Sole structures for articles of footwear and related methods of assembly

Abstract

A sole structure for an article of footwear includes a midsole including a cavity having a first protrusion extending within the cavity from a first surface in a first direction and a second protrusion extending within the cavity from a second surface in a second direction toward the first protrusion; and a cushion pad including a first recess disposed on a first side of the cushion pad and a second recess disposed on an opposite second side of the cushion pad, the first recess receiving the first protrusion and the second recess receiving the second protrusion.

Description

Cross-reference to related applications

[0001] This PCT international application claims priority to U.S. Application No. 18 / 888,530, filed September 18, 2024, which claims priority to U.S. Provisional Application No. 63 / 595,894, filed November 3, 2023, and U.S. Provisional Application No. 63 / 584,822, filed September 22, 2023, pursuant to 35 USC §119(e). The disclosures of these earlier applications are considered part of the disclosure of this application and are incorporated herein by reference in their entirety. Technical Field

[0002] This disclosure generally relates to a footwear article, and more specifically to a sole structure for a footwear article. Background Technology

[0003] This section provides background information in connection with this disclosure and is not necessarily prior art.

[0004] Footwear typically comprises an upper and a sole structure. The upper can include any suitable material to receive, secure, and support the foot against the sole structure. The upper may be fitted with laces, straps, or other fasteners to adjust the fit around the foot. The bottom portion of the upper, closest to the foot, is attached to the sole structure.

[0005] Sole construction typically comprises a layered arrangement extending between the ground surface and the upper. For example, sole construction may include a midsole and an outsole. The midsole is typically positioned between the outsole and the upper and provides cushioning for the foot. The midsole may include pressurized fluid-filled chambers that compress reboundly under applied loads to cushion the foot by reducing ground reaction forces. These fluid-filled chambers are formed separately from the midsole and are typically made of a different material than that forming the midsole. For example, the fluid-filled chambers may include a barrier layer made of thermoplastic polyurethane (TPU), while the midsole may include a foamed polymer material. After the fluid-filled chambers are formed, they are permanently attached to the sole construction by foaming the polymer material surrounding the chambers to form the midsole, or alternatively, the chambers are bonded to the foamed midsole with adhesives to fix them in the desired position relative to the midsole.

[0006] While conventional fluid-filled chambers are fully anchored to the midsole material during footwear manufacturing, traditional methods require additional assembly operations to attach the fluid-filled chambers to the midsole, such as applying an adhesive layer between the midsole and the fluid-filled chambers. These additional operations increase the overall cost and complexity associated with manufacturing the sole structure, and consequently, the overall cost and complexity of the resulting footwear. Attached Figure Description

[0007] The accompanying drawings described herein are for illustrative purposes only and not for all possible implementations, and are not intended to limit the scope of this disclosure.

[0008] Figure 1 It is a perspective view of a footwear product based on the principles of this disclosure; Figure 2 yes Figure 1 A top-down exploded view of footwear products; Figure 3 yes Figure 1 Exploded view of footwear products from below; Figure 4 It is used with Figure 1 A top view of a bag used in conjunction with footwear products; Figure 5 yes Figure 4 A side view of the sac; Figure 6 yes Figure 1 A perspective view of footwear products, showing the installation of a pouch onto... Figure 1 The bladder that is in the first position during the opening process of the midsole of footwear products; Figure 7 yes Figure 1 A perspective view of footwear products, showing the installation of a pouch onto... Figure 6 The second position during the opening of the midsole. Figure 6 The sac; Figure 8 yes Figure 1 A perspective view of footwear products, showing from Figure 7 The second position rotates to the mounting position inside the midsole. Figure 6 The sac; Figure 9 It is along Figure 8 The line 9-9 was cut off Figure 1 Cross-sectional view of footwear products; Figure 10 It is along Figure 8 The line cut from 10-10 Figure 1 Cross-sectional view of footwear products; Figure 11 A perspective view of a footwear product based on the principles of this disclosure; and Figure 12 It is along Figure 11 The line 12-12 cut Figure 11 A cross-sectional view of footwear products.

[0009] In all the accompanying drawings, the corresponding reference numerals indicate the corresponding parts. Detailed Implementation

[0010] The exemplary configurations will now be described more fully with reference to the accompanying drawings. These exemplary configurations are provided so that this disclosure will be thorough and will fully communicate the scope of this disclosure to those skilled in the art. Specific details, such as examples of particular components, apparatus, and methods, are set forth to provide a thorough understanding of the configurations of this disclosure. It will be apparent to those skilled in the art that the specific details are not required, that the exemplary configurations may be embodied in many different forms, and that the specific details and exemplary configurations should not be construed as limiting the scope of this disclosure.

[0011] The terminology used herein is for the purpose of describing specific exemplary configurations only and is not intended to be restrictive. As used herein, the singular articles “a,” “an,” and “the” may also be intended to include plural forms unless the context explicitly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having” are inclusive and therefore specify the presence of features, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and / or groups thereof. The method steps, processes, and operations described herein should not be construed as requiring them to be performed in the specific order discussed or illustrated, unless specifically identified as such. Additional or alternative steps may be employed.

[0012] When an element or layer is referred to as “on another element or layer,” “joined to,” “connected to,” “attached to,” or “linked to” another element or layer, the element or layer may be directly on, joined to, attached to, or linked to the other element or layer, or there may be intermediate elements or layers present. Conversely, when an element is referred to as “directly on another element or layer,” “directly joined to,” “directly connected to,” “directly attached to,” or “directly linked to” another element or layer, there may be no intermediate elements or layers present. Other terms used to describe relationships between elements should be interpreted in a similar manner (e.g., “between” vs. “directly between,” “adjacent” vs. “directly adjacent,” etc.). As used herein, the term “and / or” includes any and all combinations of one or more of the associated listed items.

[0013] The terms first, second, third, etc., may be used herein to describe various elements, components, areas, layers, and / or segments. These elements, components, areas, layers, and / or segments should not be limited by these terms. These terms may be used only to distinguish one element, component, area, layer, or segment from another. Unless the context clearly indicates otherwise, terms such as “first,” “second,” and other numerical terms do not imply order or sequence. Therefore, without departing from the teachings of the example configuration, the first element, component, area, layer, or segment discussed below may be referred to as the second element, component, area, layer, or segment.

[0014] In one configuration, a sole structure for footwear articles is provided, and the sole structure includes: a midsole including a cavity having a first protrusion and a second protrusion, the first protrusion extending from a first surface in a first direction within the cavity, and the second protrusion extending from a second surface in a second direction toward the first protrusion within the cavity; and a cushioning pad including a first recess disposed on a first side of the cushioning pad and a second recess disposed on an opposite second side of the cushioning pad, the first recess receiving the first protrusion and the second recess receiving the second protrusion.

[0015] The sole structure may include one or more of the following optional features. For example, a first protrusion may be aligned with a second protrusion. That is, the distal end of the first protrusion may be opposite to and aligned with the distal end of the second protrusion. Additionally or alternatively, at least one of the first and second protrusions may be elongated and may extend between a first end and a second end along a longitudinal axis of at least one of the first and second protrusions, the first end and the second end including a bevel. In this configuration, the first protrusion may substantially fill a first recess, and the second protrusion may substantially fill a second recess.

[0016] The cushioning pad may be a sac. The sac may include a first barrier layer connected to a second barrier layer to define a chamber having multiple segments defined by a ventral region of the sac. A portion of the ventral region may be disposed between the distal ends of a first protrusion and the distal ends of a second protrusion. In one configuration, the sac may be pressurized.

[0017] Footwear products may include sole structure.

[0018] A method is also provided, and the method includes: forming a midsole including a cavity and a first protrusion extending from a first surface of the midsole in a first direction within the cavity; forming a cushioning pad including a first recess disposed on a first side of the cushioning pad; inserting the cushioning pad into the cavity of the midsole; and rotating the cushioning pad within the cavity until the first protrusion is received by the first recess.

[0019] The method may include one or more of the following optional features. For example, forming the midsole may include forming a second protrusion extending within the cavity from a second surface of the midsole toward the first protrusion in a second direction. The second protrusion may be aligned with the first protrusion. For example, the second protrusion may be aligned with the first protrusion such that the distal end of the second protrusion is opposite the distal end of the first protrusion.

[0020] Forming a midsole with a first protrusion may include forming a midsole with an elongated protrusion. Additionally or alternatively, when the first protrusion is received by a first recess, the first recess may be substantially filled by the first protrusion.

[0021] In one configuration, forming the cushioning pad may include forming a sac. Forming the sac may include connecting a first barrier layer to a second barrier layer to define a chamber having multiple segments defined by a ventral region of the sac, the ventral region defining a first recess. The sac may be pressurized.

[0022] The midsole and cushioning pad can be incorporated into footwear products.

[0023] refer to Figure 1 The footwear article 10 includes a sole structure 100 and an upper 200 attached to the sole structure 100. The footwear 10 may also include a front end 12 associated with the foremost point of the footwear 10 and a rear end 14 corresponding to the rearmost point of the footwear 10. Figure 1 As shown, the longitudinal axis A of footwear 10 10 The length of the footwear 10 extends parallel to the ground surface from the front end 12 to the rear end 14, and the footwear 10 is generally divided into an inner side 16 and an outer side 18. Thus, the inner side 16 and the outer side 18 correspond to opposite sides of the footwear 10, respectively, and extend from the front end 12 to the rear end 14. As used herein, the longitudinal direction refers to the direction extending from the front end 12 to the rear end 14, while the lateral direction refers to the direction transverse to the longitudinal direction and extending from the inner side 16 to the outer side 18.

[0024] Footwear 10 can be divided into one or more zones. These zones may include a forefoot zone 20, a midfoot zone 22, and a heel zone 24. The forefoot zone 20 can be further subdivided into a toe section 20 corresponding to the metatarsal bones. T and the ball of the toes associated with the metatarsals of the foot 20 B The midfoot area 22 may correspond to the arch area of ​​the foot, and the heel area 24 may correspond to the posterior part of the foot (including the calcaneus).

[0025] Footwear product 10, and more specifically, sole structure 200, can be further described as including an outer area 26 and an inner area 28, such as Figure 1As indicated. The outer region 26 is generally described as the area between the inner region 28 and the outer periphery of the sole structure 200. Specifically, the outer region 26 extends from the forefoot region 20 to the heel region 24 along each of the medial side 16 and the lateral side 18, and surrounds each of the forefoot region 20 and the heel region 24. The inner region 28 is defined by the outer region 26 and extends from the forefoot region 20 to the heel region 24 along the central portion of the sole structure 200. Therefore, each of the forefoot region 20, the midfoot region 22, and the heel region 24 can be described as including the outer region 26 and the inner region 28.

[0026] The upper 100 forms a shell with multiple components that cooperate to define an internal cavity 102 and an ankle opening 104, which cooperate to receive and secure the foot for support on the sole structure 200. For example, the upper 100 includes a pair of quarter panels 106 located in the midfoot region 22 on opposite sides of the internal cavity 102. A throat 108 extends over the top of the upper 100 and defines a section between the quarter panels 106 extending from the ankle opening 104 to the instep region of the forefoot region 20. In the illustrated example, the throat 108 is closed, whereby a material panel extends in the instep region between opposite quarter panels 106 to cover the internal cavity 102. Here, the material panel covering the throat 108 may include a material having a higher modulus of elasticity than the material forming the quarter panels 106. Alternatively, the material of the throat 108 may be the same as or similar to the material forming the quarter panels 106.

[0027] The upper 100 of the footwear article 10 can be further described as including a heel side panel 110 that extends along the outer 16 and inner 18 of the ankle opening 104 through the heel area 24. A heel stabilizer 112 surrounds the rear end 14 of the footwear 10 and connects to the heel side panel 110. The uppermost edges of the throat 108, the heel side panel 110, and the heel stabilizer 112 engage to form a collar 114 that defines the ankle opening 104 of the internal void 102.

[0028] Although the upper 100 is described as comprising a quarter panel 106, a throat 108, a heel side panel 110, and a heel stabilizer 112, one or more of the aforementioned elements 106, 108, 110, and 112 may be integrally formed with each other to provide the shape of the upper 100 shown in the figure. For example, if a textile is formed (i.e. woven into) Figure 2The shape of the upper 100 shown, or if the shape of the upper 100 is formed using a 3D printing process, the upper 100 can have a monolithic construction. In these cases, the various elements 106, 108, 110, 112 identified above will identify different areas of the monolithic upper 100. Although the upper 100 can have a monolithic construction including textiles or can be formed using a 3D printing process, the upper 100 will be described below as being formed of one or more materials joined together to form the upper 100.

[0029] The upper 100 may include one or more materials stitched together or bonded together by adhesive to define the internal void 102. Suitable materials for the upper 100 may include, but are not limited to, textiles, foam, leather, and synthetic leather. Example upper 100 may include a combination of one or more substantially inelastic or non-stretchable materials disposed in different areas of the upper 100 and one or more substantially elastic or stretchable materials to facilitate movement of the footwear article 10 between a tightened and relaxed state. The one or more elastic materials may include any combination of one or more elastic fabrics (such as, but not limited to, spandex, elastic fibers, rubber, or neoprene). The one or more inelastic materials may include any combination of one or more of thermoplastic polyurethane, nylon, leather, vinyl, or another material / fabric that does not impart elastic properties.

[0030] For details, please refer to the following: Figure 3 The sole structure 100 is shown to include a midsole 30, a cushioning pad 32, and an outsole 34. The midsole 30 extends along the length of the sole structure 100 from the front end 12 of the footwear article 10 to the rear end 14 of the footwear article 10. In addition, the midsole 30 extends from the inner side 16 of the footwear article 10 to the outer side 18 of the footwear article 10.

[0031] like Figure 2 and Figure 3As shown, the midsole 30 includes a body 36 and a peripheral flange 38 extending from the body 36 toward the upper 200. The body 36 includes: a first surface 40 facing the upper 20; a second surface 42 disposed on the side of the body 36 opposite to the first surface 40 and opposite to the ground surface during wear; and a cavity 44 disposed in the midsole 30 at a position corresponding to the heel area 24 of the footwear 10. As will be described in more detail below, the cavity 44 receives a cushioning pad 32 therein. Although the cavity 44 will be described below as being located in the area of ​​the midsole 30 corresponding to the heel area 24 of the footwear 10, the cavity 44 can be located anywhere along the length of the midsole 30 and can extend continuously from the forefoot area 20 of the footwear 10 to the heel area 24 of the footwear 10. If the cavity 44 extends along the length of the sole structure 100 between one or more of the forefoot area 20, midfoot area 22 and heel area 24, the size of the cushioning pad 32 can be similarly set to extend along the length of the cavity 44 and substantially fill most of the cavity 44.

[0032] The main body 36 additionally includes a first window 46 located on the inner side 16 of the footwear article 10 and a second window 48 located on the outer side 18 of the footwear article 10. The first window 46 and the second window 48 are each in fluid communication with the cavity 44 and with each other. Furthermore, the first window 46 and the second window 48 can be aligned with each other over the entire width of the sole structure 100 (i.e., along the direction extending between the inner side 16 and the outer side 18).

[0033] For details, please refer to the following: Figure 9 The cavity 44 is shown to include a first plurality of protrusions 50 and a second plurality of protrusions 52. The first plurality of protrusions 50 includes protrusions 50 extending from the top surface 54 of the cavity 44 in a direction away from the upper 200. Similarly, the second plurality of protrusions 52 includes protrusions 52 extending from the bottom surface 56 of the cavity 44 in a direction toward the upper 200. Figure 9 As shown, each of the first plurality of protrusions 50 is aligned with a corresponding protrusion 52 of the second plurality of protrusions 52, and also includes a distal end 58 spaced apart from the distal end 60 of the corresponding protrusion 52. Figure 2 As shown, each protrusion 50, 52 may include a circular or arcuate end 62 opposite to the corresponding window 46, 48. Finally, each protrusion 50, 52 is elongated and extends across most of the cavity 44 between the first window 46 and the second window 48.

[0034] A peripheral flange 36 extends from the first surface 40 of the midsole 30 toward the upper 200. The peripheral flange 36 extends at least partially over the upper in each of the forefoot area 20, midfoot area 22, and heel area 24. Specifically, the midsole 30 may extend over at least a portion of the quarter panel 106, the heel side panel 110, and the heel stabilizer 112. The peripheral flange 36 includes a generally curved and undulating profile having a series of peaks 64 and valleys 66 that alternate along the inner side 16 and outer side 18 of the footwear article 10. Figure 2 As shown, the peripheral flange 36 can extend to its maximum extent in the heel area 24 in the direction toward the upper 200, such that the height of the peripheral flange 36 relative to the first surface 40 gradually increases from the forefoot area 20 to the heel area 24.

[0035] The midsole 30 may include a foam material. For example, the midsole 30 may include foam or a resilient polymer material. In one configuration, the midsole 30 is formed by a 3D printing process, whereby material layers are deposited one by one until a product is formed. Figure 2 and Figure 3 The structure of the midsole 30 is shown. The material used to form the midsole 30 can be deposited from a printhead (not shown) to build the layers one by one, thus forming the structure of the midsole 30. This material can be thermoplastic polyurethane (TPU), which foams after being extruded from the printhead. In one configuration, the deposited material expands (i.e., foams) to approximately 20% to 30% of its original size after being extruded from the printhead, thereby providing the midsole 30 with the ability to cushion forces during wear.

[0036] 3D printing processes can include any 3D printing process, method or machine, including but not limited to fused deposition modeling (also known as fused filament manufacturing), laser sintering, binder jet 3D printing (also known as powder bed and inkjet printing), stereolithography, digital light processing, liquid 3D printing and multi-jet melting.

[0037] Forming the midsole 30 using a 3D printing process allows the midsole 30 to include a cavity 44, and further allows the cavity 44 to include protrusions 50, 52. Furthermore, the midsole 30, including the aforementioned features 44, 50, 52 but excluding the cushioning pad 32, can include an integral (i.e., monolithic) structure. If the midsole 30 includes an integral structure, then the entire sole structure 100 can include an integral structure such that each element of the sole structure 100 separate from the cushioning pad 32 is part of the same monolithic structure. Additionally, the upper 200 can include an integral structure that is part of the same monolithic structure of the sole structure 100 separate from the cushioning pad 32.

[0038] When the midsole 30 is 3D printed, multiple material layers of the midsole 30 can be deposited layer by layer until the structure shown in the figure is produced. Furthermore, the midsole 30 may consist only of the 3D-printed portion, or alternatively, the entire structure of the midsole 30 may be 3D printed. Regardless of whether the midsole 30 is produced using a 3D printing process or a different process, the midsole 30 can include a lattice structure. Finally, the midsole 30 can be 3D printed separately and attached to the upper 200, or alternatively, the sole structure 100 including the midsole 30 can be 3D printed together with the upper 200 by depositing multiple material layers layer by layer until the structure of the sole structure 100 and the upper 200 shown in the figure is produced. In one configuration, the deposited multiple layers comprise an elastically deformable material.

[0039] Regardless of how many parts of the sole structure 100 and / or upper 200 are produced using 3D printing, the various parts of the sole structure 100 and / or upper 200 produced by 3D printing can be generated by depositing multiple layers of filaments arranged parallel to each other until the structure of the sole structure 100 and / or upper 200 shown in the figure is produced. The deposited filaments arranged parallel to each other can be spaced apart from each other, with gaps provided between them, such that the gap is wider than or narrower than the width of one or more of the filaments adjacent to the gap.

[0040] Understandably, conventional manufacturing processes (such as, for example, injection molding) make it difficult to form cavities (such as cavity 44) and protrusions (such as protrusions 50, 52) extending into and from the two opposing walls defining the cavity. That is, forming the midsole 30 shown in the figure by injection molding would be difficult because, given the complexity of the structures associated with cavity 44 and protrusions 50, 52, removing the midsole 30 from the injection molding tool after it has been formed would be challenging. It should be noted that conventional manufacturing processes can be used to form the midsole 30, but it may be necessary for the midsole 30 to comprise two separately formed and joined pieces.

[0041] As described below, if the midsole 30 is formed by a conventional manufacturing process, such that the midsole 30 comprises two separate pieces joined together, then the example resilient polymer material used to form the midsole 30 may include those materials based on foaming or molding one or more polymers (such as one or more elastomers (e.g., thermoplastic elastomers (TPEs))). The one or more polymers may include aliphatic polymers, aromatic polymers, or mixtures thereof; and may include homopolymers, copolymers (including terpolymers), or mixtures thereof.

[0042] In some aspects, the one or more polymers may include olefin homopolymers, olefin copolymers, or blends thereof. Examples of olefin polymers include polyethylene, polypropylene, and combinations thereof. In other aspects, the one or more polymers may include one or more ethylene copolymers, such as ethylene-vinyl acetate (EVA) copolymers, EVOH copolymers, ethylene-ethyl acrylate copolymers, ethylene-unsaturated monofatty acid copolymers, and combinations thereof.

[0043] In another aspect, the one or more polymers may include one or more polyacrylates, such as polyacrylic acid, esters of polyacrylic acid, polyacrylonitrile, polyacrylate acetate, polymethyl acrylate, polyethyl acrylate, polybutyl acrylate, polymethyl methacrylate, and polyvinyl acetate; including derivatives thereof, copolymers thereof, and any combination thereof.

[0044] In another aspect, the one or more polymers may include one or more ionic polymers. In these aspects, the ionic polymers may include polymers having carboxylic acid functional groups, sulfonic acid functional groups, their salts (e.g., sodium, magnesium, potassium, etc.), and / or their anhydrides. For example, the ionic polymers may include one or more fatty acid-modified ionic polymers, polystyrene sulfonates, ethylene-methacrylic acid copolymers, and combinations thereof.

[0045] In another aspect, the one or more polymers may include one or more styrene block copolymers, such as acrylonitrile-butadiene-styrene block copolymers, styrene-acrylonitrile block copolymers, styrene-ethylene-butene-styrene block copolymers, styrene-ethylene-butadiene-styrene block copolymers, styrene-ethylene-propylene-styrene block copolymers, styrene-butadiene-styrene block copolymers, and combinations thereof.

[0046] In another aspect, the one or more polymers may comprise one or more polyamide copolymers (e.g., polyamide-polyether copolymers) and / or one or more polyurethanes (e.g., crosslinked polyurethanes and / or thermoplastic polyurethanes). Alternatively, the one or more polymers may comprise one or more natural and / or synthetic rubbers, such as butadiene and isoprene.

[0047] When the resilient polymer material is a foamed polymer material, the foamed material can be foamed using a physical foaming agent that changes phase to gas based on changes in temperature and / or pressure, or a chemical foaming agent that forms a gas when heated above its activation temperature. For example, the chemical foaming agent can be an azo compound, such as azodicarbonamide, sodium bicarbonate, and / or isocyanate.

[0048] In some embodiments, the foamed polymer material may be a cross-linked foam material. In these embodiments, peroxide-based cross-linking agents, such as dicumyl peroxide, may be used. Furthermore, the foamed polymer material may include one or more fillers, such as pigments, modified or natural clay, modified or unmodified synthetic clay, talc glass fiber, powdered glass, modified or natural silica, calcium carbonate, mica, paper, wood chips, etc.

[0049] The resilient polymer material can be formed using a molding process. In one example, when the resilient polymer material is a molded elastomer, the uncured elastomer (e.g., rubber) can be mixed with optional fillers and curing packages (such as sulfur-based or peroxide-based curing packages) in a Banbury mixer, calendered, shaped, placed in a mold, and vulcanized.

[0050] In another example, when the resilient polymer material is a foaming material, it can be foamed during a molding process such as injection molding. The thermoplastic polymer material can be melted in the barrel of an injection molding system and combined with a physical or chemical foaming agent and optional crosslinking agent, and then injected into a mold under conditions that activate the foaming agent to form molded foam.

[0051] Optionally, when the resilient polymer material is a foam material, the foam material can be compression molded foam. Compression molding can be used to change the physical properties of the foam (e.g., density, stiffness, and / or hardness), or to change the physical appearance of the foam (e.g., fusing two or more foam sheets, shaping the foam, etc.), or both.

[0052] Compression molding ideally begins by forming one or more foam preforms, such as by injection molding and foaming polymer material, by forming foamed particles or beads, by cutting foamed sheets, etc. Compression-molded foam can then be produced by placing one or more preforms comprising foamed polymer material in a compression mold and applying sufficient pressure to the preforms to compress them within a closed mold. Once the mold is closed, sufficient heat and / or pressure are applied to the one or more preforms within the closed mold for a sufficient duration to alter the preforms by forming a skin on the outer surface of the compression-molded foam, fusing the individual foam particles together, permanently increasing the density of the foam, or any combination thereof. After heating and / or applying pressure, the mold is opened and the molded foam article is removed from the mold.

[0053] For details, please refer to the following: Figure 4 and Figure 5The cushioning pad 32 is shown as a sac comprising a pair of opposing barrier layers 68a, 68b, which may be connected to each other in discrete locations to define a fluid-filled chamber 70, a web region 72, and a peripheral seam 74. In the illustrated configuration, the barrier layers 68a, 68b comprise a first upper barrier layer 68a and a second lower barrier layer 68b. Alternatively, the fluid-filled chamber 70 may be formed by any suitable combination of one or more barrier layers. While the fluid-filled chamber 70 is shown as comprising a chamber 70 containing pressurized fluid, the chamber 70 may additionally include mechanical structures, such as, for example, tensioning elements (not shown).

[0054] As used herein, the term "barrier layer" (e.g., barrier 68a, 68b) encompasses both single-layer and multilayer films. In some embodiments, one or both of the barrier layers 68a, 68b are each produced from a single-layer film (monolayer) (e.g., thermoforming or blow molding). In other embodiments, one or both of the barrier layers 68a, 68b are each produced from a multilayer film (multiple sublayers) (e.g., thermoforming or blow molding). In any aspect, each layer or sublayer may have a film thickness ranging from about 0.2 micrometers to about 1 millimeter. In yet another embodiment, the film thickness of each layer or sublayer may range from about 0.5 micrometers to about 500 micrometers. In still another embodiment, the film thickness of each layer or sublayer may range from about 1 micrometer to about 100 micrometers.

[0055] One or both of the barrier layers 68a and 68b may be independently transparent, translucent, and / or opaque. As used herein, the term "transparent" for the barrier layer and / or fluid-filled chamber means that light passes through the barrier layer substantially in a straight line, and an observer can see through the barrier layer. In contrast, with an opaque barrier layer, light cannot pass through the barrier layer, and one cannot see clearly through the barrier layer at all. A translucent barrier layer is between a transparent barrier layer and an opaque barrier layer because light passes through the translucent layer, but some light is scattered, making it impossible for an observer to see clearly through the layer.

[0056] Barrier layers 68a and 68b can each be made of an elastomeric material comprising one or more thermoplastic polymers and / or one or more crosslinkable polymers. In one aspect, the elastomeric material may include one or more thermoplastic elastomer materials, such as one or more thermoplastic polyurethane (TPU) copolymers, one or more ethylene-vinyl alcohol (EVOH) copolymers, etc.

[0057] As used herein, “polyurethane” refers to copolymers (including oligomers) containing urethane groups (-N(C=O)O-). In addition to urethane groups, these polyurethanes may also contain additional groups such as esters, ethers, ureas, urethane esters, biuret, carbodiimides, oxazolidinyl esters, isocyanurates, diuretes, carbonates, etc. On one hand, one or more of the polyurethanes can be produced by polymerizing one or more isocyanates with one or more polyols to generate copolymer chains having (-N(C=O)O-) bonds.

[0058] Examples of suitable isocyanates for generating polyurethane copolymer chains include diisocyanates, such as aromatic diisocyanates, aliphatic diisocyanates, and combinations thereof. Examples of suitable aromatic diisocyanates include toluene diisocyanate (TDI), adducts of TDI and trimethylolpropane (TMP), methylene diphenyl diisocyanate (MDI), xylene diisocyanate (XDI), tetramethylphenyl dimethylene diisocyanate (TMXDI), hydrogenated xylene diisocyanate (HXDI), naphthalene 1,5-diisocyanate (NDI), 1,5-tetrahydronaphthalene diisocyanate, p-phenylene diisocyanate (PPDI), 3,3'-dimethyldiphenyl-4,4'-diisocyanate (DDDI), 4,4'-dibenzyl diisocyanate (DBDI), 4-chloro-1,3-phenylene diisocyanate, and combinations thereof. In some embodiments, these copolymer chains are substantially free of aromatic groups.

[0059] In certain aspects, the polyurethane polymer chain is generated from diisocyanates including HMDI, TDI, MDI, H12 aliphatic compounds, and combinations thereof. In another aspect, thermoplastic TPUs can include polyester-based TPUs, polyether-based TPUs, polycaprolactone-based TPUs, polycarbonate-based TPUs, polysiloxane-based TPUs, or combinations thereof.

[0060] On the other hand, the polymer layer may include one or more of the following: EVOH copolymers, poly(vinyl chloride), polyvinylidene ethylene polymers and copolymers (e.g., polyvinylidene chloride), polyamides (e.g., amorphous polyamides), amide-based copolymers, acrylonitrile polymers (e.g., acrylonitrile-methyl acrylate copolymers), polyethylene terephthalate, polyetherimide, polyacrylamide, and other polymeric materials known to have relatively low gas permeability. Blends of these materials, as well as blends with the TPU copolymers described herein (and optionally combinations of polyimide and crystalline polymers), are also suitable.

[0061] Barrier layers 68a, 68b may comprise two or more sublayers (multilayer films), such as those shown in U.S. Patent Nos. 5,713,141 and 5,952,065 to Mitchell et al., the disclosures of which are incorporated herein by reference in their entirety. In embodiments where barrier layers 68a, 68b comprise two or more sublayers, suitable examples of multilayer films include microlayer films, such as those disclosed in U.S. Patent No. 6,582,786 to Bonk et al., which is incorporated herein by reference in its entirety. In further embodiments, barrier layers 68a, 68b may each independently comprise alternating sublayers of one or more TPU copolymer materials and one or more EVOH copolymer materials, wherein the total number of sublayers in each of barrier layers 68a, 68b comprises at least four (4) sublayers, at least ten (10) sublayers, at least twenty (20) sublayers, at least forty (40) sublayers, and / or at least sixty (60) sublayers.

[0062] The fluid-filled chamber 70 can be produced by barrier layers 68a, 68b using any suitable technique, such as thermoforming (e.g., vacuum thermoforming), blow molding, extrusion, injection molding, vacuum molding, rotational molding, transfer molding, pressure molding, heat sealing, casting, low-pressure casting, rotational casting, reaction injection molding, radio frequency (RF) welding, etc. In one aspect, barrier layers 68a, 68b can be produced by co-extrusion followed by vacuum thermoforming to create an inflatable chamber 70, which may optionally include one or more valves (e.g., check valves) that allow the chamber 70 to be filled with a fluid (e.g., gas).

[0063] The chamber 70 can be configured to be fluid-filled (e.g., in footwear 10) or unfilled. The chamber 70 can be filled to include any suitable fluid, such as a gas or liquid. In one aspect, the gas may include air, nitrogen (N2), or any other suitable gas. In other aspects, the chamber 70 may alternatively include other media, such as granules, beads, ground recycled materials, etc. (e.g., foamed beads and / or rubber beads). The fluid supplied to the chamber 70 may pressurize the chamber 70. Alternatively, the fluid supplied to the chamber 70 may be at atmospheric pressure, so that the chamber 70 is not pressurized but simply contains a volume of fluid at atmospheric pressure.

[0064] The fluid-filled chamber 70 ideally has a low gas permeability to maintain the gas pressure it holds. In some embodiments, the gas permeability of the fluid-filled chamber 70 to nitrogen is at least about ten (10) times lower than that of a butyl rubber layer of substantially the same size. In one respect, for an average film thickness of 500 micrometers (based on the thickness of barrier layers 68a, 68b), the fluid-filled chamber 70 has 15 cubic centimeters per square meter per atmosphere per day (cm²). 3 / m 2 •atm•day) or less nitrogen transmission rate. In another aspect, this transmission rate is 10 cm. 3 / m 2 • atm • day or less, 5 cm 3 / m 2 • atm • day or less, or 1 cm 3 / m 2 • atm • day or less.

[0065] refer to Figure 4 and Figure 5 The fluid-filled chamber 70 includes a series of interconnected fluid-filled segments, including a first segment 76 and a second segment 78, which extend along the length of the fluid-filled chamber 70 and are substantially parallel to each other. The fluid-filled chamber 70 additionally includes a third segment 80, a fourth segment 82, and a fifth segment 84, which extend between the first segment 76 and the second segment 78 and fluidly connect the first segment 76 and the second segment 78. As shown, the third segment 80, the fourth segment 82, and the fifth segment 84 are substantially parallel to each other and substantially perpendicular to the longitudinal axis A of the first segment 76, the second segment 78, and the footwear article 10. 10 extend.

[0066] like Figure 4 As shown, the first segment 76 includes a first distal end 86a extending through the fifth segment 84 and a second distal end 86b extending through the third segment 80. Similarly, the second segment 78 includes a first distal end 88a extending through the fifth segment 84 and a second distal end 88b extending through the third segment 80. As shown, the first distal end 86a of the first segment 76 is opposite the first distal end 88a of the second segment 78 across the width of the fluid-filled chamber 70, and the second distal end 86b of the first segment 76 is opposite the second distal end 88b of the second segment 78 across the width of the chamber 70. Based on the foregoing, and as... Figure 4 As shown, the fluid-filled chamber 70 is symmetrical about the central longitudinal axis and about the central longitudinal axis passing through the fourth segment 82.

[0067] like Figure 5As shown, distal ends 86a, 86b, 88a, and 88b each include a tapered surface 90 extending in a direction toward the upper barrier layer 68a. When the fluid-filled chamber 70 is received within the cavity 44, the tapered surface 90 faces the corresponding tapered surface 92 of the cavity 44, as shown. Figure 9 As shown.

[0068] The web region 72 is defined by portions of an upper barrier layer 68a and a lower barrier layer 68b that are interconnected. The web region 72 generally defines the shape of segments 76, 78, 80, 82, and 84, and includes a pair of first recesses 94 and a pair of second recesses 96. Each recess 94 and 96 is elongated and extends between a first circular end 98a located near the first segment 76 and a second circular end 98b located near the second segment 78. Figure 9 As shown, a recess 94 is provided on the side of the pouch 32 opposite to a recess 96. Furthermore, each recess 94 is aligned with the corresponding recess 96 across the width of the pouch 32.

[0069] For details, please refer to the following: Figures 6 to 8 The assembly of the bladder 32 to the midsole 30 will be described in detail. Initially, the midsole 30 and the bladder 32 are formed separately. At this time, the bladder 32 can be attached to the midsole 30 by inserting the bladder 32 into one of the windows 46, 48 of the midsole 30. The dimensions of the first window 46 and the second window 48 are set such that the cross-sectional dimension of each window 46, 48 is smaller than the maximum corresponding cross-sectional dimension of the bladder 32. Therefore, and as will be described below, the bladder 32 is compressed or temporarily deformed during the insertion of the bladder 32 into the corresponding one of the windows 46, 48. Although the bladder 32 can be installed into the cavity 44 through either the first window 46 or the second window 48, the bladder 32 will be described as being inserted into the cavity 44 at the first window 46. Furthermore, although the bladder 32 is described and shown as being inserted into one of the first window 46 or the second window 48 at the inner side 16 or the outer side 18 of the sole structure 100, the bladder 32 can be inserted into any opening formed through the side surface of the midsole 30 that communicates with the cavity 44. For example, an opening of similar size and shape to windows 44 and 46 can be provided on the side wall of the heel area 24 located at the rear end 14 of the midsole 30, and this opening communicates with the cavity 44. The bladder 32 can be inserted into the cavity 44 through such an opening.

[0070] The sac 32 can be positioned adjacent to the first window 46 such that the first distal end 86a of the first segment 76 and the first distal end 88a of the second segment 78 respectively engage the outer peripheral edges of the midsole 30 defining the first window 46. At this time, forces can be applied to the first segment 76 and the second segment 78 to move the distal ends 86a, 88a in a direction toward each other in an attempt to fit the distal ends 86a, 88a into the first window 46. This movement of the distal ends 86a, 88a in a direction toward each other can be caused by compression and / or temporary deformation of the sac 32 to fit into the first window 46. This compression and / or deformation can be facilitated during insertion of the sac 32 into the first window 46 by providing an angled or tapered surface to the opening of the first window 46 to promote compression and / or temporary deformation of the sac 32.

[0071] Once the distal ends 86a and 88a are fully inserted into the first window 46, a force can be applied to the pouch 32 so that the pouch 32 is positioned relative to the cavity 44 and within the cavity 44 in a direction extending between the inner side 16 and the outer side 18, substantially perpendicular to the longitudinal axis A of the footwear 10. 10 Movement, such as Figure 7 As shown.

[0072] Once sac 32 is in Figure 7 The position shown allows for the application of a rotational force to the sac 32, causing it to rotate 90 degrees (90°) relative to the cavity 44 and within the cavity 44. Figure 8 As shown, the distal ends 86a and 88a face towards the front end 12, and the distal ends 86b and 88b face towards the rear end 14. At this point, the first segment 76 and the second segment 78 are substantially parallel to the longitudinal axis A of the footwear 10. 10 Because cavity 44 has a larger cross-sectional dimension than the first window 46 and the second window 48, when bladder 32 moves... Figure 8 In the indicated position, due to the resilient nature of the bladder 32 and / or the pressure of the fluid disposed within the chamber 70, the bladder 32 is allowed to recover from a compressed or deformed state to a relaxed or expanded state. Although the cavity 44 is described as having a larger cross-sectional dimension than the first window 46 and the second window 48, the maximum vertical height of the cavity 44 (i.e., along the direction substantially perpendicular to the second surface 42 of the midsole 30) may be less than or greater than the thickness of the bladder 32. Furthermore, the maximum inner and outer width of the bladder 32 (i.e., extending in the direction between the first segment 76 and the second segment 78) may be less than the maximum inner and outer width of the cavity 44 (i.e., extending in the direction between the inner side 16 and the outer side 18).

[0073] When sac 32 is in Figure 8In the indicated position, the first protrusion 50 is received within and substantially fills the corresponding recess in the first recess 94, and the second protrusion 52 is received within and substantially fills the corresponding recess in the second recess 96. In this manner, portions of the web region 72 are located between the relatively distal ends 58, 60 of the corresponding protrusions 50, 52 within the corresponding recesses 94, 96. Inserting the protrusions 50, 52 into the corresponding recesses 94, 96 helps to secure the position of the bladder 32 relative to the midsole 30, so that the bladder 32 remains in the desired position relative to the midsole 30 during use.

[0074] Because the protrusions 50, 52 have shapes complementary to the shapes of the recesses 94, 96, the sac 32 is held in place by the engagement between the protrusions 50, 52 and the recesses 94, 96. Therefore, when the sac 32 is rotated relative to the midsole 30 into place, the protrusions 50, 52 substantially fill each recess 94, 96. Furthermore, one or more of the top surface 54 and the bottom surface 56 of the cavity 44 may include texture to increase the frictional engagement between the sac 32 and the surfaces 54, 56 of the cavity 44 in an attempt to maintain the desired position of the sac 32 within the cavity 44.

[0075] Although the cushioning pad 32 is described and shown as a sac having a fluid-filled chamber 70, the sac 32 can be replaced by a foam element having the shape of the sac 32. This foam element may include an outer surface with a high gloss unit value, thereby giving the outer surface of the foam element a glossy appearance. In doing so, the outer surface makes the foam element appear as a sac. Replacing the sac 32 with a foam element having the same shape as the sac 32 (with or without an outer surface having a high gloss unit value) provides different cushioning characteristics to the sole structure 100 compared to the fluid-filled chamber 70. Furthermore, the cushioning pad 32 may include a mechanical cushioning structure comprising one or more of a compressible lattice structure or a compressible minimum surface area structure. See U.S. Patent No. 11,0713,48, entitled “Footwear Sole Structure,” issued July 27, 2020, the entire contents of which are expressly incorporated herein by reference.

[0076] As described above, the cushioning pad 32 can be inserted into the midsole 30 through the first window 46 or the second window 48, can be rotated to the appropriate position, and can be held in the desired position relative to the midsole 30 due to the engagement between the protrusions 50, 52 and the recesses 94, 96 of the cushioning pad 32. When the footwear 10 reaches the end of its service life, force can be similarly applied to the cushioning pad 32 to rotate it relative to the midsole 30, thereby removing the cushioning pad 32 from the midsole 30 through the first window 46 or the second window 48, in an attempt to more easily and efficiently recycle the midsole 30 and the cushioning pad 32.

[0077] For details, please refer to the following: Figure 11 and Figure 12 Footwear article 10c is provided. Given the substantial structural and functional similarity of footwear article 10c to footwear article 10, the same reference numerals will be used to identify the same parts in the following text and figures, while the same reference numerals containing the letter extension "c" will be used to identify those parts that have been modified.

[0078] The footwear article 10c includes a sole structure 100c having a midsole 30c defining a cavity 44. The cavity 44 includes a first plurality of protrusions 50c and a second plurality of protrusions 52c. The first plurality of protrusions 50c includes protrusions 50c extending from the top surface 54 of the cavity 44 in a direction away from the upper 200. Similarly, the second plurality of protrusions 52c includes protrusions 52c extending from the bottom surface 56 of the cavity 44 in a direction toward the upper 200. Each of the first plurality of protrusions 50c is aligned with a corresponding protrusion 52c of the second plurality of protrusions 52c and includes a distal end 58 spaced apart from the distal end 60 of the corresponding protrusion 52c. Figure 11 As shown, each protrusion 50c, 52c may include a circular or arcuate end 62c opposite to the corresponding window 46, 48. Finally, each protrusion 50c, 52c is elongated and extends across most of the cavity 44 between the first window 46 and the second window 48.

[0079] Protrusions 50c and 52c are similar to protrusions 50 and 52, respectively, differing only in the end of protrusions 50c and 52c near the arched end 62c. Specifically, and as... Figure 11 and Figure 12 As shown, the distal ends of protrusions 50c and 52c include an angle 300 with an inclined surface 302 extending from the respective distal ends 58 and 60 to approximately the midpoint of the curved end 62a. This angle 300 and the formed inclined surface 302 facilitate the insertion of the bladder 32 into one of the respective windows 46 and 48. For example, when the bladder 32 is inserted into one of the windows 46 and 48 (… Figure 6 and Figure 7And then rotated to the appropriate position in a manner similar to that described above with respect to footwear 10. Figure 8 The sac 32 will engage the inclined surface 302 of the protrusions 50c, 52c. As will be described in more detail below, the bevel angle 300 reduces the thickness of the protrusions 50c, 52c near the windows 46, 48, which in turn reduces the insertion of the sac 32 into the cavity 44 and the rotation of the sac 32 to... Figure 8 The force required at the indicated position.

[0080] The inclined surfaces 302 are opposite to each other, such that the gap between the opposing inclined surfaces 302 is greater than the gap between the surfaces at the distal ends 58 and 60. Specifically, the gap between the inclined surfaces 302 is greater than the central longitudinal axis A near the sole structure 100c. 10 The gap between protrusions 50c and 52c. Therefore, in order to fully insert the sac 32 into the cavity 44 and rotate the sac 32 to Figure 8 The degree to which the sac 32 and / or the protrusions 50c and 52c must be compressed at the indicated positions is reduced. Furthermore, engaging the outer surface of the sac 32 with the inclined surface 302 facilitates guiding the sac 32 into the cavity 44.

[0081] During the process of installing the bladder 32 into the cavity 44 of the midsole 30c, the bladder 32 is initially positioned relative to the sole structure 100c to... Figure 6 Positioning is similar to that shown in the footwear article 10. Specifically, the pouch 32 can be attached to the midsole 30c by inserting it into one of the windows 46, 48 of the midsole 30c. The dimensions of the first window 46 and the second window 48 are set such that the cross-sectional dimension of each window 46, 48 is smaller than the maximum corresponding cross-sectional dimension of the pouch 32. Therefore, and as will be described below, the pouch 32 is compressed or temporarily deformed during the insertion of the pouch 32 into the corresponding one of the windows 46, 48. Although the pouch 32 can be installed into the cavity 44 through either the first window 46 or the second window 48, the pouch 32 will be described as being inserted into the cavity 44 at the first window 46. Furthermore, although the pouch 32 is described and shown as being inserted into one of the first window 46 or the second window 48 at the inner side 16 or the outer side 18 of the sole structure 100c, the pouch 32 can be inserted into any opening formed through the side surface of the midsole 30c that communicates with the cavity 44. For example, an opening of similar size and shape to windows 44 and 46 can be provided on the side wall of the heel area 24 located at the rear end 14 of the midsole 30c, and this opening communicates with the cavity 44. The bladder 32 can be inserted into the cavity 44 through such an opening.

[0082] The sac 32 can be positioned adjacent to the first window 46 such that the first distal end 86a of the first segment 76 and the first distal end 88a of the second segment 78 respectively engage the outer peripheral edges of the midsole 30c defining the first window 46. At this time, forces can be applied to the first segment 76 and the second segment 78 to move the distal ends 86a and 88a toward each other in an attempt to fit the distal ends 86a and 88a into the first window 46. This movement of the distal ends 86a and 88a toward each other can be caused by compression and / or temporary deformation of the sac 32 to fit into the first window 46. This compression and / or deformation can be facilitated during insertion of the sac 32 into the first window 46 by providing an angled or tapered surface to the opening of the first window 46 to promote compression and / or temporary deformation of the sac 32.

[0083] Once the distal ends 86a and 88a are fully inserted into the first window 46, they engage the inclined surfaces 302 of the protrusions 50c and 52c. At this point, the inclined surfaces 302 at the angle 300 guide the bladder 32 and act as a ramp, guiding the bladder 32 further into the cavity 44 and between the distal ends 58 and 60. Force can be applied to the bladder 32 relative to the cavity 44 and within the cavity 44 in a direction extending between the inner side 16 and the outer side 18, substantially perpendicular to the longitudinal axis A of the footwear 10c. 10 Movement, such as Figure 7 Regarding footwear product 10, the force required to insert the bladder 32 into the cavity 44 of the midsole 30c is reduced compared to the force required to insert the bladder 32 into the cavity of the midsole 30c. This is due to the increased distance between the protrusions 50c and 52c at the opposing angles 300. Furthermore, the inclined surface 302 of the angle 300 guiding the bladder 32 facilitates the insertion of the bladder 32 into the cavity 44. Figure 7 The location shown.

[0084] Once sac 32 is in Figure 7 The position shown allows for the application of a rotational force to the sac 32, causing it to rotate 90 degrees (90°) relative to the cavity 44 and within the cavity 44. Figure 8 As shown, the distal ends 86a and 88a face towards the front end 12, and the distal ends 86b and 88b face towards the rear end 14. At this point, the first segment 76 and the second segment 78 are substantially parallel to the longitudinal axis A of the footwear 10c. 10 Because cavity 44 has a larger cross-sectional dimension than the first window 46 and the second window 48, when bladder 32 moves... Figure 8In the indicated position, due to the resilient nature of the bladder 32 and / or the pressure of the fluid disposed within the chamber 70, the bladder 32 is allowed to recover from a compressed or deformed state to a relaxed or expanded state. Although the cavity 44 is described as having a larger cross-sectional dimension than the first window 46 and the second window 48, the maximum vertical height of the cavity 44 (i.e., along the direction substantially perpendicular to the second surface 42 of the midsole 30c) may be less than or greater than the thickness of the bladder 32. Furthermore, the maximum inner and outer width of the bladder 32 (i.e., extending in the direction between the first segment 76 and the second segment 78) may be less than the maximum inner and outer width of the cavity 44 (i.e., extending in the direction between the inner side 16 and the outer side 18).

[0085] When sac 32 is in Figure 8 In the indicated positions, the first protrusion 50c is received within and substantially fills the corresponding recess in the first recess 94, and the second protrusion 52c is received within and substantially fills the corresponding recess in the second recess 96. In this manner, portions of the web region 72 are located between the relatively distal ends 58 and 60 of the corresponding protrusions 50c and 52c within the corresponding recesses 94 and 96. Inserting the protrusions 50c and 52c into the corresponding recesses 94 and 96 helps to secure the position of the bladder 32 relative to the midsole 30c, so that the bladder 32 remains in the desired position relative to the midsole 30c during use.

[0086] Because the protrusions 50c and 52c have shapes complementary to the shapes of the recesses 94 and 96, the sac 32 is held in place by the engagement between the protrusions 50c and 52c and the recesses 94 and 96. Therefore, when the sac 32 is rotated relative to the midsole 30c into place, the protrusions 50c and 52c substantially fill each recess 94 and 96. Furthermore, one or more of the top surface 54 and the bottom surface 56 of the cavity 44 may include texture to increase the frictional engagement between the sac 32 and the surfaces 54 and 56 of the cavity 44 in an attempt to maintain the desired position of the sac 32 within the cavity 44.

[0087] refer to Figure 12 Sac 32 is shown as being located in sac 32 Figure 8 The positions of the protrusions 50c and 52c are such that they are received within the recesses 94 and 96, respectively. For example... Figure 12As shown, even though protrusions 50c and 52c include a chamfer 30° at each end, the total length of protrusions 50c and 52c remains unchanged compared to protrusions 50 and 52, respectively. This is because each protrusion 50c and 52c still includes a rounded or arcuate end 62c. In other words, the length of protrusions 50c and 52c measured between the rounded ends 62c of each protrusion 50c and 52c is the same as the length of protrusions 50 and 52 measured between the rounded ends 62. The only difference is that, since the chamfer 30° is located at each end of protrusions 50c and 52c, the rounded end 62c has a reduced height relative to the rounded end 62.

[0088] Although the sole structure 100c is described and shown as including protrusions 50c and 52c, the sole structure 100c may include only protrusion 50c or only protrusion 52c. Furthermore, the sole structure 100c may include any combination of protrusions 50, 50c, 52, and 52c. For example, the sole structure 100c may include a single protrusion 50 and a single protrusion 50c, may include a single protrusion 52 and a single protrusion 52c, or may include one of each of protrusions 50, 50c, 52, and 52c. Finally, the sole structure 100c may include mixed protrusions comprising an end without bevel 300 and another opposite end including bevel 300. Such mixed protrusions can be implemented if the bladder 32 is inserted at the same windows 46, 48 during installation. For example, if the pouch 32 is always mounted at the window 46, the ends of the protrusions 50c and / or 52c opposite to the window 46 may include a chamfer 300, while the ends of the mixed protrusions opposite to the other window 48 include an end without a chamfer, as shown in the sole structure 100.

[0089] Although protrusions 50c and 52c are described as including an angle 300, protrusions 50c and 52c may alternatively include a tapered surface instead of an angle 300, or may be rounded at various locations of the angle 300. Additionally, because the midsole 30a can have an integral structure that can be formed by a 3D printing process, one or more of the protrusions 50c and 52c at a location of the angle 300 can be shaped such that the protrusions 50c and 52c are softer at the locations of the angle 300 and the rounded end 62c. Providing a softer structure for the protrusions 50c and 52c at the locations of the angle 300 and the rounded end 62c further facilitates insertion of the sac 32 into the cavity 44 by making the protrusions 50c and 52c more easily deformable when the sac 32 engages with the protrusions 50c and 52c at the inclined surface 302 and when forces are applied to the protrusions 50c and 52c. Finally, the protrusions 50, 52 of the footwear 10 may also include a softer material at the rounded end 62 to facilitate compression of the protrusions 50, 52 when the pouch 32 is inserted into the windows 46, 48.

[0090] The following clauses provide exemplary configurations of the sole structure for footwear articles, footwear articles, and related manufacturing methods.

[0091] Clause 1. A sole structure for footwear articles includes: a midsole including a cavity having a first protrusion and a second protrusion, the first protrusion extending from a first surface in a first direction within the cavity, and the second protrusion extending from a second surface in a second direction toward the first protrusion within the cavity; and a cushioning pad including a first recess disposed on a first side of the cushioning pad and a second recess disposed on an opposite second side of the cushioning pad, the first recess receiving the first protrusion and the second recess receiving the second protrusion.

[0092] Clause 2. The sole structure according to Clause 1, wherein the first protrusion is aligned with the second protrusion.

[0093] Clause 3. The sole structure according to any one of the preceding clauses, wherein the distal end of the first protrusion is opposite to and aligned with the distal end of the second protrusion.

[0094] Clause 4. The sole structure according to any one of the preceding clauses, wherein at least one of the first protrusion and the second protrusion is elongated and extends between a first end and a second end along the longitudinal axis of the at least one of the first protrusion and the second protrusion, the at least one of the first end and the second end including an angle.

[0095] Clause 5. The sole structure according to Clause 4, wherein the first protrusion substantially fills the first recess and the second protrusion substantially fills the second recess.

[0096] Clause 6. The sole structure according to any one of the preceding clauses, wherein the cushioning pad is a bladder.

[0097] Clause 7. The sole structure according to Clause 6, wherein the bladder includes a first barrier layer connected to a second barrier layer to define a chamber having a plurality of segments defined by a ventral region of the bladder.

[0098] Clause 8. The sole structure according to Clause 7, wherein a portion of the ventral region is disposed between the distal end of the first protrusion and the distal end of the second protrusion.

[0099] Clause 9. The sole structure as described in Clause 6, wherein the bladder is pressurized.

[0100] Clause 10. A footwear article comprising a sole structure according to any one of the preceding clauses.

[0101] Clause 11. A method comprising: forming a midsole, the midsole including a cavity and a first protrusion extending from a first surface of the midsole along a first direction within the cavity; forming a cushioning pad including a first recess disposed on a first side of the cushioning pad; inserting the cushioning pad into the cavity of the midsole; and The cushioning pad is rotated within the cavity until the first protrusion is received by the first recess.

[0102] Clause 12. The method according to Clause 11, wherein forming the midsole includes forming a second protrusion extending within the cavity from a second surface of the midsole toward the first protrusion in a second direction.

[0103] Clause 13. The method according to Clause 12 further includes aligning the second protrusion with the first protrusion.

[0104] Clause 14. The method according to Clause 13, wherein aligning the second protrusion with the first protrusion includes making the distal end of the second protrusion opposite to the distal end of the first protrusion.

[0105] Clause 15. The method according to any one of the preceding clauses, wherein forming a midsole having a first protrusion includes forming said midsole having an elongated protrusion.

[0106] Clause 16. The method according to any one of the preceding clauses further includes substantially filling the first recess with the first protrusion when the first protrusion is received by the first recess.

[0107] Clause 17. The method according to any one of the preceding clauses, wherein forming the cushioning pad includes forming a cyst.

[0108] Clause 18. The method according to Clause 17, wherein forming the sac includes connecting a first barrier layer to a second barrier layer to define a chamber having a plurality of segments defined by a ventral region of the sac, the ventral region of the sac defining the first recess.

[0109] Clause 19. The method according to Clause 17 further includes pressurizing the sac.

[0110] Clause 20. The method according to any one of the preceding clauses further includes incorporating the midsole and the cushioning pad into the footwear article.

[0111] The foregoing description has been provided for purposes of illustration and description. This foregoing description is not intended to be exhaustive or limiting of this disclosure. Individual elements or features of a particular configuration are generally not limited to that particular configuration, but where applicable, individual elements or features may be interchangeable and may be used in selected configurations, even if not specifically shown or described. Individual elements or features of a particular configuration may also vary in various ways. Such variations should not be considered as departing from this disclosure, and all such modifications are intended to be included within the scope of this disclosure.

Claims

1. A sole structure for footwear products, the sole structure comprising: The midsole includes a cavity having a first protrusion and a second protrusion, the first protrusion extending from a first surface along a first direction within the cavity, and the second protrusion extending from a second surface toward the first protrusion within the cavity along a second direction; as well as A cushioning pad, the cushioning pad including a first recess disposed on a first side of the cushioning pad and a second recess disposed on an opposite second side of the cushioning pad, the first recess receiving a first protrusion and the second recess receiving a second protrusion.

2. The sole structure according to claim 1, wherein the first protrusion is aligned with the second protrusion.

3. The sole structure according to claim 1, wherein the distal end of the first protrusion is opposite to and aligned with the distal end of the second protrusion.

4. The sole structure of claim 1, wherein at least one of the first protrusion and the second protrusion is elongated and extends between a first end and a second end along the longitudinal axis of the at least one of the first protrusion and the second protrusion, and at least one of the first end and the second end includes an angle.

5. The sole structure of claim 4, wherein the first protrusion substantially fills the first recess, and the second protrusion substantially fills the second recess.

6. The sole structure according to claim 1, wherein the cushioning pad is a bladder.

7. The sole structure of claim 6, wherein the bladder includes a first barrier layer connected to a second barrier layer to define a chamber having a plurality of segments defined by a ventral region of the bladder.

8. The sole structure of claim 7, wherein a portion of the ventral region is disposed between the distal end of the first protrusion and the distal end of the second protrusion.

9. The sole structure of claim 6, wherein the bladder is pressurized.

10. A footwear article comprising the sole structure according to claim 1.

11. A method comprising: A midsole is formed, the midsole including a cavity and a first protrusion extending from a first surface of the midsole along a first direction within the cavity; A buffer pad is formed, the buffer pad including a first recess disposed on a first side of the buffer pad; Insert the cushioning pad into the cavity of the midsole; as well as The cushioning pad is rotated within the cavity until the first protrusion is received by the first recess.

12. The method of claim 11, wherein forming the midsole includes forming a second protrusion extending within the cavity from a second surface of the midsole toward the first protrusion in a second direction.

13. The method of claim 12, further comprising aligning the second protrusion with the first protrusion.

14. The method of claim 13, wherein aligning the second protrusion with the first protrusion comprises making the distal end of the second protrusion opposite to the distal end of the first protrusion.

15. The method of claim 11, wherein forming the midsole having the first protrusion includes forming the midsole having an elongated protrusion.

16. The method of claim 11, further comprising substantially filling the first recess with the first protrusion when the first protrusion is received by the first recess.

17. The method of claim 11, wherein forming the cushioning pad comprises forming a sac.

18. The method of claim 17, wherein forming the sac includes connecting a first barrier layer to a second barrier layer to define a chamber having a plurality of segments defined by a ventral region of the sac, the ventral region of the sac defining the first recess.

19. The method of claim 17, further comprising pressurizing the bladder.

20. The method of claim 11, further comprising incorporating the midsole and the cushioning pad into the footwear article.

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