Integrated Manual Pump for Article of Footwear

This application is a continuation of U.S. Non-Provisional application Ser. No. 18/306,059, filed Apr. 24, 2023, which claims priority under 35 U.S.C. § 119 (e) to U.S. Provisional Application Ser. No. 63/336,098, filed Apr. 28, 2022. 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 an article of footwear, and more particularly to a sole structure for an article of footwear

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

Articles of apparel, such as garments and headwear, and articles of footwear, such as shoes and boots, typically include a receptacle for receiving a body part of a wearer. For example, an article of footwear may include an upper and a sole structure that operate to form a receptacle for receiving a foot of a wearer. Likewise, garments and headwear may include one or more pieces of material formed into a receptacle for receiving a torso or head of a wearer.

Articles of apparel or footwear are typically adjustable and/or include a relatively flexible material to allow the article of apparel or footwear to accommodate various sizes of wearers, or to provide different fits on a single wearer. While conventional articles of apparel and articles of footwear are adjustable, such articles typically require a wearer to secure the article by lacing or other means. For example, while laces adequately secure an article of footwear to a wearer by contracting or constricting a portion of an upper around the wearer's foot, the laces do not cause the upper to lock in a size or shape conforming to the user's foot. Accordingly, an optimum fit of the upper around the foot is difficult to achieve.

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.

In one configuration, an article of footwear is provided and includes an upper having a chamber, a sole structure including a recess forming a cavity, and a pump device disposed within the cavity, in fluid communication with the chamber, and operable to move the upper from a relaxed state to a constricted state by selectively evacuating fluid from the chamber.

The article of footwear may include one or more of the following optional features. For example, the article of footwear may include an actuator connected to the pump device and moveable in a tightening direction to move the upper from the relaxed state to the constricted state. The actuator may include an actuator cable including a first portion connected to the pump device and a second portion extending across the upper. The actuator cable may include a tightening grip extending across the upper and/or the pump device may include a piston coupled to the actuator.

In one configuration, the pump device may include at least one biasing member coupled to the piston. The at least one biasing member may bias the piston in a first direction and the actuator may be operable to move the piston in a second direction. A bearing may be coupled to the piston and the actuator may be connected to the bearing.

A release may be in fluid communication with the pump device and may be operable to move the upper from the constricted state to the relaxed state. Additionally or alternatively, the pump device may include a valve in fluid communication with the chamber of the upper.

In another configuration, an article of footwear is provided and includes an upper having a chamber, a pump attached to the article of footwear and in fluid communication with the chamber, the pump operable in a first state to evacuate fluid from the chamber, and an actuator having a first portion connected to the pump and a second portion disposed along the upper, the actuator operable to move the pump into the first state to move the upper from a relaxed state to a constricted state by evacuating a fluid from the chamber.

The article of footwear may include one or more of the following optional features. For example, the pump may include a housing and a piston disposed within the housing, the piston moveable in a first direction in the first state to draw fluid into the housing and in a second direction to exhaust fluid from the housing. In this configuration, the pump may include a biasing member operable to bias the piston in the second direction, the actuator may be operable to move the piston in the first direction, and/or a first portion of the actuator may be connected to the piston.

In one configuration, the housing may include a first bearing attached to the housing and the piston may include a second bearing attached to the piston, a first portion of the actuator may be routed along the first bearing and a second portion of the actuator may be routed along the second bearing. In this configuration, the first bearing may include an arcuate first bearing surface and the second bearing may include an arcuate second bearing surface facing an opposite direction than the arcuate first bearing surface.

The actuator may include a tightening grip extending around the upper. Additionally or alternatively, a release may be operable to selectively permit a flow of fluid into the chamber to move the upper from the constricted state to the relaxed state and/or the chamber may include a compressible component disposed within the chamber.

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, the drawings, and the claims.

Referring to, an article of footwearincludes a sole structureand an upperattached to the sole structure. The article of 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. 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 medial sideand a lateral side. Accordingly, the medial sideand the lateral 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 medial sideto the lateral 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 regionmay correspond with the phalanges and the metatarsal bones of a foot. 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.

As shown, the sole structureincludes a midsoleconfigured to provide cushioning and support and an outsoledefining a ground-engaging surface of the sole structure. In other examples, the midsolemay be configured as a composite structure including a plurality of components joined together.

The article of footwearmay be further described as including a pump device, an actuator cable, and a release feature. The pump deviceis disposed in the sole structureand may be in fluid communication with the upperthrough one or more valves to adjust the pressure in the upperfrom a first pressure (e.g., at or above ambient) to a second pressure (e.g., below ambient) by removing fluid (e.g., a gas or liquid) from the upper. In the illustrated example, the actuator cableis embodied as an actuator cableincluding a continuous loop that is routed through the pump deviceand includes a tightening gripextending across the upper. The release featuremay be connected to an outside surface of the sole structureand is in fluid communication with the pump devicethrough one or more valves. As discussed in greater detail below, the pump device, the actuator cable, and the release featurecooperate to transition the upperbetween a relaxed state () and a constricted state ().

With continued reference to, the midsoleis further defined by a top surfacefacing the upper, and a bottom surfaceformed on an opposite side of the midsolethan the top surfaceand facing away from the upper. Stitching or adhesives may secure the midsoleto the upper. The top surfaceof the midsoleincludes a foot cavity that defines a footbed of the sole structureextending continuously from the anterior endto the posterior endof the footwear. The outsoleis defined by a top surfacefacing the bottom surfaceof the midsole, and a bottom surfacethat defines a ground-engaging surface and is formed on an opposite side of the outsolethan the top surface.

As shown, a recessed surfaceis offset from the top surfaceof the midsoleto form a cavityin the top surfacemidsole. The cavitymay be sized to receive the pump device. Whileshows the cavitydisposed in the mid-foot regionof the midsole, the cavitymay alternatively be disposed in the forefoot regionor the heel regionof the midsole. In some implementations, the midsoleand the outsoleare integrally formed and receive the pump device. Alternatively, the pump devicemay be located on an outer surface of the article of footwear (not shown) to allow access to the pump device.

Referring to, the pump deviceincludes a housinghaving an outer shell, a check valve endcap, and a piston endcap. Securing meansreleasably fasten the outer shell, the check valve endcap, and the piston endcaptogether to enclose a chamberdefined by the housing. The outer shell, the check valve endcap, and the piston endcapmay be include any suitable lightweight material, such as polyamide, polypropylene, carbon, or an aluminum alloy. Accordingly, the chamberdesirably has a low gas transmission rate to preserve its retained gas pressure. While the securing meansshown inincludes socket head bolts, any method for securing the check valve endcapand the piston endcapto the outer shellmay be used. Optionally, the housingmay be formed as a unitary structure, whereby the outer shellis integrally formed with one or both of the check valve endcapand the piston endcap.

The check valve endcapincludes an inlet check valveconfigured to selectively allow fluid to flow into the chamber, an exhaust check valveconfigured to selectively permit fluid to flow out of the chamber, and a release valvefluidly coupled to an upstream end of the inlet check valve. As shown, the check valve endcapfurther includes an intake portconnecting the inlet check valveand the release valveof the pump deviceto the upper, and an exhaust portconnecting the exhaust check valveof the pump deviceto the upper. The inlet check valveand the exhaust check valveare further in fluid communication with the chamberof the pump device. In some implementations, the release valveis a Schrader valve that is selectively activated by the release featureto allow outside air (e.g., ambient) to enter the uppervia the intake portto return the upperto a relaxed state from a constricted state.

As shown, the piston endcapis disposed on an opposite end of the housingthan the check valve endcap. Accordingly, the check valve endcapencloses a first end of the chamberand the piston endcapencloses an opposite second end of the chamber. The piston endcapmay include a plurality of cap bearingsspaced apart from each other to define a series of apertures. As shown, each of the cap bearingsdefines a series of arcuate first bearing surfacesformed on the piston endcap. The aperturesmay be configured to receive and route the actuator cablethat extends into the chamberof the pump device, while the first bearing surfacesfurther route the actuator cablewithin the chamber. Specifically, the first bearing surfaceshave a convex curvature (e.g., semi-cylindrical) facing in an opposite direction from the chamber. Thus, as shown in, first portions of the actuator cablemay be routed around the first bearing surfacesand into the chamberthrough the spaces disposed on either side of each cap bearing

As shown, the pump devicefurther includes a pistonincluding a plurality of piston bearingsconfigured to cooperate with the first bearing surfacesof the piston endcapto route the actuator cablethrough the pump device. As discussed in greater detail below, the pistonis configured to reciprocate within the chamberbetween a first position adjacent to the check valve endcap() and a second position spaced apart from the check valve endcap() when the actuator force is applied to the actuator cable(e.g., pulling the tightening grip) in the tightening direction.

The piston bearingseach include an arcuate second bearing surfacefacing away from the plurality of first bearing surfacesfor routing the actuator cablewithin the pump device. In some implementations, the piston bearingsare integrally formed with the piston. In other implementations, the piston bearingsare mechanically attached to the piston(e.g., welded, bonded, etc.). As shown, each of the piston bearingsis offset with respect to the cap bearings. In other words, the piston bearingsare aligned with the aperturesdisposed between adjacent ones of the cap bearingsacross the length of the chamber. Each of the second bearing surfaceshas a convex curvature similar to the first bearing surfaces. Thus, as shown in, a second portion of the actuator cablemay be routed into the chamberthrough the aperturesand extend around the second bearing surfaces

With continued reference to, the pump deviceincludes one or more biasing membersconfigured to bias the pistontowards the second position (). In the illustrated example, the biasing membersinclude coil springseach extending from a first endcoupled to the piston endcapto a second end coupled to the piston. Here, the piston endcapmay include one or more first spring seatseach engaging the first endof one of the springsto secure the first endto the piston endcap. Similarly, the pistonmay include one or more second spring seatseach engaging the second endof one of the springsto secure the second endto the piston endcap. As shown in, each of the first spring seatsmay be integrally formed with one of the cap bearingsand each of the second spring seatsmay be integrally formed with one of the piston bearings

While the illustrated example of the pump deviceincludes four springs, in some implementations the plurality of springsmay include any number of springs(e.g., two springs). The material of the springsmay be selected based on a compression value associated with the springs. The springsare configured to compress when a force is applied to the piston bearings(i.e., the actuator cableis pulled in a tightening direction), and exert an opposing force to return to a resting length when the force is released (i.e., the actuator cableis released). In some examples, the springsare formed from steel (e.g., stainless steel, a steel alloy, etc.). In other examples, the springsare formed from carbon or other lightweight non-metals.

When the pump deviceis assembled, the actuator cableis routed through the apertureson either side of the pump device, and through the plurality of springsvia the bearing surfaces,. Thus, as the actuator cableis pulled in the tightening direction(i.e., a tensile force is applied), the actuator cableengages with the bearing surfaces,to draw the pistontoward the piston endcap, thereby compressing the springs. When the actuator cableis released, the springsexert an opposing force on the pistonto separate the pistonfrom the piston endcap, thereby returning the pistonto its original position and drawing a length of the actuator cableback into the chamber. Accordingly, the actuator cableis operable to actuate the pistonbetween the first position associated with a first length Lwhere the springsare in a resting state (), and a second position associated with a second length Lwhere the springsare in a compressed state ().

The actuator cablemay be highly lubricous and/or may be formed from one or more fibers having a low modulus of elasticity and a high tensile strength. For instance, the fibers may include high modulus polyethylene fibers having a high strength-to-weight ratio and a low elasticity. Additionally or alternatively, the actuator cablemay be formed from a molded monofilament polymer and/or a woven steel with or without other lubrication coating. In some examples, the actuator cableincludes multiple strands of material woven together.

Referring still to, the routing of the actuator cablewithin the chamberof the pump deviceis shown. The actuator cablecan be described as extending into the chambervia the apertures. The actuator cableis further routed within the springsand alternatingly between the first bearing surfacesof the piston endcapand the second bearing surfacesof the piston. As best shown in, while the pistonis in the first position associated with the first length Lof the springs, the actuator cableextends fully throughout the chamber. In, a tightening force has been applied in the tightening direction, thereby pulling the actuator cableout of the chamberthrough the apertures to pull the pistoninto the second position associated with the second length Lof the springs. As discussed below, the pistonis cycled between the first position and the second position to draw fluid in through the intake portand to exhaust fluid out through the exhaust port.

Referring briefly to, the uppermay be formed from one or more materials that are stitched or adhesively bonded together to define the interior void. Suitable materials of the uppermay include, but are not limited to, textiles, foam, leather, and synthetic leather. The example uppermay 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 upperto facilitate movement of the article of footwearbetween the constricted state and the relaxed 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.

In the illustrated example, the upperincludes one or more fluid chambersin fluid communication with the pump device. Each of the chambersincludes a compressible componentdisposed therein which compresses as the uppertransitions from the relaxed state () to the constricted state (). The compressible componentmay include a lattice structuredefining a plurality of reliefs(e.g., openings). As discussed above with reference to, the pump deviceis in fluid communication with the chambersof the upper. In these implementations, an intake conduitconnects the intake portincluding the inlet check valveto the chambersof the upperallowing fluid communication between the pump deviceand the upper.

In use, the pressure within the chambersof the upperis reduced by drawing a vacuum within the chambersof the uppervia the pump device. As the pressure is reduced, the uppermoves from a relaxed state to a constricted state that forms the upperaround the wearer's foot. Thus, as the vacuum is drawn by cycling the pump device, as described below with respect to, fluid is drawn from within the chambersof the upperand into the chamberof the pump deviceto compress the lattice structureof the compressible component, thereby constricting the upperaround the foot of the wearer. When the release valveis actuated, the lattice structureof the compressible componentexpands within each chamber, thereby causing an internal volume of the chamberto increase. The increase in volume draws fluid from the release valvethrough the intake portand allows the upperto move to the relaxed state around the wearer of the foot. Optionally, the uppermay include a locking system which, when activated, locks the geometry of the upperin place once it is in the constricted state.

With continued reference to, the uppermay be transitioned between the relaxed state and the constricted state via the pump device. Here, a vacuum may be drawn by pulling the actuator cablein the tightening directionand releasing the actuator cablefor a number of cycles. As the actuator cableis pulled in the tightening direction, the pistonis moved from the first position () to the second position (), creating a vacuum and drawing fluidfrom the upperinto the chambervia the intake portand the inlet check valve. Once the pistonis at the second position, the inlet check valvecloses to prevent the fluidfrom escaping from the chamberback into the chambersof the upper.

When the actuator cableis released, the springsbias the pistonfrom the second position () to the first position (), drawing the actuator cableback into the pump deviceand exhausting the fluidwithin the chamberthrough the exhaust check valveand the exhaust port. Thus, the fluiddrawn from the chamberswhen the pistonmoves from the first position to the second position is exhausted from the pump devicewhen the piston returns from the second position to the first position. Accordingly, the steps of pulling the actuator cablein the tightening directionfollowed by releasing the actuator cableconstitutes a cycle. For each cycle that the actuator cableis pulled in the tightening directionand then released, the pressure within the upperis incrementally reduced. In some examples, the pressure within the upperreaches an ideal pressure to constrict the upper(e.g. −5 psi) after 20 pulls on the actuator cablein the tightening direction. In other examples, fewer pulls on the actuator cableare required.

Referring to, when the wearer wishes to move the upperto the relaxed state, the wearer increases the pressure within the chambersof the upperby pressing the release featureof the release valve. Specifically, the wearer may press the release featurelocated on the outer surface of the sole structure, which biases the release valveto an open position to allow ambient air to flow into the chambersof the uppervia the intake port. Consequently, the pressure within the chambersof the upperincreased, and the uppertransitions from the constricted state () to the relaxed state () around the wearer's foot.

With particular reference to, another example of a configuration of an article of footwearhaving a pump deviceis shown. In view of the substantial similarity in structure and function of the components associated with the article of footwearwith respect to the article of footwear, 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.

The article of footwearincludes the sole structurehaving a pump devicediscussed above with respect to, but includes an upperhaving an alternative routing of an actuator cableincluding a tightening griprouted around the posterior endof the heel regionof the upper. Here, a vacuum may be drawn by pulling the actuator cablein a tightening directionand releasing the actuator cablefor a number of cycles. As the actuator cableis pulled in the tightening direction, the pistonof the pump deviceis moved from the first position to the second position, drawing a vacuum from the upperinto the chamberthereby increasing the pressure within the chamberof the pump devicefrom a first pressure to a second pressure higher than the first pressure. When the actuator cableis released, the springsreturn the pistonto the first position, drawing the actuator cableback into the pump deviceand exhausting the second pressure within the chamberthrough the exhaust check valve. Accordingly, the steps of pulling the actuator cablein the tightening directionfollowed by releasing the actuator cableconstitutes a cycle. For each cycle that the actuator cableis pulled in the tightening directionand then released, the pressure within the upperis incrementally reduced. In some examples, the pressure within the upperreaches an ideal pressure to constrict the upper(e.g. −5 psi) after 20 pulls on the actuator cablein the tightening direction. In other examples, fewer pulls on the actuator cableare required.

The midsoleand the outsoleinclude a resilient polymeric material, such as foam or rubber, to impart properties of cushioning, responsiveness, and energy distribution to the foot of the wearer. In the illustrated example, the midsoleis formed of a first foam material, and the outsoleis formed of a second foam material. For example, the midsolemay include foam materials providing greater cushioning and impact distribution, while the outsoleincludes a foam material having a greater stiffness and/or rigidity in order to provide increased lateral stiffness to the sole structure.

Example resilient polymeric materials for the midsoleand the outsolemay 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., cross-linked polyurethanes and/or thermoplastic polyurethanes). Alternatively, the one or more polymers may include one or more natural and/or synthetic rubbers, such as butadiene and isoprene.