Sole structure for article of footwear
Patent Information
- Application Number
- PCT/US2026/019615
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2026-03-16
- Filing Date
- 2026-03-17
- Publication Date
- 2026-09-24
Smart Images

Figure US2026019615_24092026_PF_FP_ABST
Abstract
Description
Attorney Docket No.: 201882-579925 / 250185WO01SOLE STRUCTURE FOR ARTICLE OF FOOTWEARCROSS REFERENCE TO RELATED APPLICATIONS
[0001] This PCT International application claims priority to U.S. Non-Provisional Application No. 19 / 568,067, filed on March 16, 2026, which claims priority under 35 U.S.C. §119(e) to U.S. Provisional Application No. 63 / 775,815, filed on March 21, 2025. The disclosure of this prior application is considered part of the disclosure of this application and is hereby incorporated by reference in its entirety.FIELD
[0002] The present disclosure relates generally to an article of footwear and, more particularly, to a sole structure for an article of footwear.BACKGROUND
[0003] This section provides background information related to the present disclosure, which is not necessarily prior art.
[0004] Articles of footwear conventionally include an upper and a sole structure. The upper may be formed from any suitable material(s) to receive, secure, and support a 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 to a bottom surface of the foot, attaches to the sole structure.
[0005] Sole structures generally include a layered arrangement extending between a ground surface and the upper. For example, a sole structure may include a midsole and an outsole. The midsole is generally disposed between the outsole and the upper and provides cushioning for the foot. The midsole may include various cushioning and support structures that compress resiliently under an applied load to cushion the foot by attenuating ground-reaction forces. Examples of known support structures include resilient materials, such as foams, and fluid-filled structures, such as airbags or bladders. The outsole provides abrasion-resistance and traction with the ground surface and may be formed from rubber or other materials that impart durability and wearresistance, as well as enhance traction with the ground surface.164187002.1Attorney Docket No.: 201882-579925 / 250185WO01
[0006] While sole structures have proven acceptable for their intended purposes, a continuous need for improvement in the relevant art remains. A need also exists for an article of footwear having improved overall comfort and fit while providing such improved performance. Additionally, there is a growing demand for sole structures that offer enhanced energy return, which can improve athletic performance by reducing fatigue and increasing output. Furthermore, advancements in materials science present opportunities to develop lighter, more flexible sole structures without compromising durability or support. Cost efficiency is also a critical factor, as there is a need to produce high-performance sole structures at a lower cost.DRAWINGS
[0007] The drawings described herein are for illustrative purposes only of selected configurations and are not intended to limit the scope of the present disclosure.
[0008] FIG. 1 is a rear perspective view of a sole structure for an article of footwear according to an example of the present disclosure;
[0009] FIG. 2 is a lateral side view of the sole structure of FIG. 1;
[0010] FIG. 3 is a medial side view of the sole structure of FIG. 1 ;
[0011] FIG. 4 is a top exploded perspective view of the sole structure of FIG. 1;
[0012] FIG. 5 is a bottom exploded perspective view of the sole structure of FIG. 1;
[0013] FIG. 6 is a top plan view of the sole structure of FIG. 1;
[0014] FIG. 7 is a cross-sectional view of the sole structure of FIG. 1, taken along Line 7-7 of FIG. 6;
[0015] FIG. 8 is a cross-sectional view of the sole structure of FIG. 1, taken along Line 8-8 of FIG. 6;
[0016] FIG. 9 is a cross-sectional view of the sole structure of FIG. 1, taken along Line 9-9 of FIG. 6;
[0017] FIG. 10 is a cross-sectional view of the sole structure of FIG. 1, taken along Line 10-10 of FIG. 6;
[0018] FIG. 11 is a cross-sectional view of the sole structure of FIG. 1, taken along Line Illi of FIG. 6;
[0019] FIG. 12 is a cross-sectional view of the sole structure of FIG. 1, taken along Line 12-12 of FIG. 6;264187002.1Attorney Docket No.: 201882-579925 / 250185WO01
[0020] FIG. 13 is a cross-sectional view of the sole structure of FIG. 1, taken along Line 13-13 of FIG. 6;
[0021] FIG. 14 is a cross-sectional view of the sole structure of FIG. 1, taken along Line 14-14 of FIG. 6;
[0022] FIG. 15 is a rear perspective view of a sole structure for an article of footwear according to another example of the present disclosure;
[0023] FIG. 16 is a lateral side view of the sole structure of FIG. 15;
[0024] FIG. 17 is a medial side view of the sole structure of FIG. 15;
[0025] FIG. 18 is atop exploded perspective view of the sole structure of FIG. 15;
[0026] FIG. 19 is a bottom exploded perspective view of the sole structure of FIG. 15;
[0027] FIG. 20 is a top plan view of the sole structure of FIG. 15;
[0028] FIG. 21 is a cross-sectional view of the sole structure of FIG. 15, taken along Line 21- 21 of FIG. 20;
[0029] FIG. 22 is a cross-sectional view of the sole structure of FIG. 15, taken along Line 22- 22 of FIG. 20;
[0030] FIG. 23 is a cross-sectional view of the sole structure of FIG. 15, taken along Line 23- 23 of FIG. 20;
[0031] FIG. 24 is a cross-sectional view of the sole structure of FIG. 15, taken along Line 24- 24 of FIG. 20;
[0032] FIG. 25 is a cross-sectional view of the sole structure of FIG. 15, taken along Line 25- 25 of FIG. 20;
[0033] FIG. 26 is a cross-sectional view of the sole structure of FIG. 15, taken along Line 26- 26 of FIG. 20;
[0034] FIG. 27 is a cross-sectional view of the sole structure of FIG. 15, taken along Line 27- 27 of FIG. 20;
[0035] FIG. 28 is a cross-sectional view of the sole structure of FIG. 15, taken along Line 28- 28 of FIG. 20;
[0036] FIG. 29 is a rear perspective view of a sole structure for an article of footwear according to another example of the present disclosure;
[0037] FIG. 30 is a lateral side view of the sole structure of FIG. 29;
[0038] FIG. 31 is a medial side view of the sole structure of FIG. 29;364187002.1Attorney Docket No.: 201882-579925 / 250185WO01
[0039] FIG. 32 is a top exploded perspective view of the sole structure of FIG. 29;
[0040] FIG. 33 is a bottom exploded perspective view of the sole structure of FIG. 29;
[0041] FIG. 34 is a top plan view of the sole structure of FIG. 29;
[0042] FIG. 35 is a cross-sectional view of the sole structure of FIG. 29, taken along Line 35- 35 of FIG. 34;
[0043] FIG. 36 is a cross-sectional view of the sole structure of FIG. 29, taken along Line 36- 36 of FIG. 34;
[0044] FIG. 37 is a cross-sectional view of the sole structure of FIG. 29, taken along Line 37- 37 of FIG. 34;
[0045] FIG. 38 is a cross-sectional view of the sole structure of FIG. 29, taken along Line 38- 38 of FIG. 34;
[0046] FIG. 39 is a cross-sectional view of the sole structure of FIG. 29, taken along Line 39- 39 of FIG. 34;
[0047] FIG. 40 is a cross-sectional view of the sole structure of FIG. 29, taken along Line 40- 40 of FIG. 34;
[0048] FIG. 41 is a cross-sectional view of the sole structure of FIG. 29, taken along Line 41- 41 of FIG. 34;
[0049] FIG. 42 is a cross-sectional view of the sole structure of FIG. 29, taken along Line 42- 42 of FIG. 34; and
[0050] FIG. 43 is a graph showing example force-displacement curves for the sole structures of the present disclosure.
[0051] Corresponding reference numerals indicate corresponding parts throughout the drawings.DETAILED DESCRIPTION
[0052] Example configurations will now be described more fully with reference to the accompanying drawings. Example configurations are provided so that this disclosure will be thorough, and will fully convey the scope of the disclosure to those of ordinary skill in the art. Specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of configurations of the present disclosure. It will be apparent464187002.1Attorney Docket No.: 201882-579925 / 250185WO01to those of ordinary skill in the art that specific details need not be employed, that example configurations may be embodied in many different forms, and that the specific details and the example configurations should not be construed to limit the scope of the disclosure.
[0053] The terminology used herein is for the purpose of describing particular exemplary configurations only and is not intended to be limiting. As used herein, the singular articles “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly 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 are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. Additional or alternative steps may be employed.
[0054] When an element or layer is referred to as being “on,” “engaged to,” “connected to,” “attached to,” or “coupled to” another element or layer, it may be directly on, engaged, connected, attached, or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “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 present. Other words used to describe the relationship between elements should be interpreted in a like fashion (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.
[0055] The terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and / or sections. These elements, components, regions, layers and / or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example configurations.564187002.1Attorney Docket No.: 201882-579925 / 250185WO01
[0056] Conventional cushioning elements for articles of footwear often rely on material properties of one or more compressible materials, such as fluids and polymers. For instance, known sole structures may include solid bodies of compressible foam materials to provide cushioning characteristics along the sole structure. Other examples may rely on compressible fluids, such as air or nitrogen, to provide cushioning characteristics. While suitable, the use of conventional compressible structures (e.g., foam, bladders) results in a direct relationship between displacement (e.g., compression) of the compressible material and load applied to the compressible material. In other words, increased displacement results in increased load. Furthermore, the stiffness of these materials also increases with displacement, causing the increases in load to become larger and larger. This relationship results in an underfoot feel in which increased loads associated with actions such as running or jumping (as opposed to lower loads associated with walking) may result in a stiffer underfoot feel as the cushioning material (e.g., air, foam) is compressed to a greater extent.
[0057] In the present disclosure, designs for support structures have been identified that provide an improved underfoot feel during a gait cycle. The support structures include various examples of truss structures each having a plurality of struts configured to extend between an upper support surface of a sole structure and a ground-engaging surface. When a load is applied to the upper support surface of the sole structure, the load is transferred along a longitudinal axis of each of the struts. The struts may be oriented at oblique angles relative to the support surface and the applied load such that a load applied as a purely compressive load to the support surface is converted into a compressive load and a bending load distributed along the strut. As the applied load increases, the resulting bending load applied to each strut causes the strut to bend or flex resiliently along its length. Increased bending along each strut induces a corresponding reduction in the compressive force required to displace or deflect the strut. In other words, as the strut bends more, the strut bends easier. By utilizing this structural cushioning design, a sole structure may be configured to allow for a greater degree of deflection (compression) without requiring continuously increased loading, continuously increased stiffness, or both. Thus, the use of structural cushioning according to the present disclosure allows for comparable or superior energy storage within a sole structure during a gait cycle as conventional solid compressible materials, while providing an improved underfoot feel by allowing increased displacement with minimal increases to loading. Additionally, the use of support structures according to the present disclosure allows for a highly 664187002.1Attorney Docket No.: 201882-579925 / 250185WO01tunable cushioning solution, whereby cushioning parameters can be selected by modifying any combination of strut thickness, strut angle, strut twist, material type, etc.
[0058] Additionally, material structures have been found that provide desirable cushioning properties across a wide range of displacements. For example, forming the structural cushioning components with an inner core having a first material first density and an outer sheath having a second density that is greater than the first density provides the structural cushioning elements with a composite structure, whereby the outer shell provides the strut with structural integrity while the lower density of the inner core minimizes overall weight. For example, the structural cushioning elements may be foamed using a supercritical foaming process producing microcellular to form the inner core and the outer sheath.
[0059] An aspect of the disclosure provides a sole structure for an article of footwear. The sole structure includes a support frame including (i) a first plurality of alternating support structures defining a first upper support structure and a first lower support structure adjacent to the first upper support structure and (ii) a second plurality of alternating support structures defining a second upper support structure disposed adjacent to the first lower support structure and a second lower support structure disposed adjacent to each of the first upper support structure and the second upper support structure, each of the support structures including one or more struts configured to flex when a compressive force is applied to the support frame.
[0060] Aspects of the disclosure may include one or more of the following optional features. In some examples, the first plurality of alternating support structures is aligned along a first lateral axis of the sole structure and the second plurality of alternating support structures is aligned along a second lateral axis of the sole structure. In some implementations, first plurality of alternating support structures includes a third upper support structure disposed on an opposite side of the first lower support structure from the first upper support structure. Optionally, the second plurality of alternating support structures includes a third lower support structure disposed on an opposite side of the second upper support structure from the first lower support structure.
[0061] In some configurations, the sole structure further includes a chassis disposed adjacent to the support frame and including a plurality of lobes each received by one of the upper support structures. In some implementations, the sole structure includes at least one of an outsole or an outsole plate disposed on an opposite side of the chassis from the support frame. Optionally, each764187002.1Attorney Docket No.: 201882-579925 / 250185WO01of the lower support structures contacts the at least one of the outsole or the outsole plate through the chassis. In some configurations, the support frame is encapsulated within a barrier element.
[0062] Another aspect of the disclosure provides a sole structure for an article of footwear. The sole structure includes a support frame including (i) a plurality of first rows of alternating support structures arranged in series along a longitudinal direction of the sole stmcture and each including a first upper support structure and a first lower support structure adjacent to the first upper support structure and (ii) a plurality of second rows of alternating support structures each disposed between adjacent ones of the first rows and including a second upper support structure disposed adjacent to the first lower support structures and a second lower support structure disposed adjacent to each of the first upper support structures and the second upper support structure, each of the support structures including one or more struts configured to flex when a compressive force is applied to the support frame.
[0063] Aspects of the disclosure may include one or more of the following optional features. In some examples, each first row of alternating support structures is aligned along a respective first lateral axis of the sole structure and each second row of alternating structures is aligned along a second respective lateral axis of the sole stmcture. In some implementations, each first row of alternating support structures includes a third upper support stmcture disposed on an opposite side of the first lower support stmcture from the first upper support stmcture. In some configurations, each second row of upper support stmctures includes a third lower support stmcture disposed on an opposite side of the second upper support stmcture from the second lower support stmcture.
[0064] In some examples, the sole stmcture includes a chassis disposed adjacent to the support frame and including a plurality of lobes each received by one of the upper support stmctures. In some configurations, the sole stmcture includes at least one of an outsole or an outsole plate disposed on an opposite side of the chassis from the support frame. In some configurations, each of the lower support stmctures contacts the at least one of the outsole or the outsole plate through the chassis. In some implementations, the sole stmcture includes a cushioning supported by each of the upper support stmctures of the support frame.
[0065] Another aspect of the disclosure provides a support frame for a sole stmcture of an article of footwear. The support frame includes a central frame, a first row of alternating support stmctures extending from the central frame and defining a first upper support stmcture and a first lower support stmcture adjacent to the first upper support stmcture, each of the support stmctures 864187002.1Attorney Docket No.: 201882-579925 / 250185WO01of the first row of alternating support structures including one or more struts configured to flex when a compressive force is applied to the support frame, a second row of alternating support structures extending from the central frame and defining a second upper support structure disposed adjacent to the first lower support structure and a second lower support structure disposed adjacent to each of the first upper support structure and the second upper support structure, each of the support structures of the second row of alternating support structures including one or more struts configured to flex when a compressive force is applied to the support frame.
[0066] Aspects of the disclosure may include one or more of the following optional features. In some examples, each of the upper support structures includes a plurality of trusses each extending from the central frame to a platform. In some examples, the upper support structures extend in a first direction from the central frame and the lower support structures extend in an opposite second direction from the central frame. In some implementations, the first row of alternating support structures includes a third upper support structure disposed on an opposite side of the first lower support structure from the first upper support structure and the second row of upper support structures includes a third lower support structure disposed on an opposite side of the second upper support structure from the first lower support structure.
[0067] Referring to FIGS. 1-3, an article of footwear 10 includes a sole structure 100 having an upper 30 attached to the sole structure 100. The footwear 10 may further include an anterior end 12 associated with a forward-most point of the footwear 10, and a posterior end 14 corresponding to a rearward-most point of the footwear 10. As shown in FIG. 1, a longitudinal axis Awo of the sole structure 100 extends along a length of the footwear 10 from the anterior end 12 to the posterior end 14 parallel to a ground surface, and generally divides the footwear 10 into a medial side 16 and a lateral side 18. Accordingly, the medial side 16 and the lateral side 18 respectively correspond with opposite sides of the footwear 10 and extend from the anterior end 12 to the posterior end 14. As used herein, a longitudinal direction refers to the direction extending from the anterior end 12 to the posterior end 14, while a lateral direction or axis refers to the direction transverse to the longitudinal direction and extending from the medial side 16 to the lateral side 18. References to the vertical direction refer to the direction transverse to the longitudinal and lateral directions.
[0068] The article of footwear 10 may be divided into one or more regions. The regions may include a forefoot region 20, a mid-foot region 22, and a heel region 24. The forefoot region 20964187002.1Attorney Docket No.: 201882-579925 / 250185WO01includes a toe portion 20-rthat corresponds with phalanges and a ball portion 20B that corresponds to the metatarsal bones of a foot. The mid-foot region 22 may correspond with an arch area of the foot, and the heel region 24 may correspond with rear portions of the foot, including a calcaneus bone.
[0069] The upper 30 forms an enclosure having plurality of components that cooperate to define an interior void and an ankle opening, which cooperate to receive and secure a foot for support on the sole structure 100. The upper 30 may be formed from one or more materials that are stitched or adhesively bonded together to define the interior void. Suitable materials of the upper 30 may include, but are not limited to, textiles, foam, leather, and synthetic leather. The example upper 30 may be formed from a combination of one or more substantially inelastic or non-stretchable materials and one or more substantially elastic or stretchable materials disposed in different regions of the upper 30 to facilitate movement of the article of footwear 10 between the tightened state and the loosened state. The one or more elastic materials may include any combination of one or more elastic fabrics such as, without limitation, spandex, elastane, rubber or neoprene. The one or more inelastic materials may include any combination of one or more of thermoplastic polyurethanes, nylon, leather, vinyl, or another material / fabric that does not impart properties of elasticity.
[0070] The sole structure 100 includes midsole a 102 configured to provide cushioning and support and an outsole 104 defining a ground-engaging surface (i.e., contacts the ground during a stance phase of a gait cycle) of the sole structure 100. Unlike conventional sole structures, which include monolithic midsoles and outsoles, the sole structure 100 of the present disclosure is configured as a composite structure including a plurality of components joined together. For example, the midsole 102 may include a support layer 110 attached to the upper 30, an intermediate support assembly 108 attached to the support layer 110, and a chassis 114 disposed between the support assembly 108 and the outsole 104. Thus, the support assembly 108 is disposed between support layer 110 and the chassis 114. An overall height Hioo (FIG. 3) of the sole structure 100 extends from a top side defined by the support layer 110 to a bottom side associated with a groundengaging surface of the sole structure 100. The support assembly 108 includes a support frame 112 and an outer barrier element 116 covering at least a portion of the support frame 112.
[0071] Turning to FIGS. 4 and 5, the support layer 110 extends from a first end 120 disposed at the anterior end 12 of the sole structure 100 to a second end 122 disposed at the posterior end 14 of the sole structure 100. The support layer 110 includes a top side 124 that faces the upper 30 and 1064187002.1Attorney Docket No.: 201882-579925 / 250185WO01a bottom side 126 formed on an opposite side from the top side 124. A peripheral side 128 extends between the top side 124 and the bottom side 126 and defines a peripheral profile of the support layer 110. The top side 124 includes a footbed surface 130 that defines a profile of the footbed of the sole structure 100 for supporting a plantar surface of the foot. Optionally, the support layer 110, or portions thereof, include materials having a greater hardness than the materials forming the support frame 112 and the chassis 114, whereby the support layer 110 is configured to distribute support forces along the plantar surface of the foot.
[0072] Referring to FIG. 5, the bottom side 126 of the support layer 110 includes a plurality of retainers 132, 134, 136 and a plurality of sockets 138, 140, 142 each configured to interface with a respective portion of the support assembly 108. The retainers 132, 134, 136 are generally disposed adjacent to the peripheral side 128 of the support layer 110 and include forefoot retainers 132 disposed in the forefoot region 20, mid-foot retainers 134 disposed in the mid-foot region 22, and heel retainers 136 disposed in the heel region 24. The sockets 138, 140, 142 are arranged in series along the longitudinal axis Aioo and include a forefoot socket 138 disposed in the forefoot region 20, mid-foot sockets 140 disposed in the mid-foot region 22, and a heel socket 142 disposed in the heel region 24. While the retainers 132, 134, 136 and the sockets 138, 140, 142 are all configured to receive corresponding upper support structures of the support assembly 108, the retainers 132, 134, 136 are formed as concave recesses within protrusions extending from the bottom side 126 of the support layer 110 while the sockets 138, 140, 142 are formed as concave recesses within the bottom side 126 of the support layer 110.
[0073] Referring still to FIGS. 4 and 5, the support assembly 108 includes the support frame 112 and the barrier element 116 encapsulating the support frame 112. The support frame 112 is disposed within an interior void defined by the barrier element 116 and the barrier element 116 of the present example conforms to the exterior profile of the support frame 112. Thus, geometries and features described herein with respect to the support frame 112 should be understood to be imparted to the overall support assembly 108 through the barrier element 116. Optionally, the interior void defined by the barrier element 116 may include a positively pressurized fluid, such as air or liquid.
[0074] The support frame 112 extends from a first end 150 at the anterior end 12 of the sole structure 100 to a second end 152 at the posterior end 14 of the sole structure 100. The support frame 112 and features thereof may be described in terms of having a top side 154 that faces the 1164187002.1Attorney Docket No.: 201882-579925 / 250185WO01upper 30 and the bottom side 126 of the support layer 110. The support frame 112 and features thereof may also be described in terms of having a bottom side 156 formed on an opposite side from the top side 154. The support frame 112 includes a peripheral edge 158 connecting the top side 154 of the support frame 112 and the bottom side 156 of the support frame 112.
[0075] Structurally, the support frame 112 includes an intermediate frame 160 providing a centralized base from which support features of the support frame 112 are formed. The support frame 112 includes a plurality of upper support structures 164-178 extending from the intermediate frame 160 on the top side 154 of the support frame 112 and a plurality of lower support structures 180-192 extending from the intermediate frame 160 on the bottom side 156 of the support frame 112. As shown in FIG. 4 and 5, the support frame 112 includes a pair of tabs 196, 198 formed in the toe portion 20T of the support frame 112 on opposite sides of the longitudinal axis Aioo. Particularly, the support frame 112 includes a medial toe tab 196 disposed on the medial side 16 and a lateral toe tab 198 disposed on the lateral side 18. The medial toe tab 196 and the lateral toe tab 198 are separated by a toe opening 200 that extends from the first end 150 and through the toe portion 20T. Thus, the medial toe tab 196 and the lateral toe tab 198 are independently articulable at the first end 150 of the support frame 112 to provide increased flexibility between the medial side 16 and the lateral side 18 of the sole structure 100.
[0076] Referring still to FIGS. 4 and 5, the upper support structures 164-178 are arranged along the length of the support frame 112 and include peripheral upper support structures 164, 168, 172, 176 that are arranged adjacent to the peripheral edge 158 of the support frame 112. The upper support structures 164-178 further include interior upper support structures 166, 170, 174, 178 arranged generally along the longitudinal axis Aioo of the sole structure 100. The peripheral upper support structures 164, 168, 172, 176 and the interior upper support structures 166, 170, 174, 178 are altematingly arranged (e.g., peripheral protrusions, interior protrusion, peripheral protrusions, interior protrusion, etc.) along the length of the support frame 112 to provide an alternating undulated profile along the top side 154 of the support frame 112.
[0077] As shown in FIG. 4, the upper support structures 164-178 include a first pair of toe peripheral upper support structures 164 disposed in the toe portion 20-rof the support frame 112. The toe peripheral upper support structures 164 include a medial toe peripheral upper support structure 164 disposed on the medial toe tab 196 and a lateral peripheral upper support structure 164 disposed on the lateral toe tab 198. The upper support structures 164-178 further include a toe 1264187002.1Attorney Docket No.: 201882-579925 / 250185WO01interior upper support structure 166 disposed in the toe portion 20T adjacent to a posterior end of the toe opening 200. Thus, the toe interior upper support structure 166 is longitudinally offset towards the second end 152 of the support frame 112 from the toe peripheral upper support structures 164.
[0078] Referring still to FIG. 4, the upper support structures 164-178 include a pair of ball peripheral upper support structures 168 disposed in the ball portion 20B of the support frame 112. The ball peripheral upper support structures 168 include a medial ball peripheral upper support structure 168 disposed on the medial side 16 in the ball portion 20B and a lateral ball peripheral upper support structure 168 disposed on the lateral side 18 in the ball portion 20B. The upper support structures 164-178 further include a ball interior upper support structure 170 disposed in the ball portion 20B that is longitudinally offset towards the second end 152 of the support frame 112 from the ball peripheral upper support structures 168.
[0079] The upper support structures 164-178 include a pair of mid-foot peripheral upper support structures 172 disposed in the mid-foot region 22 of the support frame 112. The mid-foot peripheral upper support structures 172 include a medial mid-foot peripheral upper support structure 172 disposed on the medial side 16 in the mid-foot region 22 and a lateral mid-foot peripheral upper support structure 172 disposed on the lateral side 18 in the mid-foot region 22. The upper support structures 164-178 further include a mid-foot interior upper support structure 174 disposed in the mid-foot region 22 that is longitudinally offset towards the second end 152 of the support frame 112 from the mid-foot peripheral upper support structures 172.
[0080] The upper support structures 164-178 further include a plurality of heel upper support structures 176, 178 disposed in the heel region 24 of the support frame 112. Particularly, the heel upper support structures include a first pair of heel peripheral upper support structures 176 disposed adjacent to the mid-foot region 22 and a second pair of heel peripheral upper support structures 176 disposed adjacent to the second end 152 of the support frame 112. The heel upper support structures 176, 178 include a heel interior upper support structure 178 disposed in the heel region that is longitudinally offset towards the second end 152 of the support frame 112 from the mid-foot peripheral upper support structures 172.
[0081] Referring still to FIG. 4 and 5, the lower support structures 180-192 are arranged along the length of the support frame 112 and include peripheral lower support structures 180, 184, 188, 192 that are arranged adjacent to the peripheral edge 158 of the support frame 112. The lower 1364187002.1Attorney Docket No.: 201882-579925 / 250185WO01support structures 180-192 further include interior lower support structures 182, 186, 190 arranged in series along the longitudinal axis Aioo of the sole structure 100. The peripheral lower support structures 180, 184, 188, 192 and the interior lower support structures 182, 186, 190 are altematingly arranged (e.g., peripheral protrusions, interior protrusion, peripheral protrusions, interior protrusion, etc.) along the length of the support frame 112 to provide an alternating undulated profde along the bottom side 156 of the support frame 112.
[0082] As shown in FIG. 5, the lower support structures 180-192 include a pair of toe peripheral lower support structures 180 disposed in the toe portion 20T of the support frame 112. The toe peripheral lower support structures 180 include a medial toe peripheral lower support structure 180 disposed on the medial side 16 and a lateral toe peripheral lower support structure 180 disposed on the lateral side 18. Thus, toe peripheral lower support structures 180 are aligned along the lateral direction with the toe interior upper support structure 166 and are disposed on opposite sides of the toe interior upper support structure 166 to provide a first row 202a of support structures having an undulated profile across the width of the support frame 112 in the toe portion 20T.
[0083] The lower support structures 180-192 further include a ball interior lower support structure 182 disposed in the toe portion 20 that is longitudinally offset towards the second end 152 of the support frame 112 from the toe peripheral lower support structures 180. The ball interior lower support structure 182 is aligned along the lateral direction with the ball peripheral upper support structures 168 and is disposed between ball peripheral upper support structures 168 to provide a second row 202b of support structures having an undulated profile across the width of the support frame 112 in the ball portion 20B.
[0084] Referring still to FIG. 5, the lower support structures 180-192 include a pair of ball peripheral lower support structures 184 disposed in the ball portion 20B of the support frame 112. The ball peripheral lower support structures 184 include a medial ball peripheral lower support structure 184 disposed on the medial side 16 in the ball portion 20B and a lateral ball peripheral lower support structure 184 disposed on the lateral side 18 in the ball portion 20B. Thus, the ball peripheral lower support structures 184 are aligned along the lateral direction with the ball interior upper support structure 170 and are disposed on opposite sides of the ball interior upper support structure 170 to provide a third row 202c of support structures having an undulated profile across the width of the support frame 112 in the toe portion 20T.1464187002.1Attorney Docket No.: 201882-579925 / 250185WO01
[0085] The lower support structures 180-192 further include a mid-foot interior lower support structure 186 disposed in the mid-foot region 22 that is longitudinally offset towards the second end 152 of the support frame 112 from the ball peripheral lower support structures 184. The midfoot interior lower support structure 186 is aligned along the lateral direction with the mid-foot peripheral upper support structures 172 and is disposed between the mid-foot peripheral upper support structures 172 to provide a fourth row 202d of support structures having an undulated profile across the width of the support frame 112 in the mid-foot region 22.
[0086] Referring still to FIG. 5, the lower support structures 180-192 include a pair of mid-foot peripheral lower support structures 188 disposed in the mid-foot region 22 of the support frame 112. The mid-foot peripheral lower support structures 188 include a medial mid-foot peripheral lower support structure 188 disposed on the medial side 16 in the mid-foot region 22 and a lateral mid-foot peripheral lower support structure 188 disposed on the lateral side 18 in the mid-foot region 22. Thus, the mid-foot peripheral lower support structures 188 are aligned along the lateral direction with the mid-foot interior upper support structure 174 and are disposed on opposite sides of the mid-foot interior upper support structure 174 to provide a fifth row 202e of support structures having an undulated profile across the width of the support frame 112 in the mid-foot region 22.
[0087] The lower support structures 180-192 further include a plurality of heel lower support structures 190, 192 disposed in the heel region 24 of the support frame 112. Particularly, the heel lower support structures 190 include a first heel interior lower support structure 190 disposed adjacent to the mid-foot region 22 and a second heel interior lower support structure 190 disposed adjacent to the second end 152 of the support frame 112. The first heel interior lower support structure 190 is aligned along the lateral direction with the first pair of heel peripheral upper support structures 176 and is disposed between the first pair of heel peripheral upper support structures 176 to provide a sixth row 202f of support structures having an undulated profile across the width of the support frame 112 in the mid-foot region 22.
[0088] Referring still to FIG. 5, the heel lower support structures 190, 192 include a pair of heel peripheral lower support structures 192 disposed in the heel region 24 of the support frame 112. The heel peripheral lower support structures 192 include a medial mid-foot peripheral lower support structure 192 disposed on the medial side 16 in the heel region 24 and a lateral mid-foot peripheral lower support structure 192 disposed on the lateral side 18 in the heel region 24. Thus, the heel peripheral lower support structures 192 are aligned along the lateral direction with the 1564187002.1Attorney Docket No.: 201882-579925 / 250185WO01heel interior upper support structure 178 and are disposed on opposite sides of the heel interior upper support structure 178 to provide a seventh row 202g of support structures having an undulated profile across the width of the support frame 112 in the heel region 24.
[0089] The second heel interior lower support structure 190 is disposed adjacent to the second end 152. The second heel interior lower support structure 190 is aligned along the lateral direction with the second pair of heel peripheral upper support structures 176 and is disposed between the second pair of heel peripheral upper support structures 176 to provide an eighth row 202h of support structures having an undulated profile across the width of the support frame 112 in the heel region 24.
[0090] As set forth in the foregoing paragraphs, the upper support structures 164-178 and the lower support structures 180-192 are arranged to form laterally-extending rows 202a-202h of the support structures 164-192 arranged in series between the first end 150 and the second end 152 of the support frame 112. Each row 202a-202h includes an undulating profile defined by alternating support structures (e.g., lower, upper, lower) in the lateral direction. Additionally, adjacent ones of the rows 202a-202h have alternating configurations, whereby a first one of the rows 202a, 202c, 202e, 202g is arranged in a lower-upper-lower configuration and an adjacent one of the rows 202b, 202d, 202f, 202h is arranged in an upper-lower-upper configuration. Thus, in addition to forming laterally-extending rows 202a-202h each defining an undulating profile, the support structures 164-192 define three longitudinally-extending columns 204a-204c of undulating support structures 164-192 extending between the first end 150 and the second end 152. Optionally, one or more of the rows 202a-202h may be omitted from the support frame 112, wherein instead of forming the support frame 112 as a continuous structure extending along the entire length of the sole structure 100, the support frame 112 is provided as a segmented structure along one or more of the regions 20, 22, 24.
[0091] The upper support structures 164-178 and the lower support structures 180-192 each have a similar construction. Particularly, the upper support structures 164-178 have a support structure base 206 disposed at or integrated with the intermediate frame 160 of the support frame 112. The upper support structures 164-178 further include a support structure platform 208 vertically offset from the support structure base 206 in a direction away from the top side 154 of the support frame 112. Each upper support structure 164-178 includes a plurality of struts 210 extending between and connecting the support structure base 206 to the support structure platform 1664187002.1Attorney Docket No.: 201882-579925 / 250185WO01208. In the illustrated example, each upper support structure 164-178 includes four of the struts 210 arranged in a radial array about the support structure platform 208. The struts 210 converge with each other along a direction from the support structure base 206 to the support structure platform 208 to provide each upper support structure 164-178 with a tapering profde. Each of the upper support structures 164-178 define a protruding profile along the top side 154 of the support frame 112 and a corresponding recess on the bottom side 156 of the support frame 112.
[0092] The lower support structures 180-192 have a support structure base 212 disposed at or integrated with the intermediate frame 160 of the support frame 112. The lower support structures 180-192 further include a support structure platform 214 vertically offset from the support structure base 206 in a direction away from the bottom side 156 of the support frame 112. Each lower support structures 180-192 includes a plurality of struts 216 extending between and connecting the support structure base 212 to the support structure platform 214. In the illustrated example, each lower support structure 180-192 includes four of the struts 216 arranged in a radial array about the support structure platform 214. The struts 216 converge with each other along a direction from the support structure base 212 to the support structure platform 214 to provide each lower support structure 180-192 with a tapering profile. Each of the lower support structures 1 SO-192 define a protruding profile along the bottom side 156 of the support frame 112 and a corresponding recess on the top side 154 of the support frame 112.
[0093] As provided above, each of the support structure struts 210, 216 extends continuously between the support structure base 206, 212 and the support structure platform 208, 214. In other words, each support structure strut 210, 216 only includes a pair of attachment points - one at each end - such that an intermediate portion is unconstrained and is free to flex or bend. Thus, each support structure strut 210, 216 may be configured to act as a mechanical biasing element, whereby a combination of the geometry and the material of the support structure strut 210, 216 is selected to impart desired properties of cushioning and responsiveness. While the illustrated example contemplates forming the support frame 112 using injection molding processes, the support frame 112 may also be formed using other suitable techniques, such as thermoforming (e.g. vacuum thermoforming), blow molding, extrusion, injection molding, vacuum molding, rotary molding, transfer molding, pressure forming, heat sealing, casting, low-pressure casting, spin casting, reaction injection molding, radio frequency (RF) welding, and the like. Optionally, the support frame 112 may be formed using a supercritical foaming process, whereby the support structure 1764187002.1Attorney Docket No.: 201882-579925 / 250185WO01strut 210, 216 or other portions of the support frame 112 include composite structures having an inner core formed of first material and an outer sheath formed of a second material. In such examples, at least a portion of the support frame 112 or the support structure strut 210, 216 may be formed using a supercritical foaming process producing microcellular foam to form the inner core and the outer sheath.
[0094] With continued reference to FIGS. 4 and 5, the chassis 114 is configured to engage and support the bottom side 156 of the support frame 112 and to provide secondary support and cushioning properties to the sole structure 100. The relationship between the chassis 114 and the support frame 112 is more clearly shown and described below with respect to FIGS. 7 and 8. Optionally, the chassis 114 may be provided as a fragmentary structure including an anterior chassis segment 220 disposed in the forefoot region 20 and the mid-foot region 22, and a posterior chassis segment 222 disposed in the heel region 24. The chassis 114 includes one or more polymeric foam materials (discussed below) to provide a resilient and compressible cushioning structure between the support frame 112 and the outsole 104.
[0095] The anterior chassis segment 220 extends from a first end 224 disposed at the anterior end 12 of the article of footwear 10 to a second end 226 disposed in the mid-foot region 22 of the sole structure 100. The anterior chassis segment 220 and features thereof may be described in terms of a top side 228 that faces the upper 30 and the support frame 112 and a bottom side 230 formed on an opposite side from the top side 228. The posterior chassis segment 222 extends from a first end 232 disposed in the heel region 24 adjacent to the mid-foot region 22 to a second end 234 disposed at the posterior end 14. The posterior chassis segment 222 and features thereof may be described in terms of a top side 236 that faces the upper 30 and the support frame 112 and a bottom side 238 formed on an opposite side from the top side 236.
[0096] Each of the chassis segments 220, 222 includes a plurality of support lobes 240-246, 256, 257 each configured to engage a respective one of the upper support structures 164-178 on the bottom side 156 of the support frame 112 and / or the bottom side 126 of the support layer 110. The chassis segments 220, 220 are formed whereby the bottom sides 230, 238 are substantially smooth and are configured to rest upon the outsole 104 while the top sides 228, 236 define the protruding contours of each of the support lobes 240-246, 256, 257. Thus, each of the lobes 240-246, 256, 257 provides a bulbous profile along the top sides 228, 236 of the respective chassis segments 220, 222.1864187002.1Attorney Docket No.: 201882-579925 / 250185WO01
[0097] The anterior chassis segment 220 includes an anterior lobe 240 disposed at the first end 224 of the chassis segment 220, which defines a bulbous portion of the top side 228 that extends through the toe opening 200 of the support frame 112 and engages the bottom side 126 of the support layer 110. The anterior chassis segment 220 further includes a pair of toe peripheral lobes 242 extending from opposite sides of the anterior chassis segment 220 in the toe portion 20T, a pair of ball peripheral lobes 244 extending form opposite sides of the anterior chassis segment 220 in the ball portion 20B, and a pair of mid-foot peripheral lobes 246 extending from opposite sides of the anterior chassis segment 220 in the mid-foot region 22. Adjacent ones of the peripheral lobes 240, 242, 244, 246 are separated by corresponding recesses 248, 252, 254 formed along the periphery of the anterior chassis segment 220. Particularly, the anterior chassis segment 220 includes a pair of toe recesses 248 that separate the toe peripheral lobes 242 from the ball peripheral lobes 244. Likewise, ball recesses 252 separate the ball peripheral lobes 242 from the mid-foot peripheral lobes 246 along each side of the anterior chassis segment 220. A mid-foot recess 254 is formed at the second end 226 and separates the mid-foot peripheral lobes 246.
[0098] Along with the peripheral features, the anterior chassis segment 220 includes a plurality of interior lobes 243, 245 arranged along a central portion of the anterior chassis segment 220 between the peripheral lobes 240, 242, 244, 246. Particularly, the anterior chassis segment 220 includes a toe interior lobe 243 disposed in the toe portion 20T, which is longitudinally offset between the toe peripheral lobes 242 and the ball peripheral lobes 244. Similarly, the anterior chassis segment 220 includes a mid-foot interior lobe 245 disposed in the mid-foot region 22, which is longitudinally offset between the ball peripheral lobes 244 and the mid-foot peripheral lobes 246. Thus, the peripheral lobes 240, 242, 244, 246 and the interior lobes 243, 245 have an alternating arrangement configured to mate with the bottom sides of the upper support structures 164-174 in the forefoot region 20 and mid-foot region 22. Optionally, the anterior chassis segment may include an opening 250 in the ball portion 20B between the ball interior lobe 243 and the midfoot interior lobe 245. Adjacent ones of the lobes 240-246 of the anterior chassis segment 220 are connected to each other by respective necked portions 249 of the anterior chassis segment 220 having a reduced thickness relative to the lobes 240-246. These necked portions 249 provide flexibility between adjacent ones of the lobes 240-246 and provide a recessed portion that accommodates a corresponding portion of the support frame 112 when the sole structure 100 is assembled.1964187002.1Attorney Docket No.: 201882-579925 / 250185WO01
[0099] The posterior chassis segment 222 includes a plurality of heel peripheral lobes 256 and an interior lobe 257. Particularly, the heel peripheral lobes 256 include a first pair of the heel peripheral lobes 256 disposed at the first end 232 of the posterior chassis segment 222 and a second pair of the heel peripheral lobes 256 disposed at the second end 234 of the posterior chassis segment 222. Each of the heel peripheral lobes 256 is connected to the interior lobe 257 by a respective necked portion 258 of the posterior chassis segment 222 having a reduced thickness relative to the lobes 256, 257. These necked portions 258 provide flexibility between adjacent ones of the lobes 256, 257 and provide a recessed portion that accommodates a corresponding portion of the support frame 112 when the sole structure is assembled. Similar to the anterior chassis segment 220, adjacent ones of the peripheral lobes 256 are separated from each other by respective heel recesses 259.
[0100] The outsole 104 extends from a first end 264 at the anterior end 12 to a second end 266 at the posterior end 14. The outsole 104 includes a top side 268 facing the upper 30 and a bottom side 270 formed on an opposite side from the top side 268. The outsole 104 further includes a peripheral side 272 extending between the top side 268 and the bottom side 270 and defining a peripheral profile of the outsole 104. Optionally, the outsole 104 may include a mid-foot opening 278. Additionally, the second end 266 of the outsole 104 may include a pair of heel tabs 280 that are separated by a heel recess 282, thereby allowing independent articulation of the heel peripheral lobes 256 and the sole structure 100 at the second end 266.
[0101] The outsole 104 attaches to the bottom sides 230, 238 of the chassis 114 and supports the lower support structures 180-192 of the support frame 112. Particularly, one or more of the lower support structures 180-192 extend through the respective recesses and openings formed in the chassis 114 and contacts the outsole 104, whereby the support frame 112 is directly supported against the outsole 104. Optionally, the outsole 104 includes a plurality of support pads 274, 276 that are aligned with respective ones of the lower support structures 180-192 to provide additional cushioning and support. Particularly, the support pads 274, 276 may include mid-foot support pads 274 disposed in the mid-foot region 22, which are aligned with and support the platforms 214 of the mid-foot peripheral lower support structures 188 (FIG. 8). Additionally, the support pads 276 may include heel support pads 276 disposed in the heel region 24, which are aligned with and support the platforms 214 of the heel lower support structures 190, 192.2064187002.1Attorney Docket No.: 201882-579925 / 250185WO01
[0102] Turning now to FIGS. 6-14, the relationships of the components 110, 112, 114 of the sole structure 100 are shown with the sole structure 100 in an assembled configuration. Generally, the sole structure 100 is configured such that the upper platforms 208 of the upper support structures 164-178 contact the bottom side 126 of the support layer 110 while the lower platforms 214 of the lower support structures 180-192 contact the top side 268 of the outsole 104. More specifically, the upper platforms 208 may be received within the retainers 132, 134, 136 and sockets 138, 140, 142 of the support layer 110 while the lower platforms 214 may be supported on the support pads 274, 276.
[0103] FIG. 7 shows a cross-sectional view of the sole structure 100 taken along Line 7-7 of FIG. 6, which generally extends along the longitudinal axis Aioo and through the interior features of the sole structure 100. Starting at the anterior end 12, the anterior lobe 240 of the anterior chassis segment 220 contacts the bottom side 126 of the support layer 110 in the toe portion 20T. The toe interior upper support structure 166 and the toe interior lobe 243 are arranged in the toe portion 20T, whereby the toe interior upper support structure 166 is spaced apart from the top side 228 of the toe interior lobe 243 by a first distance DI and the upper platform 208 of the toe interior upper support structure 166 contacts the bottom side 126 of the support layer 110 at one of the forefoot sockets 138. The ball interior upper support structure 170 and the ball interior lobe 245 are arranged in the ball portion 20B, whereby the ball interior upper support structure 170 is spaced apart from the top side 228 of the ball interior lobe 245 by a second distance D2 and the upper platform 208 of the ball interior upper support structure 170 contacts the bottom side 126 of the support layer 110 at one of the forefoot sockets 138. The mid-foot interior upper support structure 174 is arranged in the mid-foot region 22 and includes an upper platform 208 that engages the midfoot socket 140. The mid-foot interior upper support structure 174 does not include a corresponding lobe of the chassis 114. The heel interior upper support structure 178 and the heel interior lobe 257 are arranged in the heel region 24, whereby the heel interior upper support structure 178 is spaced apart from the top side 236 of the heel interior lobe 257 by a third distance D3 and the upper platform 208 of the heel interior upper support structure 178 contacts the bottom side 126 of the support layer 110 at one of the heel sockets 142. The interior lower support structures 182, 186, 190 extend between adjacent ones of the interior upper support structures 166, 170, 174, 178 and include the lower platforms 214 that contact respective portions of the outsole 104 between adjacent ones of the interior lobes 243, 245, 257.2164187002.1Attorney Docket No.: 201882-579925 / 250185WO01
[0104] FIG. 8 shows a cross-sectional view of the sole structure 100 taken along Line 8-8 of FIG. 6, which generally extends along the direction of the longitudinal axis Aioo and through the peripheral features of the sole structure 100. Starting at the anterior end 12, the medial toe tab 196 of the support frame 112 contacts the bottom side 126 of the support layer 110 in the toe portion 20T. The medial toe peripheral upper support structure 164 and the toe peripheral lobe 242 are arranged in the toe portion 20T, whereby the medial toe peripheral upper support structure 164 is spaced apart from the top side 228 of the toe peripheral lobe 242 by a fourth distance D4 and the upper platform 208 of medial toe peripheral upper support structure 164 contacts the bottom side 126 of the support layer 110 at one of the forefoot retainers 132. The medial ball peripheral upper support structure 168 and the medial ball peripheral lobe 244 are arranged in the ball portion 20B, whereby the medial ball peripheral upper support structure 168 is spaced apart from the top side 228 of the medial ball peripheral lobe 244 by a fifth distance D5 and the upper platform 208 of the medial ball peripheral upper support structure 168 contacts the bottom side 126 of the support layer 110 at one of the forefoot retainers 132. The medial mid-foot peripheral upper support structure 172 and the medial mid-foot peripheral lobe 246 are arranged in the mid-foot region 22, whereby the medial mid-foot peripheral upper support structure 172 is spaced apart from the top side 228 of the medial mid-foot peripheral lobe 246 by a sixth distance D6 and the upper platforms 208 of the medial mid-foot peripheral upper support structure 172 contacts the bottom side 126 of the support layer 110 at one of the mid-foot retainers 134. The medial heel peripheral upper support structures 176 and the medial heel peripheral lobes 256 are arranged in the heel region 24, whereby medial heel peripheral upper support structures 176 are spaced apart from the top side 236 of the medial heel peripheral lobes 256 by seventh and eighth distances D7, D8 and the upper platforms 208 of the medial heel peripheral upper support structures 176 contact the bottom side 126 of the support layer 110 at one of the heel retainers 136. The medial peripheral lower support structures 180, 184, 188, 192 extend between adjacent ones of the medial peripheral upper support structures 164, 168, 172, 176 and include the lower platforms 214 that contact respective portions of the outsole 104 between adjacent ones of the medial peripheral lobes 242, 244, 246, 256.
[0105] Referring now to FIG. 9, a lateral cross-sectional view is taken along Line 9-9 of FIG.6, which includes the second row 202b of the support structures 168, 182. As shown, the second row 202b includes the ball peripheral upper support structures 168 and the ball peripheral lobes 244 disposed on the medial side 16 and the lateral side 18, whereby the ball peripheral upper 2264187002.1Attorney Docket No.: 201882-579925 / 250185WO01support structures 168 are spaced apart from the top side 228 of the ball peripheral lobes 244 by respective distances D4, D9 and the upper platforms 208 of the ball peripheral upper support structures 168 contact the bottom side 126 of the support layer 110 at one of the forefoot retainers 132. The ball interior lower support structure 182 is disposed between the ball peripheral upper support structures 168 in the middle of the sole structure 100 and includes a lower platform 214 contacting the top side 268 of the outsole 104.
[0106] FIG. 10 provides a lateral cross-sectional view taken along Line 10-10 of FIG. 6, which includes the third row 202c of the support structures 170, 184. As shown, the third row 202c includes the ball interior upper support structure 170 and the ball interior lobe 245 disposed in the middle of the support frame 112, whereby the ball interior upper support structure 170 is spaced apart from the top side 228 of the ball interior lobe 245 by the second distance D2 and the upper platform 208 of the ball interior upper support structure 170 contacts the bottom side 126 of the support layer 110 at one of the forefoot sockets 138. The ball peripheral lower support structures 182 are respectively disposed on opposite sides of the ball interior upper support structure 170 adjacent to the medial side 16 and the lateral side 18 of the sole structure 100, and each include a lower platform 214 contacting the top side 268 of the outsole 104.
[0107] Referring now to FIG. 11, a lateral cross-sectional view is taken along Line 11-11 of FIG. 6, which includes the fourth row 202d of the support structures 172, 186. As shown, the fourth row 202d includes the mid-foot peripheral upper support structures 172 and the mid-foot peripheral lobes 246 disposed on the medial side 16 and the lateral side 18, whereby the mid-foot peripheral upper support structures 172 are spaced apart from the top side 228 of the mid-foot peripheral lobes 246 by respective distances D5, D10 and the upper platforms 208 of the mid-foot peripheral upper support structures 172 contact the bottom side 126 of the support layer 110 at one of the mid-foot retainers 134. The mid-foot interior lower support structure 186 is disposed between the mid-foot peripheral upper support structures 172 in the middle of the sole structure 100 and includes a lower platform 214 contacting the top side 268 of the outsole 104.
[0108] FIG. 12 provides a lateral cross-sectional view taken along Line 12-12 of FIG. 6, which includes the fifth row 202e of the support structures 174, 188. As shown, the fifth row 202e includes the mid-foot interior upper support structure 174 disposed in the middle of the support frame 112, whereby the upper platform 208 of the mid-foot interior upper support structure 174 contacts the bottom side 126 of the support layer 110 at one of the mid-foot sockets 140. The mid- 2364187002.1Attorney Docket No.: 201882-579925 / 250185WO01foot peripheral lower support structures 188 are respectively disposed on opposite sides of the midfoot interior upper support structure 174 adjacent to the medial side 16 and the lateral side 18 of the sole structure, and each include a lower platform 214 contacting one of the mid-foot support pads 274 on the top side 268 of the outsole 104.
[0109] Referring now to FIG. 13, a lateral cross-sectional view is taken along Line 13-13 of FIG. 6, which includes the sixth row 202f of the support structures 176, 190. As shown, the sixth row 202f includes the heel peripheral upper support structures 176 and the heel peripheral lobes 256 disposed on the medial side 16 and the lateral side 18, whereby the heel peripheral upper support structures 176 are spaced apart from the top side 236 of the heel peripheral lobes 256 by respective distances D6, Dll and the upper platforms 208 of the heel peripheral upper support structures 176 contact the bottom side 126 of the support layer 110 at one of the heel retainers 136. The heel interior lower support structure 190 is disposed between the heel peripheral upper support structures 176 in the middle of the sole structure 100 and includes a lower platform 214 contacting one of the heel support pads 276 formed on the top side 268 of the outsole 104.
[0110] FIG. 14 provides a lateral cross-sectional view is taken along Line 14-14 of FIG. 6, which includes the seventh row 202g of the support structures 178, 192. As shown, the seventh row 202g includes the heel interior upper support structure 178 disposed in the middle of the support frame 112, whereby the upper platform 208 of the heel interior upper support structure 178 contacts the bottom side 126 of the support layer 110 at one of the mid-foot sockets 140. The heel peripheral lower support structures 192 are respectively disposed on opposite sides of the mid-foot interior upper support structure 174 adjacent to the medial side 16 and the lateral side 18 of the sole structure, and each include a lower platform 214 contacting one of the mid-foot support pads 274 on the top side 268 of the outsole 104.
[0111] As provided above, the lobes 240-246, 256, 257 are configured to mate with the bottom sides of the upper support structures 164-178 along the length of the sole structure 100. Optionally, the mating interface between the top sides 228 of the lobes 240-246, 256, 257 and the bottom sides 156 of the upper support structures 164-178 may include one or more bearing elements to modify a coefficient of friction between the structures. For instance, the top sides 228 of the lobes 240-246, 256, 257 and / or the bottom sides 156 of the upper support structures 164-178 may be coated or laminated with a friction layer to increase or decrease the relative friction between lobes 240-246, 256, 257 and the upper support structures 164-178. Additionally or 2464187002.1Attorney Docket No.: 201882-579925 / 250185WO01alternatively, the top sides 228 of the lobes 240-246, 256, 257 and / or the bottom sides 156 of the upper support structures 164-178 may be provided with a surface roughness to modify friction between the lobes 240-246, 256, 257 and the upper support structures 164-178. For example, the top sides 228 of the lobes 240-246 and / or the bottom sides 156 of the upper support structures 164-178 may include textured bearing surfaces. By modifying the mating interface to include increased or decreased frictional properties, the overall cushioning response of the structure may be modified. Modifying frictional properties may also be utilized to mitigate undesirable acoustics (e.g., squeaking) between the lobes 240-246, 256, 257 and the upper support structures 164-178 during compression.
[0112] As shown in FIGS. 7-16, the sole structure 100 is configured to provide a primary cushioning phase and a secondary cushioning phase. In an uncompressed state (FIGS. 7-16), upper platforms 208 of the upper support structures 164-178 are spaced apart from the top sides 228, 236 of the lobes 240-246, 256, 257, whereby the support frame 112 is entirely self-supported between the outsole 104 and the support layer 110. During a primary cushioning response, the sole structure 100 moves from the uncompressed state (FIGS. 7-16) to a first compressed state (i.e., support frame 112 is compressed and the chassis 114 is uncompressed). Here, cushioning properties are provided solely by the mechanics of support structure struts 210, 216. As the support structures 164-192 are compressed through the primary cushioning phase, support structure struts 210, 216 are configured to resiliently deform (e.g., flex or bow) to accommodate compression of the support structures 164-192. In some examples, the support structure struts 210, 216 are configured to bow outwardly such that the support structures 164-192 compress without rotation. In other examples, one or more of the support structures 164-192 may include support structure struts 210, 216 that are configured to bow outwardly and / or in a rotational direction about a central axis of the support structure 164-192 (i.e., an axis extending normal to the platform 208, 214), whereby compression of the support structure struts 210, 216 induces a rotational response of the support structure 164-192. During a secondary cushioning response, the sole structure 100 moves from the first compressed state (i.e., support frame 112 is compressed and the chassis 114 is uncompressed) to a second compressed state where the upper platforms 208 contact and compress the lobes 240-246, 256, 257. During the secondary cushioning response, the struts 210, 216 may reach a cushioning threshold and begin to yield through a second distance. This deformation may result in a decrease in responsive force provided by the struts 210, 216 and an increased reliance 2564187002.1Attorney Docket No.: 201882-579925 / 250185WO01on cushioning properties provided by the lobes 240-246, 256, 257. This supplemental or complementary cushioning configuration can be tuned to provide a constant underfoot feel through the stance phase of the gait cycle.
[0113] With particular reference to FIGS. 7 and 8, the distances D1-D8 between the top sides 228 of the lobes 242-257 and the respective upper support structures 164-178 may vary along the longitudinal direction of the sole structure 100. Generally, the sole structure 100 is configured such that distances D1-D8 between the top sides 228 of the lobes 242-257 and the upper support structures 164-178 are greater at areas of the sole structure 100 having a greater overall height Hioo than at areas of the sole structure 100 having lesser overall height Hioo. For example, FIG. 7 illustrates that the second distance D2 associated with the ball interior upper support structure 170 and the ball interior lobe 245 is greater than the first distance DI associated with the toe interior upper support structure 166 and the toe interior lobe 243, as the sole structure 100 has a greater overall height Hioo in the ball portion 20B than in the toe portion 20T. Likewise, the third distance D3 associated with the heel interior upper support structure 178 and the heel interior lobe 257 is greater than the second distance D2 associated with the ball interior upper support structure 170 and the ball interior lobe 245, as the sole structure has a greater overall height Hioo in the heel region 24 than in the ball portion 20B. FIG. 8 illustrates a similar relationship along the peripheral upper support structures 164, 168, 172, 176 and the peripheral lobes 242, 244, 246, 256. For example, the seventh and eighth distances D7, D8 in the heel region 24 are greater than the fourth and fifth distances D4, D5 in the forefoot region 20.
[0114] Similarly, the medial-to-lateral cushioning properties of the sole structure 100 may be tuned by varying the distances D4-D11 between the peripheral upper support structures 164, 168, 172, 176 and the peripheral lobes 242, 244, 246, 256. For example, the fifth distance D5 between the medial ball peripheral upper support structure 168 and the medial ball peripheral lobe 244 may be different than a ninth distance D9 between the lateral ball peripheral upper support structure 168 and the lateral ball peripheral lobe 244 to provide different cushioning properties in the ball portion 20B. This may be desirable in sole structures where forces applied to the medial side 16 of the sole structure 100 are expected to be different than forces applied to the lateral side 18 of the sole structure 100. This medial-to-lateral variability in distances D4-D11 may be incorporated along any region or combination of regions 20, 22, 24 of the sole structure 100.2664187002.1Attorney Docket No.: 201882-579925 / 250185WO01
[0115] By providing complementary support structures 112, 114, the overall performance of the sole structure 100 can be tuned for particular cushioning parameters. For example, the distance between the upper platforms 208 and the top sides 228, 228 of the lobes 240-246, 256, 257 can be increased or decreased to modify a range of the primary cushioning phase. Thus, decreasing the distance will advance engagement of the lobes 240-246, 256, 257 in the stance phase of the gait cycle (i.e., earlier loading) and increasing the distance will retard engagement of the lobes 240- 246, 256, 257 in the stance phase of the gait cycle (i.e., later loading). This tuning may be desirable to accommodate sole structures 100 for different types of activities, such as a running sole structure used for forward motion versus a tennis or basketball sole structure used for lateral motion. This relationship is described in greater detail below with respect to FIG. 43.
[0116] With particular reference to FIGS. 15-28, an article of footwear 10a is provided and includes a sole structure 100a and the upper 30 attached to the sole structure 100a. In view of the substantial similarity in structure and function of the components associated with the article of footwear 10 with respect to the article of footwear 10a, like reference numerals are used hereinafter and in the drawings to identify like components while like reference numerals containing letter extensions are used to identify those components that have been modified. Similarly, the following description of the article of footwear 10a is limited to elements that are distinguishable from features of the article of footwear 10. Unless stated otherwise, it should be appreciated that the features of the article of footwear 10a having common reference numerals with the article of footwear 10 are provided as described previously.
[0117] Referring to FIGS. 15-17, the article of footwear 10a includes a sole structure 100a having an upper 30 attached to the sole structure 100a. The sole structure 100a includes a midsole 102a configured to provide cushioning and support and an outsole 104a defining a groundengaging surface (i.e., contacts the ground during a stance phase of a gait cycle) of the sole structure 100a. Unlike conventional sole structures, which include monolithic midsoles and outsoles, the sole structure 100a of the present disclosure is configured as a composite structure including a plurality of components joined together. For example, the midsole 102a may include a support layer 110a attached to the upper 30, an intermediate support assembly 108a attached to the support layer 110a, and a chassis 114a disposed between the support assembly 108a and the outsole 104a. Thus, the support assembly 108a is disposed between support layer 110a and the2764187002.1Attorney Docket No.: 201882-579925 / 250185WO01chassis 114a. The support assembly 108a includes a support frame 112a and an outer barrier element 116a covering at least a portion of the support frame 112a.
[0118] Turning to FIGS. 18 and 19, the support layer 110a extends from afirstend 120a disposed at the anterior end 12 of the sole structure 100a to a second end 122a disposed at the posterior end 14 of the sole structure 100a. The support layer 110a includes a top side 124 that faces the upper 30 and a bottom side 126a formed on an opposite side from the top side 124. A peripheral side 128 extends between the top side 124 and the bottom side 126a and defines a peripheral profile of the support layer 110a. The top side 124 includes a footbed surface 130 that defines a profile of the footbed of the sole structure 100a for supporting a plantar surface of the foot.
[0119] Referring to FIG. 19, the bottom side 126a of the support layer 110a includes a plurality of retainers 132, 134, 136 and a plurality of sockets 138, 140, 142 each configured to interface with a respective portion of the support assembly 108a. The retainers 132, 134, 136 are generally disposed adjacent to the peripheral side 128 of the support layer 110 and include forefoot retainers 132 disposed in the forefoot region 20, mid-foot retainers 134 disposed in the mid-foot region 22, and heel retainers 136 disposed in the heel region 24. The sockets 138, 140, 142 are arranged in series along the longitudinal axis Aiooa and include forefoot sockets 138 disposed in the forefoot region 20, mid-foot sockets 140 disposed in the mid-foot region 22, and a heel socket 142 disposed in the heel region 24. While the retainers 132, 134, 136 and the sockets 138, 140, 142 are all configured to receive corresponding upper support structures of the support assembly 108a, the retainers 132, 134, 136 are formed as concave recesses within protrusions extending from the bottom side 126a of the support layer 110a while the sockets 138, 140, 142 are formed as concave recesses within the bottom side 126a of the support layer 110a.
[0120] Referring still to FIGS. 18 and 19, the support assembly 108a includes the support frame 112a and the barrier element 116a encapsulating the support frame 112a. The support frame 112a is disposed within an interior void defined by the barrier element 116a and the barrier element 116a of the present example conforms to the exterior profile of the support frame 112a. Thus, geometries and features described herein with respect to the support frame 112a should be understood to be imparted to the overall support assembly 108 through the barrier element 116a. Optionally, the interior void defined by the barrier element 116a may include a positively pressurized fluid, such as air or liquid.2864187002.1Attorney Docket No.: 201882-579925 / 250185WO01
[0121] The support frame 112a extends from a first end 150a at the anterior end 12 of the sole structure 100a to a second end 152a at the posterior end 14 of the sole structure 100a. The support frame 112a and features thereof may be described in terms of having a top side 154a that faces the upper 30 and the bottom side 126a of the support layer 110a. The support frame 112a and features thereof may also be described in terms of having a bottom side 156a formed on an opposite side from the top side 154a. The support frame 112a includes a peripheral edge 158a connecting the top side 154a of the support frame 112a and the bottom side 156a of the support frame 112a.
[0122] Structurally, the support frame 112a includes an intermediate frame 160a providing a centralized base from which support features of the support frame 112a are formed. The support frame 112a includes a plurality of upper support structures 164a-178 extending from the intermediate frame 160a on the top side 154a of the support frame 112a and a plurality of lower support structures 180a-192 extending from the intermediate frame 160a on the bottom side 156a of the support frame 112a. In this example, the support frame 112a is configured such that the intermediate frame 160ais spaced apart from the outsole 104 by the lower support structures 180a-188a in the forefoot region 20 and the mid-foot region 22. This is in contrast to the sole structure 100 described previously, wherein the intermediate frame 160 is supported on and contacts the outsole 104 in the forefoot region 20.
[0123] Referring still to FIG. 18 and 19, the upper support structures 164a-178 are arranged along the length of the support frame 112a and include peripheral upper support structures 164a, 168a, 172a, 176 that are arranged adjacent to the peripheral edge 158a of the support frame 112a. The upper support structures 164a-178 further include interior upper support structures 162a, 166a, 170a, 174a, 178 arranged generally along the longitudinal axis Awoaof the sole structure 100a. The peripheral upper support structures 164a, 168a, 172a, 176 and the interior upper support structures 162a, 166a, 170a, 174a, 178 are alternatingly arranged (e.g., peripheral protrusions, interior protrusion, peripheral protrusions, interior protrusion, etc.) along the length of the support frame 112a to provide an alternating undulated profile along the top side 154a of the support frame 112a.
[0124] Unlike the support frame 112, which includes the toe opening 200, the support frame 112a of the present example includes an anterior upper support structure 162a disposed in the middle of the support frame 112 at the first end 150a. As shown in FIG. 18, the upper support structures 162a-178 further include a first pair of toe peripheral upper support structures 164a 2964187002.1Attorney Docket No.: 201882-579925 / 250185WO01disposed in the toe portion 20T of the support frame 112a. The toe peripheral upper support structures 164a include a medial toe peripheral upper support structure 164a disposed on the medial side 16 and a lateral peripheral upper support structure 164a disposed on the lateral side 18. The upper support structures 162a-178 further include a toe interior upper support structure 166a disposed in the toe portion 20T, which is longitudinally offset towards the second end 152a of the support frame 112a from the toe peripheral upper support structures 164a.
[0125] Referring still to FIG. 18, the upper support structures 164a-178 include a pair of ball peripheral upper support structures 168a disposed in the ball portion 20B of the support frame 112a. The ball peripheral upper support structures 168a include a medial ball peripheral upper support structure 168a disposed on the medial side 16 in the ball portion 20B and a lateral ball peripheral upper support structure 168a disposed on the lateral side 18 in the ball portion 20B. The upper support structures 164a-178 further include a ball interior upper support structure 170a disposed in the ball portion 20B that is longitudinally offset towards the second end 152a of the support frame 112a from the ball peripheral upper support structures 168a.
[0126] The upper support structures 164a-178 include a pair of mid-foot peripheral upper support structures 172a disposed in the mid-foot region 22 of the support frame 112a. The midfoot peripheral upper support structures 172a include a medial mid-foot peripheral upper support structure 172a disposed on the medial side 16 in the mid-foot region 22 and a lateral mid-foot peripheral upper support structure 172a disposed on the lateral side 18 in the mid-foot region 22. The upper support structures 164a-178 further include a mid-foot interior upper support structure 174a disposed in the mid-foot region 22 that is longitudinally offset towards the second end 152a of the support frame 112a from the mid-foot peripheral upper support structures 172a.
[0127] The upper support structures 164a-178 further include the heel upper support structures 176, 178 described previously. Thus, as mentioned above, the support frame 112a is configured with portions in the forefoot region 20 and a mid-foot region 22 that are distinguishable from the support frame 112 while having a similar portion in the heel region 24.
[0128] Referring still to FIGS. 18 and 19, the lower support structures 180a-192 are arranged along the length of the support frame 112a and include peripheral lower support structures 180a, 184a, 188a, 192 that are arranged adjacent to the peripheral edge 158a of the support frame 112a. The lower support structures 180a-192 further include interior lower support structures 182a, 186a, 190 arranged generally along the longitudinal axis Aiooa of the sole structure 100a. The 3064187002.1Attorney Docket No.: 201882-579925 / 250185WO01peripheral lower support structures 180a, 184a, 188a, 192 and the interior lower support structures 182a, 186a, 190 are alternatingly arranged (e.g., peripheral protrusions, interior protrusion, peripheral protrusions, interior protrusion, etc.) along the length of the support frame 112a to provide an alternating undulated profile along the bottom side 156a of the support frame 112a.
[0129] As shown in FIG. 19, the lower support structures 180a-192 include a pair of toe peripheral lower support structures 180a disposed in the toe portion 20T of the support frame 112a. The toe peripheral lower support structures 180a include a medial toe peripheral lower support structure 180a disposed on the medial side 16 and a lateral toe peripheral lower support structure 180a disposed on the lateral side 18. Thus, toe peripheral lower support structures 180a are aligned along the lateral direction with the toe interior upper support structure 166a and are disposed on opposite sides of the toe interior upper support structure 166a to provide a first row 202i of support structures having an undulated profile across the width of the support frame 112a in the toe portion 20T.
[0130] The lower support structures 180a-192 further include a ball interior lower support structure 182a disposed in the toe portion 20 that is longitudinally offset towards the second end 152a of the support frame 112a from the toe peripheral lower support structures 180a. The ball interior lower support structure 182a is aligned along the lateral direction with the ball peripheral upper support structures 168a and is disposed between ball peripheral upper support structures 168a to provide a second row 202j of support structures having an undulated profile across the width of the support frame 112a in the ball portion 20B.
[0131] Referring still to FIG. 19, the lower support structures 180a-192 include a pair of ball peripheral lower support structures 184a disposed in the ball portion 20B of the support frame 112a. The ball peripheral lower support structures 184a include a medial ball peripheral lower support structure 184a disposed on the medial side 16 in the ball portion 20B and a lateral ball peripheral lower support structure 184a disposed on the lateral side 18 in the ball portion 20B. Thus, the ball peripheral lower support structures 184a are aligned along the lateral direction with the ball interior upper support structure 170a and are disposed on opposite sides of the ball interior upper support structure 170a to provide a third row 202k of support structures having an undulated profile across the width of the support frame 112a in the toe portion 20T.
[0132] The lower support structures 180a-192 further include a mid-foot interior lower support structure 186a disposed in the mid-foot region 22 that is longitudinally offset towards the second 3164187002.1Attorney Docket No.: 201882-579925 / 250185WO01end 152a of the support frame 112a from the ball peripheral lower support structures 184a. The mid-foot interior lower support structure 186a is aligned along the lateral direction with the midfoot peripheral upper support structures 172a and is disposed between the mid-foot peripheral upper support structures 172a to provide a fourth row 2021 of support structures having an undulated profile across the width of the support frame 112a in the mid-foot region 22.
[0133] Referring still to FIG. 19, the lower support structures 180a-192 include a pair of midfoot peripheral lower support structures 188a disposed in the mid-foot region 22 of the support frame 112a. The mid-foot peripheral lower support structures 188a include a medial mid-foot peripheral lower support structure 188a disposed on the medial side 16 in the mid-foot region 22 and a lateral mid-foot peripheral lower support structure 188a disposed on the lateral side 18 in the mid-foot region 22. Thus, the mid-foot peripheral lower support structures 188a are aligned along the lateral direction with the mid-foot interior upper support structure 174a and are disposed on opposite sides of the mid-foot interior upper support structure 174a to provide a fifth row 202m of support structures having an undulated profile across the width of the support frame 112a in the mid-foot region 22.
[0134] The lower support structures 180a-192 further include the heel lower support structures 190, 192 disposed in the heel region 24 of the support frame 112a. Thus, the support frame 112a includes a heel portion that is substantially the same as the support frame 112, while the portions of the support frame 112a in the forefoot region 20 and the mid-foot region 22 are configured with lower support structures 180a-188a that project below the intermediate frame 160a to provide the support frame 112a and the sole structure 100a with an increased overall height Hiooa (FIG. 17) in the forefoot region 20 and the mid-foot region 22. Thus, as best shown in FIGS. 16 and 17, the lower support structures 180a-188a space the intermediate frame 160a of the intermediate frame 160a away from the outsole 104a to provide additional structural -based cushioning.
[0135] As set forth in the foregoing paragraphs, the upper support structures 164a-178 and the lower support structures 180a-192 are arranged to form laterally-extending rows 202f-202n of the support structures 164a- 192 arranged in series between the first end 1 0a and the second end 152a of the support frame 112a. Each row 202f-202n includes an undulating profile defined by alternating support structures (e.g., lower, upper, lower) in the lateral direction. Additionally, adjacent ones of the rows 202f-202n alternate configurations, whereby a first one of the rows 202i, 202k, 202m, 202g is arranged in a lower-upper-lower configuration and an adjacent one of the 3264187002.1Attorney Docket No.: 201882-579925 / 250185WO01rows 202j, 2021, 202f, 202h is arranged in an upper-lower-upper configuration. Thus, in addition to forming laterally-extending rows 202f-202n each defining an undulating profile, the support structures 164a-192 define three longitudinally-extending columns 204a-204c of undulating support structures 164a-192 extending between the first end 150a and the second end 152a. Optionally, one or more of the rows 202f-202n may be omitted from the support frame 112, wherein instead of forming the support frame 112 as a continuous structure extending along the entire length of the sole structure 100, the support frame 112 is provided as a segmented structure along one or more of the regions 20, 22, 24.
[0136] With continued reference to FIGS. 18 and 19, the chassis 114a is configured to engage and support the bottom side 156a of the support frame 112a and to provide secondary support and cushioning properties to the sole structure 100a. The relationship between the chassis 114a and the support frame 112a is more clearly shown and described below with respect to FIGS. 21 and 22. Optionally, the chassis 114a may be provided as a fragmentary structure including an anterior chassis segment 220a disposed in the forefoot region 20 and the mid-foot region 22, and the posterior chassis segment 222 disposed in the heel region 24.
[0137] The anterior chassis segment 220a extends from a first end 224a disposed at the anterior end 12 of the article of footwear 10a to a second end 226a disposed in the mid-foot region 22 of the sole structure 100a. The anterior chassis segment 220a and features thereof may be described in terms of a top side 228a that faces the upper 30 and the support frame 112a and a bottom side 230a formed on an opposite side from the top side 228a.
[0138] Each of the chassis segments 220a, 222 includes a plurality of support lobes 240a-246a, 256, 257 each configured to engage a respective one of the upper support structures 162a-178 on the bottom side 156a of the support frame 112a and / or the bottom side 126a of the support layer 110a. The chassis segments 220a, 222 are formed whereby the bottom sides 230, 238 are substantially smooth and are configured to rest upon the outsole 104a while the top sides 228a, 236 define the protruding contours of each of the support lobes 240a-246a, 256, 257. Thus, each of the lobes 240a-246a, 256, 257 provides a bulbous profile along the top sides 228a, 236 of the respective chassis segments 220a, 222.
[0139] The anterior chassis segment 220a includes an anterior lobe 240a disposed at the first end 224a of the anterior chassis segment 220a, which defines a bulbous portion of the top side 228a that is received within the bottom side of the anterior upper support structure 162a. The 3364187002.1Attorney Docket No.: 201882-579925 / 250185WO01anterior chassis segment 220a further includes a pair of toe peripheral lobes 242a extending from opposite sides of the anterior chassis segment 220a in the toe portion 20T, a pair of ball peripheral lobes 244a extending form opposite sides of the anterior chassis segment 220a in the ball portion 20B, and a pair of mid-foot peripheral lobes 246a extending from opposite sides of the anterior chassis segment 220a in the mid-foot region 22. Adjacent ones of the peripheral lobes 240a, 242a, 244a, 246a are separated by the recesses 248, 252, 254 formed along the periphery of the anterior chassis segment 220a. Particularly, the anterior chassis segment 220a includes the pair of toe recesses 248 that separate the toe peripheral lobes 242a from the ball peripheral lobes 244a. Likewise, the ball recesses 252 separate the ball peripheral lobes 242a from the mid-foot peripheral lobes 246a along each side of the anterior chassis segment 220a. The mid-foot recess 254 is formed at the second end 226a and separates the mid-foot peripheral lobes 246a.
[0140] Along with the peripheral features, the anterior chassis segment 220a includes a plurality of interior lobes 243a, 245a arranged along a central portion of the anterior chassis segment 220a between the peripheral lobes 240a, 242a, 244a, 246a. Particularly, the anterior chassis segment 220a includes a toe interior lobe 243a disposed in the toe portion 20T, which is longitudinally offset between the toe peripheral lobes 242a and the ball peripheral lobes 244a. Similarly, the anterior chassis segment 220a includes a mid-foot interior lobe 245a disposed in the mid-foot region 22, which is longitudinally offset between the ball peripheral lobes 244a and the mid-foot peripheral lobes 246a. Thus, the peripheral lobes 240a, 242a, 244a, 246a and the interior lobes 243a, 245a have an alternating arrangement configured to mate with the bottom sides of the upper support structures 164a-174a in the forefoot region 20 and mid-foot region 22. Optionally, the anterior chassis segment 220a may include a toe opening 247 in the toe portion 20T between the anterior lobe 240a and the ball interior lobe 243a. The anterior chassis segment 220a may also include the ball opening 250 in the ball portion 20B between the ball interior lobe 243a and the mid-foot interior lobe 245a. Adjacent ones of the lobes 240a-246a of the anterior chassis segment 220a are connected to each other by respective necked portions 249 of the anterior chassis segment 220a having a reduced thickness relative to the lobes 240a-246a. These necked portions 249 provide flexibility between adjacent ones of the lobes 240a-246a and provides a recessed portion that accommodates a corresponding portion of the support frame 112a.
[0141] The outsole 104a extends from a first end 264 at the anterior end 12 to a second end 266 at the posterior end 14. The outsole 104a includes a top side 268a facing the upper 30 and a bottom 3464187002.1Attorney Docket No.: 201882-579925 / 250185WO01side 270 formed on an opposite side from the top side 268a. The outsole 104a further includes a peripheral side 272 extending between the top side 268a and the bottom side 270 and defining a peripheral profile of the outsole 104a. Optionally, the outsole 104a may include a mid-foot opening 278. Additionally, second end 266 of the outsole 104a may include the pair of heel tabs 280 that are separated by the heel recess 282, thereby allowing independent articulation of the heel peripheral lobes 256 and the sole structure 100a at the second end 266.
[0142] The outsole 104a attaches to the bottom sides 230a, 238 of the chassis 114a and supports the lower support structures 180a-192 of the support frame 112a. Particularly, one or more of the lower support structures 180a-192 extend through the respective recesses and openings formed in the chassis 114a and contacts the outsole 104a, whereby the support frame 112a is directly supported against the outsole 104a. Optionally, the outsole 104a includes a plurality of support pads 273, 274, 276 that are aligned with respective ones of the lower support structures 180a-192 to provide additional cushioning and support. Particularly, the support pads 273, 274, 276 may include forefoot support pads 273 disposed in the forefoot region 20 and the mid-foot support pads 274 disposed in the mid-foot region 22, which are aligned with and support the platforms 214 of the mid-foot peripheral lower support structures 188a (FIG. 22). Additionally, the support pads 276 may include the heel support pads 276 disposed in the heel region 24, which are aligned with and support the platforms 214 of the heel lower support structures 190, 192.
[0143] Turning now to FIGS. 20-28, the relationships of the components 110a, 112a, 114a of the sole structure 100a are shown with the sole structure 100a in an assembled configuration. Generally, the sole structure 100a is configured such that the upper platforms 208 of the upper support structures 164a-178 contact the bottom side 126a of the support layer 110a while the lower platforms 214 of the lower support structures 180a-192 contact the top side 268a of the outsole 104a. More specifically, the upper platforms 208 may be received within the retainers 132, 134, 136 and sockets 138, 140, 142 of the support layer 110a while the lower platforms 214 may be supported on the support pads 273, 274, 276.
[0144] FIG. 21 shows a cross-sectional view of the sole structure 100a taken along Line 21-21 of FIG. 20, which generally extends along the longitudinal axis Awoa and through the interior features of the sole structure 100a. Starting at the anterior end 12, the anterior upper support structure 162a and the anterior lobe 240a of the anterior chassis segment 220a are arranged in the toe portion 20T, whereby anterior upper support structure 162a is spaced apart from the top side 3564187002.1Attorney Docket No.: 201882-579925 / 250185WO01228a of the anterior lobe 240a by a first distance D21 and the upper platform 208 of the anterior upper support structure 162a contacts the bottom side 126a of the support layer 110a at one of the forefoot sockets 138. The toe interior upper support structure 166a and the toe interior lobe 243a are arranged in the toe portion 20T, whereby the toe interior upper support structure 166a is spaced apart from the top side 228a of the toe interior lobe 243a by a second distance D22 and the upper platform 208 of the toe interior upper support structure 166a contacts the bottom side 126a of the support layer 110a at one of the forefoot sockets 138. The ball interior upper support structure 170a and the ball interior lobe 245a are arranged in the ball portion 20B, whereby the ball interior upper support structure 170a is spaced apart from the top side 228a of the ball interior lobe 245a by a third distance D23 and the upper platform 208 of the ball interior upper support structure 170a contacts the bottom side 126a of the support layer 110a at one of the forefoot sockets 138. The mid-foot interior upper support structure 174a is arranged in the mid-foot region 22 and includes an upper platform 208 that engages the mid-foot socket 140. The mid-foot interior upper support structure 174a does not include a corresponding lobe of the chassis 114a. The heel interior upper support structure 178 and the heel interior lobe 257 are arranged in the heel region 24, whereby the heel interior upper support structure 178 is spaced apart from the top side 236 of the heel interior lobe 257 by a fourth distance D24 and the upper platform 208 of the heel interior upper support structure 178 contacts the bottom side 126a of the support layer 110a at one of the heel sockets 142. The interior lower support structures 182a, 186a, 190 extend between adjacent ones of the interior upper support structures 162a, 166a, 170a, 174a, 178 and include the lower platforms 214 that contact respective portions of the outsole 104 between adjacent ones of the interior lobes 243a, 245a, 257.
[0145] FIG. 22 shows a cross-sectional view of the sole structure 100a taken along Line 22-22 of FIG. 20, which generally extends along the longitudinal axis Aiooa and through the peripheral features of the sole structure 100a. Starting at the anterior end 12, the medial toe peripheral upper support structure 164a and the toe peripheral lobe 242a are arranged in the toe portion 20T, whereby the medial toe peripheral upper support structure 164a is spaced apart from the top side 228a of the toe peripheral lobe 242a by a fifth distance D25 and the upper platform 208 of medial toe peripheral upper support structure 164a contacts the bottom side 126a of the support layer 110a at one of the forefoot retainers 132. The medial ball peripheral upper support structure 168a and the medial ball peripheral lobe 244a are arranged in the ball portion 20B, whereby the medial ball 3664187002.1Attorney Docket No.: 201882-579925 / 250185WO01peripheral upper support structure 168a is spaced apart from the top side 228a of the medial ball peripheral lobe 244a by a sixth distance D26 and the upper platform 208 of the medial ball peripheral upper support structure 168a contacts the bottom side 126a of the support layer 110a at one of the forefoot retainers 132. The medial mid-foot peripheral upper support structure 174a and the medial mid-foot peripheral lobe 246a are arranged in the mid-foot region 22, whereby the medial mid-foot peripheral upper support structure 174a is spaced apart from the top side 228a of the medial mid-foot peripheral lobe 246a by a seventh distance D27 and the upper platforms 208 of the medial mid-foot peripheral upper support structure 174a contacts the bottom side 126a of the support layer 110a at one of the mid-foot retainers 134. The medial heel peripheral upper support structures 176 and the medial heel peripheral lobes 256 are arranged in the heel region 24, whereby medial heel peripheral upper support structures 176 are spaced apart from the top side 236 of the medial heel peripheral lobes 256 eighth and ninth distances D28, D29 and the upper platforms 208 of the medial heel peripheral upper support structures 176 contact the bottom side 126a of the support layer 110a at one of the heel retainers 136. The medial peripheral lower support structures 180a, 184a, 188a, 192 extend between adjacent ones of the medial peripheral upper support structures 164a, 168a, 172a, 176 and include the lower platforms 214 that contact respective portions of the outsole 104a between adjacent ones of the medial peripheral lobes 242a, 244a, 246a, 256.
[0146] Referring now to FIG. 23, a lateral cross-sectional view is taken along Line 23-23 of FIG. 20, which includes the second row 202j of the support structures 168a, 182a. As shown, the second row 202j includes the ball peripheral upper support structures 168a and the ball peripheral lobes 244a disposed on the medial side 16 and the lateral side 18, whereby the ball peripheral upper support structures 168a are spaced apart from the top side 228a of the ball peripheral lobes 244a and the upper platforms 208 of the ball peripheral upper support structures 168a contact the bottom side 126a of the support layer 110a at one of the forefoot retainers 132. The ball interior lower support structure 182a is disposed between the ball peripheral upper support structures 168a in the middle of the sole structure 100a and includes a lower platform 214 contacting the top side 268a of the outsole 104a.
[0147] FIG. 24 provides a lateral cross-sectional view taken along Line 24-24 of FIG. 20, which includes the third row 202k of the support structures 170a, 184a. As shown, the third row 202k includes the ball interior upper support structure 170a and the ball interior lobe 245a disposed 3764187002.1Attorney Docket No.: 201882-579925 / 250185WO01in the middle of the support frame 112a, whereby the ball interior upper support structure 170a is spaced apart from the top side 228a of the ball interior lobe 245a and the upper platform 208 of the ball interior upper support structure 170a contacts the bottom side 126a of the support layer 110a at one of the forefoot sockets 138. The ball peripheral lower support structures 182a are respectively disposed on opposite sides of the ball interior upper support structure 170a adjacent to the medial side 16 and the lateral side 18 of the sole structure 100a, and each include a lower platform 214 contacting the top side 268a of the outsole 104a.
[0148] Referring now to FIG. 25, a lateral cross-sectional view is taken along Line 25-25 of FIG. 20, which includes the fourth row 2021 of the support structures 172a, 186a. As shown, the fourth row 2021 includes the mid-foot peripheral upper support structures 172a and the mid-foot peripheral lobes 246a disposed on the medial side 16 and the lateral side 18, whereby the mid-foot peripheral upper support structures 172a are spaced apart from the top side 228a of the mid-foot peripheral lobes 246a and the upper platforms 208 of the mid-foot peripheral upper support structures 172a contact the bottom side 126a of the support layer 110a at one of the mid-foot retainers 134. The mid-foot interior lower support structure 186a is disposed between the midfoot peripheral upper support structures 172a in the middle of the sole structure 100a and includes a lower platform 214 contacting the top side 268a of the outsole 104a.
[0149] FIG. 26 provides a lateral cross-sectional view taken along Line 26-26 of FIG. 20, which includes the fifth row 202m of the support structures 174a, 188a. As shown, the fifth row includes the mid-foot interior upper support structure 174a disposed in the middle of the support frame 112a, whereby the upper platform 208 of the mid-foot interior upper support structure 174a contacts the bottom side 126a of the support layer 110a at one of the mid-foot sockets 140. The mid-foot peripheral lower support structures 188a are respectively disposed on opposite sides of the mid-foot interior upper support structure 174a adjacent to the medial side 16 and the lateral side 18 of the sole structure, and each include a lower platform 214 contacting one of the mid-foot support pads 274 on the top side 268a of the outsole 104a.
[0150] Referring now to FIG. 27, a lateral cross-sectional view is taken along Line 27-27 of FIG. 20, which includes the sixth row 202f of the support structures 172a, 186a. As shown, the sixth row 202f includes the heel peripheral upper support structures 176 and the heel peripheral lobes 256 disposed on the medial side 16 and the lateral side 18, whereby the heel peripheral upper support structures 176 are spaced apart from the top side 236 of the heel peripheral lobes 256 and 3864187002.1Attorney Docket No.: 201882-579925 / 250185WO01the upper platforms 208 of the heel peripheral upper support structures 176 contact the bottom side 126a of the support layer 110a at one of the heel retainers 136. The heel interior lower support structure 190 is disposed between the heel peripheral upper support structures 176 in the middle of the sole structure 100a and includes a lower platform 214 contacting one of the heel support pads 276 formed on the top side 268a of the outsole 104a.
[0151] FIG. 28 provides a lateral cross-sectional view is taken along Line 28-28 of FIG. 20, which includes the seventh row of the support structures 178, 192. As shown, the seventh row includes the mid-foot interior upper support structure 174a disposed in the middle of the support frame 112a, whereby the upper platform 208 of the mid-foot interior upper support structure 174a contacts the bottom side 126a of the support layer 110a at one of the mid-foot sockets 140. The mid-foot peripheral lower support structures 188a are respectively disposed on opposite sides of the mid-foot interior upper support structure 174a adjacent to the medial side 16 and the lateral side 18 of the sole structure, and each include a lower platform 214 contacting one of the mid-foot support pads 274 on the top side 268a of the outsole 104a.
[0152] As provided above, the lobes 240a-246, 256a, 257 are configured to mate with the bottom sides of the upper support structures 164a-178 along the length of the sole structure 100. Optionally, the mating interface between the top sides 228a of the lobes 240a-246a, 256, 257 and the bottom sides 156a of the upper support structures 164a-178 may include one or more bearing elements to modify a coefficient of friction between the structures. For instance, the top sides 228a of the lobes 240a-246a, 256, 257 and / or the bottom sides 156a of the upper support structures 164a-178 may be coated or laminated with a friction layer to increase or decrease the relative friction between lobes 240a-246a, 256, 257 and the upper support structures 164a-178a. Additionally or alternatively, the top sides 228 of the lobes 240a-246a, 256, 257 and / or the bottom sides 156a of the upper support structures 164a-178 may be provided with a surface roughness to modify friction between the lobes 240a-246a, 256, 257 and the upper support structures 164a- 178. For example, the top sides 228 of the lobes 240a-246a and / or the bottom sides 156a of the upper support structures 164a- 178 may include textured bearing surfaces. By modifying the mating interface to include increased or decreased frictional properties, the overall cushioning response of the structure may be modified. Modifying frictional properties may also be utilized to mitigate undesirable acoustics (e.g., squeaking) between the lobes 240a-246a, 256, 257 and the upper support structures 164a-178 during compression.3964187002.1Attorney Docket No.: 201882-579925 / 250185WO01
[0153] As shown in FIGS. 20-28, the sole structure 100a is configured to provide a primary cushioning phase and a secondary cushioning phase. In an uncompressed state (FIGS. 20-28), upper platforms 208 of the upper support structures 164a-178 are spaced apart from the top sides 228a, 236 of the lobes 240a-246a, 256, 257, whereby the support frame 112a is entirely selfsupported between the outsole 104a and the support layer 110a. During a primary cushioning response, the support frame 112a moves from the uncompressed state (FIGS. 7-16) to a first compressed state (i.e., support frame 112a is compressed and the chassis is uncompressed). Here, cushioning properties are provided solely by the mechanics of support structure struts 210, 216. As the support structures 164a-192 are compressed through the primary cushioning phase, support structure struts 210, 216 are configured to resiliently deform (e.g., flex or bow) to accommodate compression of the support structures 164a-192. In some examples, the support structure struts 210, 216 are configured to bow outwardly such that the support structures 164a-192 compress without rotation. In other examples, one or more of the support structures 164a- 192 may include support structure struts 210, 216 that are configured to bow outwardly and / or in a rotational direction about a central axis of the support structure 164a-192 (i.e., an axis extending normal to the platform 208, 214), whereby compression of the support structure struts 210, 216 induces a rotational response of the support structure 164a-192. During a secondary cushioning response, the support frame 112a moves from the first compressed state (i.e., support frame 112a is compressed and the chassis 114a is uncompressed) to a second compressed state where the upper platforms 208 contact and compress the lobes 240a-246a, 256, 257. During the secondary cushioning response, the struts 210, 216 may reach a cushioning threshold and begin to yield through a second distance. This deformation may result in a decrease in responsive force provided by the struts 210, 216 and an increased reliance on cushioning properties provided by the lobes 240a-246a, 256, 257. This supplemental or complementary cushioning configuration can be tuned to provide a constant underfoot feel through the stance phase of the gait cycle.
[0154] With particular reference to FIGS. 21 and 22, the distances D21-D29 between the top sides 228 of the lobes 240a-257 and the respective upper support structures 164a-178 may vary along the longitudinal direction of the sole structure 100a. Generally, the sole structure 100a is configured such that distances D21-D29 between the top sides 228a of the lobes 242a-257 and the upper support structures 164a-178 are greater at areas of the sole structure 100a having a greater overall height Hiooa than at areas of the sole structure 100a having lesser overall height 4064187002.1Attorney Docket No.: 201882-579925 / 250185WO01Hiooa. For example, FIG. 21 illustrates that the third distance D23 associated with the ball interior upper support structure 170a and the ball interior lobe 245 is greater than the second distance D22 associated with the toe interior upper support structure 166a and the toe interior lobe 243, as the sole structure has a greater overall height Hioo in the ball portion 20B than in the toe portion 20T. Likewise, the third distance D3 associated with the heel interior upper support structure 178 and the heel interior lobe 257 is greater than the second distance D2 associated with the ball interior upper support structure 170a and the ball interior lobe 245a, as the sole structure 100a has a greater overall height Hiooa in the heel region 24 than in the ball portion 20B. FIG. 22 illustrates a similar relationship along the peripheral upper support structures 164a, 168a, 172a, 176 and the peripheral lobes 242a, 244a, 246a, 256. For example, the eighth and ninth distances D28, D29 in the heel region 24 are greater than the fifth and sixth distances D5, D6 in the forefoot region 20.
[0155] Similarly, the medial -to-lateral cushioning properties of the sole structure 100a may be tuned by varying the distances D25-D33 between the peripheral upper support structures 164a, 168a, 172a, 176 and the peripheral lobes 242a, 244a, 246a, 256. For example, the sixth distance D26 between the medial ball peripheral upper support structure 168a and the medial ball peripheral lobe 244a may be different than a tenth distance D30 between the lateral ball peripheral upper support structure 168a and the lateral ball peripheral lobe 244a to provide different cushioning properties in the ball portion 20B. This may be desirable in sole structures where forces applied to the medial side 16 of the sole structure 100a are expected to be different than forces applied to the lateral side 18 of the sole structure 100. This medial-to-lateral variability in distances D25-D33 may be incorporated along any region or combination of regions 20, 22, 24 of the sole structure 100a.
[0156] By providing complementary support structures 112a, 114a, the overall performance of the sole structure 100a can be tuned for particular cushioning parameters. For example, the distance between the upper platforms 208 and the top sides 228a, 228a of the lobes 240-246, 256a, 257 can be increased or decreased to modify a range of the primary cushioning phase. Thus, decreasing the distance will advance engagement of the lobes 240-246, 256a, 257 in the stance phase of the gait cycle (i.e., earlier loading) and increasing the distance will retard engagement of the lobes 240-246, 256a, 257 in the stance phase of the gait cycle (i.e., later loading). This tuning may be desirable to accommodate sole structures 100a for different types of activities, such as a running4164187002.1Attorney Docket No.: 201882-579925 / 250185WO01sole structure used for forward motion versus a tennis or basketball sole structure used for lateral motion.
[0157] With particular reference to FIGS. 29-42, an article of footwear 10b is provided and includes a sole structure 100b and the upper 30 attached to the sole structure 100b. In view of the substantial similarity in structure and function of the components associated with the article of footwear 10 with respect to the article of footwear 10b, like reference numerals are used hereinafter and in the drawings to identify like components while like reference numerals containing letter extensions are used to identify those components that have been modified. Similarly, the following description of the article of footwear 10a is limited to elements that are distinguishable from features of the article of footwear 10. Unless stated otherwise, it should be appreciated that the features of the article of footwear 10a having common reference numerals with the article of footwear 10 are provided as described previously.
[0158] The sole structure 100b of the article of footwear of FIGS. 29-42 is substantially the same as the sole structure 100 described previously, and further includes an outsole plate 106 disposed between the outsole 104a and the midsole 102. Particularly, the outsole plate 106 includes materials having a greater stiffness than the outsole 104 and is disposed between the outsole 104 and the chassis 114 of the midsole 102 to provide a semi-rigid interface between the lobes 240-246, 256, 257 and the ground surface. In some examples, the outsole plate 106 includes materials having a Young’s modulus of at least 10 gigapascals.
[0159] With particular references to FIGS. 32 and 33, an example of the outsole plate 106 is provided. In the illustrated example, the outsole plate 106 is a full-length outsole plate 106 that is configured to extend continuously from the first end 264 of the outsole 104 to the second end 266 of the outsole 104. Thus, the outsole plate 106 supports each of anterior chassis segment 220 and the posterior chassis segment 222 on the outsole 104. As shown, the outsole plate 106 includes a forefoot segment 290 extending through the forefoot region 20, a mid-foot segment 292 extending through the mid-foot region 22, and a heel segment 294 extending through the heel region 24. While the illustrated example of the outsole plate 106 is a full-length plate including all three segments 290, 292, 294, other implementations of the sole structure 100b may include one of or a combination of the segments 290, 292, 294. For instance, any one of the segments 290, 292, 294 may be omitted from the outsole plate 106. Optionally, the sole structure 100b is configured such that the outsole 104a is formed without the support pads, and the support pads 298, 300 are instead 4264187002.1Attorney Docket No.: 201882-579925 / 250185WO01provided on a top side of the outsole plate 106 to provide a rigid interface for supporting the lower support structures 180-192. Additionally, while the outsole plate 106 is shown as being incorporated into a sole structure 100b that is similar to the sole structure 100, the outsole plate 106 may also be incorporated into the sole structure 100a.
[0160] With reference to FIG. 43, a graph illustrating the respective responses for the upper support structures 164-178 and the lobes 242-257 as the midsole 102 advances from unloaded state through each of a primary cushioning phase and a secondary cushioning phase. A first line of the chart illustrates the force-displacement curve representing a primary reaction force Fsupport of one of the upper support structures 164-178. As shown, through a first distance Z1 corresponding to the distance (e.g., D1-D8) between the upper support structures 164-178 and the lobes 242-257, the primary reaction force Fsupport of the upper support structures 164-178 increases as the upper support structures 164-178 are compressed. The upper support structures 164-178 yield at point Pl and the primary reaction force Fsupport of the upper support structures 164-178 begins to decrease through the second distance Z2.
[0161] A second line of the chart illustrates the force-displacement curve representing a supplemental reaction force Fiobe the corresponding one of the lobes 242-257. As shown, the lobes 242-257 provides zero reaction force through the first distance Zl, as the upper support structures 164-178 are solely responsible for providing cushioning in this range. The lobes 242-257 are initially engaged at the end of the first distance Zl and provides the supplemental reaction force Fiobe that increases continuously through the second distance Z2.
[0162] A third line of the chart illustrates the force-displacement curve representing the aggregate reaction force Fioo of the midsole 102. The aggregate reaction force F wo of the midsole 102 is calculated as the aggregate of the reaction forces Fsuppoit, Fiobe of the upper support structures 164-178 and the lobes 242-257. Thus, as shown, the reaction force Fioo of the midsole 102 is the same as the reaction force FSUpport of the upper support structures 164-178 through the first distance Zl. Through the second distance Z2, the rection force Fiobe of the lobes 242-257 is added to the reaction force Fsupport of the upper support structures 164-178 to define the overall reaction force F102 of the midsole 102. Thus, the decreasing reaction force Fsupport of the upper support structures 164-178 through the second distance is complemented by an increasing rection force Fiobe of the lobes 242-257 through the second distance Z2 to provide a relatively constant overall reaction4364187002.1Attorney Docket No.: 201882-579925 / 250185WO01force F102 of the midsole 102. This supplemental or complementary cushioning configuration can be tuned to provide a constant underfoot feel through the second distance Z2.
[0163] As illustrated by FIG. 43, by providing complementary cushioning structures 164-178, 242-257 the overall performance of the upper support structures 164-178 can be tuned for particular cushioning parameters. For example, the distance Z1 between the support frame 112 and the distal end of the lobes 242-257 can be increased or decreased to modify length of the primary cushioning phase. Thus, decreasing the distance Z1 will advance engagement of the lobes 242-257 in the stance phase of the gait cycle (i.e., earlier loading) and increasing the distance DI will retard engagement of the lobes 242-257 of the stance phase of the gait cycle (i.e., later loading). This tuning may be desirable to accommodate areas of the sole structures 100 that are subjected to different loads during an activity. For example, the first distance Zl.
[0164] The support frame 112 (e.g., the first strut, the second strut, etc.), the chassis 114, and or the support layer 110 may be made using polymeric materials (e.g., a polymeric first sheath material, a polymeric first core material, a polymeric second sheath material, a polymeric second core material, a polymeric filler material, etc.). Accordingly, the polymeric materials described herein are understood to comprise, consist essentially of, or consist of one or more polymers. All the one or more polymers present in a polymeric material constitute the polymeric component of the polymeric material. Similarly, when a polymeric material comprises one or more non-polymer additives, all of the non-polymeric additives present in the polymeric material constitute the non-polymeric component of the polymeric material. The one or more polymers of a polymeric material may comprise, consist essentially of, or consist of thermoplastics. A thermoplastic is a polymer that is a solid when cooled, and which can be repeatedly softened and melted on heating. The one or more polymers of a polymeric material may comprise, consist essentially of, or consist of elastomers. An elastomer may be defined as a polymer having an elongation at break greater than 100 percent, or greater than 200 percent, or greater than 400 percent, as determined using ASTM D-412-98 at 25 degrees Celsius. An elastomeric material may be defined as a composition having an elongation at break greater than 100 percent, or greater than 200 percent, or greater than 400 percent, as determined using ASTM D-412-98 at 25 degrees Celsius.
[0165] The one or more polymers of a polymeric material may include one or more of a variety of polymers, including homopolymers and copolymers and combinations of homopolymers and copolymers. The one or more polymers may comprise, consist essentially of, or consist of a 4464187002.1Attorney Docket No.: 201882-579925 / 250185WO01polymer chosen from a polyurethane, a polyurea, a polyester, a polyether, a polyamide, a polyimide, a polyolefin, a polystyrene, a polysiloxane, a polycarbonate, a polyacetate, and any combination thereof, including homopolymers and copolymers thereof. The one or more polymers may comprise, consist essentially of, or consist of a polymer chosen from a polyurethane, a polyester, a polyamide, a polystyrene, a polyolefin, and any combination thereof, including homopolymers and copolymers thereof. The one or more polymers may comprise, consist essentially of, or consist of polyurethanes. Examples of polyurethanes include thermoplastic polyurethanes (TPUs), such as polyester-polyurethane copolymers and polyether-polyurethane copolymers, including thermoplastic elastomeric polyurethanes. The one or more polymers may comprise, consist essentially of, or consist of polyesters. Examples polyesters include polyester homopolymers such as polyethylene terephthalate (PET), and polyester copolymers such as polyetheresters, including thermoplastic polyester copolymers. The one or more polymers may comprise, consist essentially of, or consist of polyamides. Examples of polyamide homopolymers include thermoplastic polyamide homopolymers such as Nylon-6, Nylon-6, 6, and Nylon-11. Examples of polyamide copolymers include thermoplastic polyamide copolymers such as thermoplastic elastomeric polyamide block copolymers, for example polyether block amide (PEBA) thermoplastic elastomers. The one or more polymers may comprise, consist essentially of, or consist of polystyrenes. Examples of polystyrenes include thermoplastic polystyrene homopolymers such as thermoplastic polystyrene homopolymer elastomers. Examples of polystyrenes also include thermoplastic polystyrene copolymers such as thermoplastic polystyrene copolymer elastomers, for example, a styrene-butadiene-styrene (SBS) copolymer or a styrene-ethylene-butadiene-styrene (SEBS) copolymer. The one or more polymers may comprise, consist essentially of, or consist of polyolefins. Examples of polyolefins include thermoplastic polyolefin elastomers, including thermoplastic polyolefin homopolymer elastomers and thermoplastic polyolefin copolymer elastomers. Examples of polyolefin homopolymers include polyethylene and polypropylene. Examples of polyolefin copolymers include polyethylene-polypropylene copolymers, as well as ethylene-vinyl acetate copolymers (EVA) and ethylene-vinyl alcohol (EVOH) copolymers.
[0166] The polymeric material may comprise from about 5 weight percent to about 100 weight percent of the polymeric component based on a total weight of the polymeric material. The polymeric component can comprise from about 15 weight percent to about 100 weight percent,4564187002.1Attorney Docket No.: 201882-579925 / 250185WO01from about 30 weight percent to about 100 weight percent, from about 50 weight percent to about 100 weight percent, or from about 70 weight percent to about 100 weight percent of the polymeric material. When the polymeric material comprises a non-polymeric component, the non-polymeric component may comprise from about 1 weight percent to about 20 weight percent, or from about 1 weight percent to about 10 weight percent, or from about 1 weight percent to about 5 weight percent based on a total weight of the polymeric material. As used herein, the terms “consist essentially of’, “consists essentially of’ and “consisting essentially of’ refer to compositions which consist of less than 1 weight percent of materials other than those recited, based on a total weight of the composition. For example, “a polymeric material consisting essentially of thermoplastics” is understood to be a polymeric material which included less than 1 weight percent of nonthermoplastic polymers and non-polymeric materials; while “a polymeric material comprising a polymeric component consisting essentially of thermoplastics” is understood to include a polymeric component in which less than 1 weight percent of the polymers present are nonthermoplastic polymers, but this polymeric material may include more than 1 weight percent of non-polymeric materials.
[0167] In some aspects, the polymeric material may be a material which polymerizes or crosslinks or both polymerizes and crosslinks during the process of forming the support or during the process of forming the sole structure. The polymerization or crosslinking may be initiated by including a chemical polymerization or crosslinking initiator in the polymeric material (e.g., a chemical which initiates polymerization or crosslinking reactions within the polymeric material when it is exposed to thermal energy, UV light, or another form of actinic radiation), or the polymerization or crosslinking may be initiated by mixing together two compositions which react to produce polymerization or crosslinking reactions, or by exposing a polymeric material to a form of actinic radiation in sufficient quantity to polymerize pre-polymers or oligomers present in the exposed material, or to crosslink polymers present in the exposed polymeric material. In aspects where the material polymerizes, the polymeric material may initially comprise one or more prepolymers or oligomers which react and polymerize during the manufacturing process, resulting in a support or sole structure comprising the reacted polymeric material. In aspects where the material crosslinks, the polymeric material may initially comprise one or more crosslinkable polymers which react with crosslinking agents or crosslinking energy and become crosslinked polymers during the manufacturing process, resulting in a support or sole structure comprising a crosslinked 4664187002.1Attorney Docket No.: 201882-579925 / 250185WO01polymeric material. In some aspect, the resulting reacted polymeric material is a thermoset material. Similarly, in some aspects, the initial polymeric material may be a thermosetting thermoplastic material (e.g., a polymeric material comprising one or more thermoplastics and a crosslinking agent before it is thermally processed), and the resulting crosslinked polymeric material is a thermoset material (e g., after the crosslinking agent reacts with the thermoplastics and crosslinks them, and the resulting thermoset material is solidified). One example of this is a thermosettable molten thermoplastic material comprising a thermally-activated crosslinking agent and a foaming agent, where the thermally-activated crosslinking agent is activated during a foaming process, resulting in a thermoset foam material.
[0168] Optionally, the polymeric material may comprise one or more additives. Examples of additives include fillers, polymerization initiators, crosslinking agents, UV light absorbers, antioxidants, processing aids such as lubricants and plasticizers, and colorants, such as pigments and dyes. Fillers may include non-polymeric fillers such as silica, clay, and titanium dioxide. Fillers may include polymeric fillers such as polymeric fibers and finely-ground polymeric powders, including ground thermoset rubber. Colorants such as naturally-occurring and synthetic pigments and dyes may be used. The polymeric material may comprise one or more additives at a concentration of from about 0.1 weight percent to about 20 weight percent, or from about 0.2 weight percent to about 10 weight percent, or from about 0.5 weight percent to about 5 weight percent, based on a total weight of the polymeric material.
[0169] The polymeric material may comprise one or more foaming agents. As understood in the art, foaming agents are substances that react, decompose or vaporize to produce quantities of gases or vapors. A chemical foaming agent is a compound which, when reacted with a second chemical or on decomposition, release a gas. Examples of chemical foaming agents include sodium bicarbonate, ammonium carbonate, ammonium bicarbonate, calcium azide, azodi carbonamide, hydrazocarbonamide, benzenesulfonyl hydrazide, dinitrosopentamethylene tetramine, toluenesulfonyl hydrazide, p,p’-oxybis(benzenesulfonylhydrazide), azobisisobutyronitrile, barium azodicarboxylate, and any combination thereof. A physical blowing agent is a compound which phase transitions from a solid, liquid or supercritical fluid to a gas when the temperature, pressure, or temperature and pressure are changed. Physical blowing agents include low-boiling-point hydrocarbons, including hydrocarbons such as isobutene and pentane, and partially halogenated hydrocarbons such as partially halogenated fluorochlorohydrocarbons, inert gasses, and 4764187002.1Attorney Docket No.: 201882-579925 / 250185WO01supercritical fluids. In some aspects, the foaming agent is a supercritical fluid, such as supercritical carbon dioxide (CO2) or supercritical nitrogen (N2). The one or more foaming agents may include a chemical foaming agent and a physical foaming agent.
[0170] When a foaming agent is used, prior to the foaming step, the foaming agent may be present in the polymeric material in an amount effective to foam the polymeric material into a multicellular foam during the manufacturing process. The amount of foaming agent may be measured as the concentration of foaming agent by weight in the polymeric material prior to the foaming step. An amount of blowing agent is considered effective when the foaming process results in at least a 10 percent increase in the volume of the polymeric material, or at least a 20 percent increase in the volume of the polymeric material, or in at least a 30 percent increase in the volume of the polymeric material. The polymeric material may comprise from about 1 percent to about 30 percent by weight, or from about 1 percent to about 20 percent by weight, or from about 1 percent to about 10 percent by weight of the foaming agent based on a total weight of the polymeric material. The polymeric material may comprise a concentration of the foaming agent sufficient to expand the polymeric material by at least 100 percent by volume, or by 100 percent to 900 percent by volume, or by 200 percent to 500 percent by volume, or by 300 percent to 400 percent by volume, based on an initial volume of the polymeric material prior to foaming.
[0171] As used herein, the term “barrier element” encompasses both monolayer and multilayer films. In some embodiments, the barrier element 116 is produced (e.g., thermoformed or blow molded) from a monolayer film (a single layer). In other embodiments, the barrier element 116 is produced (e.g., thermoformed or blow molded) from a multilayer film (multiple sublayers). In either aspect, each layer or sublayer can have a film thickness ranging from about 0.2 micrometers to about 1 millimeter. In further embodiments, the film thickness for each layer or sublayer can range from about 0.5 micrometers to about 500 micrometers. In yet further embodiments, the film thickness for each layer or sublayer can range from about 1 micrometer to about 100 micrometers.
[0172] The barrier element 116 can independently be transparent, translucent, and / or opaque. As used herein, the term “transparent” for a barrier layer and / or a fluid-filled chamber means that light passes through the barrier layer in substantially straight lines and a viewer can see through the barrier layer. In comparison, for an opaque barrier layer, light does not pass through the barrier layer and one cannot see clearly through the barrier layer at all. A translucent barrier layer falls between a transparent barrier layer and an opaque barrier layer, in that light passes through a 4864187002.1Attorney Docket No.: 201882-579925 / 250185WO01translucent layer but some of the light is scattered so that a viewer cannot see clearly through the layer.
[0173] The barrier element 116 can be produced from an elastomeric material that includes one or more thermoplastic polymers and / or one or more cross-linkable polymers. In an aspect, the elastomeric material can include one or more thermoplastic elastomeric materials, such as one or more thermoplastic polyurethane (TPU) copolymers, one or more ethylene-vinyl alcohol (EVOH) copolymers, and the like.
[0174] As used herein, “polyurethane” refers to a copolymer (including oligomers) that contains a urethane group (-N(C=O)O-). These polyurethanes can contain additional groups such as ester, ether, urea, allophanate, biuret, carbodiimide, oxazolidinyl, isocynaurate, uretdione, carbonate, and the like, in addition to urethane groups. In an aspect, one or more of the polyurethanes can be produced by polymerizing one or more isocyanates with one or more polyols to produce copolymer chains having (-N(C=O)O-) linkages.
[0175] Examples of suitable isocyanates for producing the polyurethane copolymer chains include diisocyanates, such as aromatic diisocyanates, aliphatic diisocyanates, and combinations thereof. Examples of suitable aromatic diisocyanates include toluene diisocyanate (TDI), TDI adducts with trimethyloylpropane (TMP), methylene diphenyl diisocyanate (MDI), xylene diisocyanate (XDI), tetramethylxylylene diisocyanate (TMXDI), hydrogenated xylene diisocyanate (HXDI), naphthalene 1,5 -diisocyanate (NDI), 1,5-tetrahydronaphthalene diisocyanate, para-phenylene diisocyanate (PPDI), 3,3’ - dimethyldiphenyl -4, 4’ -diisocyanate (DDDI), 4,4 ’-dibenzyl diisocyanate (DBDI), 4-chl oro-1, 3 -phenylene diisocyanate, and combinations thereof. In some embodiments, the copolymer chains are substantially free of aromatic groups.
[0176] In particular aspects, the polyurethane polymer chains are produced from diisocynates including HMDI, TDI, MDI, H12 aliphatics, and combinations thereof. In an aspect, the thermoplastic TPU can include polyester-based TPU, polyether-based TPU, polycaprolactone-based TPU, polycarbonate-based TPU, polysiloxane-based TPU, or combinations thereof.
[0177] In another aspect, the polymeric layer can be formed of one or more of the following: EVOH copolymers, poly(vinyl chloride), polyvinylidene 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,4964187002.1Attorney Docket No.: 201882-579925 / 250185WO01polyether imides, polyacrylic imides, and other polymeric materials known to have relatively low gas transmission rates. Blends of these materials as well as with the TPU copolymers described herein and optionally including combinations of polyimides and crystalline polymers, are also suitable.
[0178] The barrier element 116 may include two or more sublayers (multilayer film) such as shown in Mitchell et al., U.S. Patent No. 5,713,141 and Mitchell et al., U.S. Patent No. 5,952,065, the disclosures of which are incorporated by reference in their entirety. In embodiments where the barrier element 116 includes two or more sublayers, examples of suitable multilayer films include microlayer films, such as those disclosed in Bonk et al., U.S. Patent No. 6,582,786, which is incorporated by reference in its entirety. In further embodiments, barrier element 116a may include alternating sublayers of one or more TPU copolymer materials and one or more EVOH copolymer materials, where the total number of sublayers in each of the barrier element 116 includes 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.
[0179] The foregoing description has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular configuration are generally not limited to that particular configuration, but, where applicable, are interchangeable and can be used in a selected configuration, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.5064187002.1
Claims
Attorney Docket No.: 201882-579925 / 250185WO01CLAIMSWhat is claimed is:
1. A sole structure for an article of footwear, the sole structure comprising:a support frame including (i) a first plurality of alternating support structures defining a first upper support structure and a first lower support structure adjacent to the first upper support structure and (ii) a second plurality of alternating support structures defining a second upper support structure disposed adjacent to the first lower support structure and a second lower support structure disposed adj acent to each of the first upper support structure and the second upper support structure, each of the support structures including one or more struts configured to flex when a compressive force is applied to the support frame.
2. The sole structure of Claim 1, wherein the first plurality of alternating support structures is aligned along a first lateral axis of the sole structure and the second plurality of alternating support structures is aligned along a second lateral axis of the sole structure.
3. The sole structure of Claim 2, wherein the first plurality of alternating support structures includes a third upper support structure disposed on an opposite side of the first lower support structure from the first upper support structure.
4. The sole structure of Claim 3, wherein the second plurality of alternating support structures includes a third lower support structure disposed on an opposite side of the second upper support structure from the first lower support structure.
5. The sole structure of Claim 1, further comprising a chassis disposed adjacent to the support frame and including a plurality of lobes each received by one of the upper support structures.
6. The sole structure of Claim 5, further comprising at least one of an outsole or an outsole plate disposed on an opposite side of the chassis from the support frame.5164187002.1Attorney Docket No.: 201882-579925 / 250185WO017. The sole structure of Claim 6, wherein each of the lower support structures contacts the at least one of the outsole or the outsole plate through the chassis.
8. The sole structure of Claim 1, wherein the support frame is encapsulated within a barrier element.
9. A sole structure for an article of footwear, the sole structure comprising:a support frame including (i) a plurality of first rows of alternating support structures arranged in series along a longitudinal direction of the sole structure and each including a first upper support structure and a first lower support structure adjacent to the first upper support structure and (ii) a plurality of second rows of alternating support structures each disposed between adjacent ones of the first rows and including a second upper support structure disposed adjacent to the first lower support structures and a second lower support structure disposed adjacent to each of the first upper support structures and the second upper support structure, each of the support structures including one or more struts configured to flex when a compressive force is applied to the support frame.
10. The sole structure of Claim 9, wherein each first row of alternating support structures is aligned along a respective first lateral axis of the sole structure and each second row of alternating structures is aligned along a second respective lateral axis of the sole structure.
11. The sole structure of Claim 10, wherein each first row of alternating support structures includes a third upper support structure disposed on an opposite side of the first lower support structure from the first upper support structure.
12. The sole structure of Claim 11, wherein each second row of upper support structures includes a third lower support structure disposed on an opposite side of the second upper support structure from the second lower support structure.
13. The sole structure of Claim 9, further comprising a chassis disposed adjacent to the support frame and including a plurality of lobes each received by one of the upper support structures.5264187002.1Attorney Docket No.: 201882-579925 / 250185WO0114. The sole structure of Claim 13, further comprising at least one of an outsole or an outsole plate disposed on an opposite side of the chassis from the support frame.
15. The sole structure of Claim 14, wherein each of the lower support structures contacts the at least one of the outsole or the outsole plate through the chassis.
16. The sole structure of Claim 9, further comprising a cushioning supported by each of the upper support structures of the support frame.
17. A support frame for a sole structure of an article of footwear, the support frame comprising:a central frame;a first row of alternating support structures extending from the central frame and defining a first upper support structure and a first lower support structure adjacent to the first upper support structure, each of the support structures of the first row of alternating support structures including one or more struts configured to flex when a compressive force is applied to the support frame; anda second row of alternating support structures extending from the central frame and defining a second upper support structure disposed adjacent to the first lower support structure and a second lower support structure disposed adjacent to each of the first upper support structure and the second upper support structure, each of the support structures of the second row of alternating support structures including one or more struts configured to flex when a compressive force is applied to the support frame.
18. The support frame of Claim 17, wherein each of the upper support structures includes a plurality of trusses each extending from the central frame to a platform.
19. The support frame of Claim 18, wherein the upper support structures extend in a first direction from the central frame and the lower support structures extend in an opposite second direction from the central frame.5364187002.1Attorney Docket No.: 201882-579925 / 250185WO0120. The support frame of Claim 17, wherein the first row of alternating support structures includes a third upper support structure disposed on an opposite side of the first lower support structure from the first upper support structure and the second row of upper support structures includes a third lower support structure disposed on an opposite side of the second upper support structure from the first lower support structure.5464187002.1