Sole Structure for Article of Footwear

This application is a continuation of U.S. application Ser. No. 18/518,776, filed Nov. 24, 2023, which is a continuation of U.S. application Ser. No. 17/330,333, filed May 25, 2021, which claims priority under 35 U.S.C. § 119 (e) to U.S. Provisional Application No. 63/032,690, filed on May 31, 2020. The disclosures of these prior applications are considered part of the disclosure of this application and are hereby incorporated by reference in their entirety.

The present disclosure relates generally to sole structures for articles of footwear, and more particularly, to sole structures incorporating a bladder.

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

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.

Sole structures generally include a layered arrangement extending between a ground surface and the upper. One layer of the sole structure includes an outsole that provides traction with the ground surface. The outsole may be formed from rubber or other materials that impart durability and wear-resistance, as well as enhance traction with the ground surface. Another layer of the sole structure includes a midsole disposed between the outsole and the upper. The midsole provides cushioning for the foot and may be partially formed from a polymer foam material that compresses resiliently under an applied load to cushion the foot by attenuating ground-reaction forces. The midsole may additionally or alternatively incorporate a fluid-filled bladder to provide cushioning to the foot by compressing resiliently under an applied load to attenuate ground-reaction forces. Sole structures may also include a comfort-enhancing insole or a sockliner located within a void proximate to the bottom portion of the upper and a strobel attached to the upper and disposed between the midsole and the insole or sockliner.

Midsoles employing bladders typically include a bladder formed from two barrier layers of polymer material that are sealed or bonded together. The bladders may contain air, and are designed with an emphasis on balancing support for the foot and cushioning characteristics that relate to responsiveness as the bladder resiliently compresses under an applied load.

Corresponding reference numerals indicate corresponding parts throughout the drawings.

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 apparent to 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.

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.

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.

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.

One aspect of the disclosure provides a sole structure for an article of footwear. The sole structure includes a chassis having a recess formed between a first surface and a second surface facing the first surface. The sole structure also includes a cushioning arrangement including a first cushioning element protruding from the first surface and including a plurality of lobes and a second cushioning element protruding from the second surface to a distal end contacting the plurality of lobes. Implementations of the disclosure may include one or more of the following optional features.

In some examples, the first cushioning element includes a bladder.

In some implementations, a first side of the first cushioning element includes a substantially planar base and a second side of the first cushioning element includes the plurality of lobes formed on an opposite side from the base. In some configurations, lobes of the plurality of lobes are arranged in a quad-shaped configuration.

In some examples, each lobe of the plurality of lobes is hemispherical.

In some configurations, the first surface includes a first socket receiving a first end of the cushioning arrangement including the first cushioning element.

In some examples, the sole structure includes a cradle defining the first surface of the recess, the cradle including a harder material than the chassis. In some implementations, a length of the recess extends between a first concave end and a second concave end.

In some examples, the sole structure has a support plate disposed between the first cushioning element and the second cushioning element and including a plurality of receptacles receiving the plurality of lobes of the first cushioning element. Here, the support plate includes a material having a greater hardness than each of the first cushioning element and the second cushioning element.

Another aspect of the disclosure provides a sole structure for an article of footwear. The sole structure has a chassis including a recess formed between a first surface and a second surface facing the first surface. The sole structure also has a cushioning arrangement including a first cushioning element protruding from the first surface and including a first plurality of lobes, and a second cushioning element protruding from the second surface and including a second plurality of lobes contacting the first plurality of lobes. Implementations of the disclosure may include one or more of the following optional features.

In some examples, at least one of the first cushioning element and the second cushioning element includes a fluid-filled bladder.

In some implementations, a first side of the first cushioning element includes a substantially planar first base and the second cushioning element includes a substantially planar second base. Here, the first plurality of lobes is disposed on an opposite side of the first cushioning element than the substantially planar first base and the second plurality of lobes is disposed on an opposite side of the second cushioning element than the substantially planar second base.

In some examples, lobes of the first plurality of lobes and lobes of the second plurality of lobes are arranged in a quad-shaped configuration.

In some implementations, each lobe of the first plurality of lobes and each lobe of the second plurality of lobes is hemispherical.

In some configurations, the first surface includes a first socket receiving the first cushioning element and the second surface includes a second socket receiving the second cushioning element.

In some examples, the sole structure includes a cradle defining the first surface of the recess, the cradle including a harder material than the chassis.

In some configurations, a length of the recess extends between a first concave end and a second concave end.

In some examples, the sole structure includes a support plate disposed between the first cushioning element and the second cushioning element and including a plurality of receptacles receiving lobes of the first cushioning element and lobes of the second cushioning element. Here, the support plate includes a material having a greater hardness than each of the first cushioning element and the second cushioning element.

The details of one or more implementations of the disclosure are set forth in the accompanying drawings and the description below. Other aspects, features, and advantages will be apparent from the description and drawings, and from the claims.

Referring to, an article of footwearincludes a sole structureand an upperattached to the sole structure. The footwearmay further include an anterior endassociated with a forward-most point of the footwear, and a posterior endcorresponding to a rearward-most point of the footwear. As shown in, a longitudinal axis Aof the footwearextends along a length of the footwearfrom the anterior endto the posterior endparallel to a ground surface, and generally divides the footwearinto a lateral sideand a medial side. Accordingly, the lateral sideand the medial siderespectively correspond with opposite sides of the footwearand extend from the anterior endto the posterior end. As used herein, a longitudinal direction refers to the direction extending from the anterior endto the posterior end, while a lateral direction refers to the direction transverse to the longitudinal direction and extending from the lateral sideto the medial side.

The article of footwearmay be divided into one or more regions. The regions may include a forefoot region, a mid-foot region, and a heel region. The forefoot regioncorresponds to a ball portion of the foot including the metatarsophalangeal (MTP) joint. The mid-foot regionmay correspond with an arch area of the foot, and the heel regionmay correspond with rear portions of the foot, including a calcaneus bone.

With reference to, the sole structureincludes a midsoleconfigured to provide cushioning characteristics to the sole structure, and an outsoleconfigured to provide a ground-engaging surface of the article of footwear. Unlike conventional sole structures, the midsoleof the sole structuremay be formed compositely and include a plurality of subcomponents for providing desired forms of cushioning and support throughout the sole structure. For example, the midsoleincludes a chassisextending from the anterior endto the posterior end, and a cushioning arrangementdisposed within the heel region. Optionally, the midsolemay include a cradleconfigured to receive and support a lower portion of the cushioning arrangementwithin the chassis. The chassisis configured to be attached to the upperand provides an interface between the upperand the cushioning arrangement. As described in greater detail below, the cushioning arrangement includes a lower cushioning elementand an upper cushioning elementarranged in a stacked configuration in the heel region. Optionally, the cushioning arrangementincludes a support plateinterposed between the lower cushioning elementand the upper cushioning element.

With reference to, the chassisof the midsoleextends continuously from a first endat the anterior endto a second endat the posterior end. An upper portion of the chassisincludes a footbedconfigured to attach to the upperand to provide support and cushioning for a plantar surface of the foot. A lower portion of the chassisincludes a forefoot support memberformed in the forefoot regionand the mid-foot region, and a recessextending through the mid-foot regionand the heel region. As discussed below, the forefoot support memberis configured to provide cushioning along the forefoot region, while the recessis configured to receive the cushioning arrangementfor supporting the heel regionof the upper.

The footbedextends continuously from the first endto the second endof the chassisand defines a top surfaceof the chassisconfigured to face the upperwhen the article of footwearis assembled. The footbedalso includes a lower surfaceformed on an opposite side from the top surface, where a distance between the top surfaceand the lower surfaceforms a thickness of the footbed. As shown, the forefoot support memberdepends from the lower surfaceof the footbedand defines a bottom surfaceof the chassis. Here, the forefoot support memberextends continuously from the first endto a first end wallformed in the mid-foot region. A thickness Tof the support memberprogressively increases along a direction from the first endto the end wall.

The recessis formed adjacent to the forefoot support memberand extends at least partially through the heel regionfrom the first end wallin the mid-foot regionto a second end wallin the heel region, adjacent to the second end. The first end wallfaces the second end wallto define a length of the recess. As shown, each end wall,may have a concave profile extending across a width of the chassisfrom the lateral sideto the medial side. In use, the concave geometries of the end walls,allow upper and lower portions of the end walls,to flex towards each other, which provides a spring-like compression of the end walls,during use. A depth or height of the recessis defined by a distance from the bottom surfaceof the chassisto the lower surfaceof the footbed. The lower surfaceof the footbedmay include an upper socketfacing the recess. As described in greater detail below, the upper socketis configured to interface with or receive an upper portion of the cushioning arrangementto secure a position of the cushioning arrangementwithin the recess.

As described above, the chassisis formed of a resilient polymeric material, such as foam or rubber, to impart properties of cushioning, responsiveness, and energy distribution to the foot of the wearer. Example resilient polymeric materials for the chassismay include those based on foaming or molding one or more polymers, such as one or more elastomers (e.g., thermoplastic elastomers (TPE)). The one or more polymers may include aliphatic polymers, aromatic polymers, or mixtures of both; and may include homopolymers, copolymers (including terpolymers), or mixtures of both.

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

In further aspects, the one or more polymers may include one or more polyacrylates, such as polyacrylic acid, esters of polyacrylic acid, polyacrylonitrile, polyacrylic acetate, polymethyl acrylate, polyethyl acrylate, polybutyl acrylate, polymethyl methacrylate, and polyvinyl acetate; including derivatives thereof, copolymers thereof, and any combinations thereof.

In yet further aspects, the one or more polymers may include one or more ionomeric polymers. In these aspects, the ionomeric polymers may include polymers with carboxylic acid functional groups, sulfonic acid functional groups, salts thereof (e.g., sodium, magnesium, potassium, etc.), and/or anhydrides thereof. For instance, the ionomeric polymer(s) may include one or more fatty acid-modified ionomeric polymers, polystyrene sulfonate, ethylene-methacrylic acid copolymers, and combinations thereof.

In further aspects, the one or more polymers may include one or more styrenic block copolymers, such as acrylonitrile butadiene styrene block copolymers, styrene acrylonitrile block copolymers, styrene ethylene butylene styrene block copolymers, styrene ethylene butadiene styrene block copolymers, styrene ethylene propylene styrene block copolymers, styrene butadiene styrene block copolymers, and combinations thereof.

In further aspects, the one or more polymers may include one or more polyamide copolymers (e.g., polyamide-polyether copolymers) and/or one or more polyurethanes (e.g., crosslinked polyurethanes and/or thermoplastic polyurethanes). Examples of suitable polyurethanes include those discussed below for the barrier layers,. Alternatively, the one or more polymers may include one or more natural and/or synthetic rubbers, such as butadiene and isoprene.

When the resilient polymeric material is a foamed polymeric material, the foamed material may be foamed using a physical blowing agent which phase transitions to a gas based on a change in temperature and/or pressure, or a chemical blowing agent which forms a gas when heated above its activation temperature. For example, the chemical blowing agent may be an azo compound such as azodicarbonamide, sodium bicarbonate, and/or an isocyanate.

In some embodiments, the foamed polymeric material may be a crosslinked foamed material. In these embodiments, a peroxide-based crosslinking agent such as dicumyl peroxide may be used. Furthermore, the foamed polymeric material may include one or more fillers such as pigments, modified or natural clays, modified or unmodified synthetic clays, talc glass fiber, powdered glass, modified or natural silica, calcium carbonate, mica, paper, wood chips, and the like.

The resilient polymeric material may be formed using a molding process. In one example, when the resilient polymeric material is a molded elastomer, the uncured elastomer (e.g., rubber) may be mixed in a Banbury mixer with an optional filler and a curing package such as a sulfur-based or peroxide-based curing package, calendared, formed into shape, placed in a mold, and vulcanized.

In another example, when the resilient polymeric material is a foamed material, the material may be foamed during a molding process, such as an injection molding process. A thermoplastic polymeric material may be melted in the barrel of an injection molding system and combined with a physical or chemical blowing agent and optionally a crosslinking agent, and then injected into a mold under conditions which activate the blowing agent, forming a molded foam.

Optionally, when the resilient polymeric material is a foamed material, the foamed material may be a compression molded foam. Compression molding may be used to alter the physical properties (e.g., density, stiffness and/or durometer) of a foam, or to alter the physical appearance of the foam (e.g., to fuse two or more pieces of foam, to shape the foam, etc.), or both.

The compression molding process desirably starts by forming one or more foam preforms, such as by injection molding and foaming a polymeric material, by forming foamed particles or beads, by cutting foamed sheet stock, and the like. The compression molded foam may then be made by placing the one or more preforms formed of foamed polymeric material(s) in a compression mold, and applying sufficient pressure to the one or more preforms to compress the one or more preforms in a closed mold. Once the mold is closed, sufficient heat and/or pressure is applied to the one or more preforms in the closed mold for a sufficient duration of time to alter the preform(s) by forming a skin on the outer surface of the compression molded foam, fuse individual foam particles to each other, permanently increase the density of the foam(s), or any combination thereof. Following the heating and/or application of pressure, the mold is opened and the molded foam article is removed from the mold.

When included, the cradleis disposed within the recessof the chassisand extends from the first end wallof the forefoot support memberto the second end wallof the chassis. The cradleincludes an inner surfacethat faces the recessand is configured to interface with a lower portion of the cushioning arrangement. For instance, the inner surfacemay define a lower socketconfigured to receive the lower portion of the cushioning arrangement. Thus, the lower surfaceof the footbedand the inner surfaceof the cradleare arranged on opposite sides of the recessand cooperate to define the height of the recess. The cradleincludes one or more materials having a greater hardness than the materials of the chassisand the outsole. Accordingly, the cradleprovides a stiffer stabilizing interface between the cushioning arrangementand the ground surface.

With continued reference to, the cushioning arrangementof the midsoleincludes the lower cushioning elementand the upper cushioning elementarranged in a stacked configuration within the recess. The cushioning arrangementmay further include the support plateinterposed between the lower cushioning elementand the upper cushioning element. The cushioning elements,include resilient and compressible materials, and are configured to provide cushioning in the heel region. Conversely, the support platemay include materials having a greater hardness than the cushioning elements,such that the support plateprovides a stabilizing interface between the cushioning elements,.

In the illustrated example, each of the cushioning elements,is formed as a bladder,having an interior void filled with a compressible material. In this example, each of the bladders,has the same configuration and size, where the lower bladderis attached to the cradleand faces upward while the upper bladderis attached to the lower surfaceof the footbedand faces downward, as shown in. As shown in the cross-sectional views of, each of the bladders,may be formed by an opposing pair of barrier layers,, which can be joined to each other at a peripheral seam to define an overall shape of the bladders,. As discussed below, the barrier layers,include a substantially flat base barrier layerattached to the midsoleand a deformable cushioning barrier layerextending into the recess.

As used herein, the term “barrier layer” (e.g., barrier layers,) encompasses both monolayer and multilayer films. In some embodiments, one or both of the barrier layers,are each produced (e.g., thermoformed or blow molded) from a monolayer film (a single layer). In other embodiments, one or both of the barrier layers,are each 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 be 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.