantity of particulate matter as the second quantity of particulate matter.

[0187] Clause 32: The method of Clause 25, wherein providing the first amount of particulate matter to the first compartment comprises providing the first compartment with an amount of particulate matter that is different than the second amount of particulate matter.

[0188] Clause 33: The method of any of the preceding clauses, wherein providing the first quantity of particulate matter to the first compartment and providing the second quantity of particulate matter to the second compartment comprises providing foam beads to the first compartment and the second compartment.

[0189] Clause 34: The method of Clause 33, wherein providing the foam beads to the first compartment and the second compartment comprises providing the foam beads having a substantially spherical shape.

[0190] Clause 35: The method of Clause 33, wherein providing the foam beads to the first compartment and the second compartment comprises providing foam beads having substantially the same size and shape.

[0191] Clause 36: The method of Clause 33, wherein providing the first compartment and the second compartment with foam beads comprises providing foam beads having different sizes and shapes.

[0192] Clause 37: The method of Clause 25, wherein forming the first barrier member from the first material and forming the second barrier member from the second material includes forming one of the first barrier member and the second barrier member from a permeable material and forming the other of the first barrier member and the second barrier member from an impermeable material.

[0193] Clause 38: The method of Clause 25, wherein forming the first barrier member from a first material and forming the second barrier member from a second material comprises forming the first barrier member from an impermeable material and forming the second barrier member from a permeable material.

[0194] Clause 39: The method of Clause 25, wherein providing the first quantity of particulate matter to the first compartment and providing the second quantity of particulate matter to the second compartment is performed before the first compartment and the second compartment are covered by the second barrier member.

[0195] Clause 40: The method of Clause 25, wherein providing the first quantity of particulate matter to the first compartment and providing the second quantity of particulate matter to the second compartment is performed after the first compartment and the second compartment are covered by a second barrier member.

[0196] Clause 41: The method of any of the preceding clauses, further comprising attaching a second barrier member to the first barrier member.

[0197] Clause 42: The method of clause 41, wherein attaching the second barrier member to the first barrier member comprises attaching the second barrier member to the first barrier member at a first attachment location surrounding the first compartment, and comprises attaching the second barrier member to the first barrier member at a second attachment location surrounding the second compartment.

[0198] Clause 43: The method of Clause 41, wherein attaching the second barrier member to the first barrier member comprises attaching the second barrier member to the first barrier member via an adhesive.

[0199] Clause 44: The method of Clause 43, wherein attaching the second barrier member to the first barrier member via an adhesive comprises attaching the second barrier member to the first barrier member via a hot melt adhesive.

[0200] Clause 45: The method of Clause 25, wherein forming the first barrier member from the first material comprises applying heat and a vacuum to the sheet of the first material.

[0201] Clause 46: The method of Clause 25, wherein forming the first barrier member from the first material comprises compression molding a sheet of the first material within a mold.

[0202] Item 47: A method as described in Item 25, wherein providing a first quantity of particulate matter to the first compartment and providing a second quantity of particulate matter to the second compartment includes injecting the first quantity of particulate matter between the first barrier member and the second barrier member at a first port connected to the fluid of the first compartment, and includes injecting the second quantity of particulate matter between the first barrier member and the second barrier member at a second port connected to the fluid of the second compartment.

[0203] Clause 48: The method of Clause 47, further comprising sealing the first port and the second port after injecting the first quantity of particulate matter into the first compartment and after injecting the second quantity of particulate matter into the second compartment.

[0204] Clause 49: The method of Clause 48, wherein sealing the first port and the second port comprises attaching the first barrier member to the second barrier member using radio frequency (RF) welding.

[0205] Clause 50: The method of any of the preceding clauses, wherein providing the midsole comprises forming the midsole from a foamed polymer material.

[0206] Item 51: A method of manufacturing a sole structure for an article of footwear, comprising: providing an outsole; providing a midsole, the midsole comprising a first cavity, a first hole, and a second hole, the first hole being formed in a first surface of the midsole and being fluidly connected to the first cavity, the second hole being formed in a second surface of the midsole and being fluidly connected to the first cavity, the second surface being disposed on a side of the midsole opposite to the first surface and opposite to the outsole; positioning a cushioning member comprising a first compartment within the first cavity, the first compartment containing a first quantity of particulate matter, the first quantity of particulate matter being visible at the outsole through the second hole.

[0207] Clause 52: The method of clause 51, wherein positioning a cushioning member within the first cavity comprises positioning a cushioning member having a first barrier member and a second barrier member that cooperate to contain the first quantity of particulate matter within the first compartment.

[0208] Clause 53: The method of Clause 52, further comprising shaping the first barrier member to define the first compartment, and attaching the second barrier member to the first barrier member.

[0209] Clause 54: The method of Clause 52, further comprising positioning an adhesive between the first barrier member and the second barrier member.

[0210] Clause 55: The method of Clause 54, wherein positioning the adhesive between the first barrier member and the second barrier member comprises surrounding the first compartment with the adhesive.

[0211] Clause 56: The method of Clause 54, wherein positioning the adhesive between the first barrier member and the second barrier member comprises positioning a hot melt adhesive.

[0212] Clause 57: The method of any of Clauses 52-56, further comprising tapering the first compartment in a direction away from the second barrier member.

[0213] Clause 58: The method of any of Clauses 52-57, further comprising covering the first compartment with a second barrier member to define a first interior cavity, the first quantity of particulate matter being disposed within the first interior cavity.

[0214] Clause 59: The method of any of Clauses 52-58, further comprising forming the first barrier member from a first material, and forming the second barrier member from a second material different from the first material.

[0215] Clause 60: The method of Clause 59, wherein forming the first barrier member from a first material comprises forming the first barrier member from a polymer.

[0216] Clause 61: The method of Clause 59, wherein forming the first barrier member from a first material comprises forming the first barrier member from thermoplastic polyurethane (TPU).

[0217] Clause 62: The method of any of Clauses 59-61, wherein forming the second barrier member from a second material comprises forming the second barrier member from a spandex.

[0218] Clause 63: The method of Clause 59, wherein forming the first barrier member from a first material and forming the second barrier member from a second material comprises forming one of the first material and the second material from a permeable material and forming the other of the first material and the second material from an impermeable material.

[0219] Clause 64: The method of Clause 59, wherein forming the first barrier member from a first material and forming the second barrier member from a second material comprises forming the first material from an impermeable material and forming the second material from a permeable material.

[0220] Clause 65: The method of any of the preceding clauses, wherein positioning a cushioning member comprising a first compartment comprising a first quantity of particulate matter comprises positioning a cushioning member comprising foam beads.

[0221] Clause 66: The method of Clause 65, wherein positioning the cushioning member comprising foam beads comprises providing the foam beads having a substantially spherical shape.

[0222] Clause 67: The method of Clause 65, wherein positioning the cushioning member comprising foam beads comprises providing the foam beads having substantially the same size and shape.

[0223] Clause 68: The method of Clause 65, wherein positioning the cushioning member comprising foam beads comprises providing the foam beads having at least one of different sizes and different shapes.

[0224] Clause 69: The method of clause 51, further comprising forming the outsole from one of a transparent material and a translucent material, the first quantity of particulate matter being visible through the material of the outsole at the second aperture.

[0225] Clause 70: The method of any of the preceding clauses, further comprising providing the midsole with a second cavity, a third hole formed in a first surface of the midsole and in fluid communication with the second cavity, and a fourth hole formed in a second surface of the midsole and in fluid communication with the second cavity.

[0226] Clause 71: The method of clause 70, further comprising providing the cushioning member with a second compartment, the second compartment being received by the second cavity of the midsole and containing a second quantity of particulate matter, the second quantity of particulate matter being visible at the outsole through the fourth aperture.

[0227] Clause 72: The method of Clause 51, wherein positioning the cushioning member within the first cavity comprises positioning an outer surface of the cushioning member substantially flush with the first surface of the midsole.

[0228] Clause 73: The method of Clause 51, wherein positioning the cushioning member within the first cavity comprises extending an outer surface of the cushioning member from the first surface of the midsole to form at least one protrusion.

[0229] Clause 74: The method of Clause 73, wherein forming at least one protrusion comprises forming at least one protrusion at the first compartment.

[0230] The foregoing description has been provided for the purpose of illustration and description. The foregoing description is not intended to be exhaustive or to limit the present disclosure. The individual elements or features of a particular configuration are generally not limited to the particular configuration, but are interchangeable where applicable and can be used in the selected configuration, even if not explicitly shown or described. The individual elements or features of a particular configuration can also be varied in many ways. Such variations are not considered to be out of the present disclosure, and all such modifications are intended to be included within the scope of the present disclosure.

Claims

1. A sole structure (14a) for an article of footwear, the sole structure (14a) comprising: A midsole (32a), the midsole (32a) comprising a plurality of chambers (116, 54a, 56a, 58a), the plurality of chambers (116, 54a, 56a, 58a) comprising a first chamber (58a) and a second chamber (56a); a first quantity of particulate matter (98), the first quantity of particulate matter (98) being disposed directly within the first cavity (58a); as well as A cushioning member (36a), the cushioning member (36a) comprising a first portion (128) and a second portion (130), the first portion (128) having at least one compartment (100a, 102a, 104c), the at least one compartment (100a, 102a, 104c) containing a second amount of particulate matter (98) and disposed within the second cavity (56a), the second portion (130) extending from the first portion (128) and covering the first cavity (58a).

2. The sole structure (14a) according to claim 1, wherein the first portion (128) of the cushioning member (36a) includes a first barrier member (94a) and a second barrier member (96a) attached to the first barrier member (94a) to define the at least one compartment, and the second portion (130) of the cushioning member (36a) includes the second barrier member (96a).

3. The sole structure (14a) according to claim 2, wherein the first cavity (58a) includes a first hole (82a) and a second hole (84a), the first hole (82a) being formed in the first surface (60) of the midsole (32a), and the second hole (84a) being formed in the second surface (64) of the midsole (32a) at an end of the first cavity (58a) opposite to the first hole (60).

4. The sole structure (14a) of claim 3, wherein the first hole (82a) is covered by the second portion (130) of the cushioning member (36a).

5. The sole structure (14a) of claim 2, wherein at least one of the compartments (100a, 102a, 104c) tapers in a direction away from the second barrier member (96a).

6. A sole structure (14a) according to any one of the preceding claims, wherein the first cavity (58a) is arranged in the heel area (20), and the second cavity (56a) is arranged in one of the forefoot area (16) of the sole structure (14a) and the midfoot area (18) of the sole structure (14a).

7. The sole structure (14a) of any one of the preceding claims, wherein the cushioning member (36a) is formed from a first material and a second material different from the first material.

8. The sole structure (14a) of claim 7, wherein the first material is a polymer and the second material is a spandex.

9. The sole structure (14a) according to any one of the preceding claims, wherein the particulate matter (98) comprises foam beads.

10. The sole structure (14a) according to any one of the preceding claims, further comprising an outsole (34a) attached to the midsole (32a) and defining a ground engaging surface of the sole structure (14a).

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