Shoe with Foam Pods and Chassis

This application is a continuation of U.S. patent application Ser. No. 17/963,482, filed on Oct. 11, 2022, which claims the benefit of and priority to U.S. Provisional App. No. 63/256,874, filed on Oct. 18, 2021, entitled “SHOE WITH FOAM PODS AND CHASSIS”, which is herein incorporated by reference in its entirety.

The present disclosure relates generally to an article of footwear.

Many conventional shoes or other articles of footwear generally comprise an upper and a sole attached to a lower end of the upper. Conventional shoes further include an internal space, i.e., a void or cavity, which is created by interior surfaces of the upper and sole, that receives a foot of a user before securing the shoe to the foot. The sole is attached to a lower surface or boundary of the upper and is positioned between the upper and the ground. As a result, the sole typically provides stability and cushioning to the user when the shoe is being worn. In some instances, the sole may include multiple components, such as an outsole, a midsole, and an insole. The outsole may provide traction to a bottom surface of the sole, and the midsole may be attached to an inner surface of the outsole, and may provide cushioning or added stability to the sole. For example, a sole may include a particular foam material that may increase stability at one or more desired locations along the sole, or a foam material that may reduce stress or impact energy on the foot or leg when a user is running, walking, or engaged in another activity. The sole may also include additional components, such as plates, embedded with the sole to increase the overall stiffness of the sole and reduce energy loss during use.

The upper generally extends upward from the sole and defines an interior cavity that completely or partially encases a foot. In most cases, the upper extends over the instep and toc regions of the foot, and across medial and lateral sides thereof. Many articles of footwear may also include a tongue that extends across the instep region to bridge a gap between edges of medial and lateral sides of the upper, which define an opening into the cavity. The tongue may also be disposed below a lacing system and between medial and lateral sides of the upper, to allow for adjustment of shoe tightness. The tongue may further be manipulable by a user to permit entry or exit of a foot from the internal space or cavity. In addition, the lacing system may allow a user to adjust certain dimensions of the upper or the sole, thereby allowing the upper to accommodate a wide variety of foot types having varying sizes and shapes.

The upper may comprise a wide variety of materials, which may be chosen based on one or more intended uses of the shoe. The upper may also include portions comprising varying materials specific to a particular area of the upper. For example, added stability may be desirable at a front of the upper or adjacent a heel region so as to provide a higher degree of resistance or rigidity. In contrast, other portions of a shoe may include a soft woven textile to provide an area with stretch-resistance, flexibility, air-permeability, or moisture-wicking properties.

However, while many currently-available shoes have varying features related to the above-noted properties, many shoes, and the sole structures thereof, may be further optimized to provide targeted support to a user's foot to aid in stability while running, walking, or engaging in strenuous athletic activities. Additionally, many shoes, and their sole structures, may be further optimized to provide targeted support to a user's foot to reduce energy dissipation and thereby increase the efficiency of a user during physical activity, such as running. Moreover, many shoes, and their sole structures, may be further optimized to provide additional support and cushioning to a user's bones and tissue in the user's foot. Still further, many shoes, and their sole structures, may be optimized to provide protection for a user's tissue, bones, and ligaments from excessive loads.

Therefore, articles of footwear having features providing such effects across areas of the foot are desired. These and other deficiencies with the prior art are outlined in the following disclosure.

An article of footwear, as described herein, may have various configurations. The article of footwear may have an upper and a sole structure that is coupled with the upper. The sole structure may define a forefoot region, a midfoot region, and a heel region. The sole structure may include a plurality of pods. Each pod may have a pod body and may also optionally have a coating that is disposed on an outer surface of the pod body. The sole structure may also include a chassis that is attached to a bottom surface of each pod in the plurality of pods. The pod body of each pod in the plurality of pods may be formed from a foam material. The chassis may include a plurality of ground contacting regions. The chassis may have an elongated fork structure. The elongated fork includes a chassis stem, a first chassis leg that extends from the chassis stem through the heel region, the midfoot region, and the forefoot region of the sole structure, and a second chassis leg that also extends from the chassis stem through the heel region, the midfoot region, and the forefoot region. The elongated fork structure also has a continuous elongated groove that is positioned between the first chassis leg and the second chassis leg. The continuous elongated groove extends along substantially the entire length of the first chassis leg and the second chassis leg.

The article of footwear, as described herein, may have an upper and a sole structure that is coupled with the upper. The sole structure may define a forefoot region, a midfoot region, and a heel region. The sole structure may include a plurality of pods. Each pod may have a pod body and may also optionally have a coating that is disposed on an outer surface of the pod body. The sole structure may also include a chassis that is attached to a bottom surface of each pod in the plurality of pods. The pod body of each pod in the plurality of pods is formed from a foam material. The foam material in the pod body of at least one pod in the plurality of pods may have a density that is different than the density of the foam material in the pod body of at least one other pod in the plurality of pods. The chassis may include a plurality of ground contacting regions. The chassis may not be attached to the upper.

In another embodiment, the article of footwear may have an upper and a sole structure that is coupled with the upper. The sole structure may define a forefoot region, a midfoot region, and a heel region. The sole structure may include a plurality of pods. Each pod may have a pod body and may also optionally have a coating that is disposed on an outer surface of the pod body. The sole structure may also include a chassis that is attached to a bottom surface of each pod in the plurality of pods. The pod body of each pod in the plurality of pods is formed from a foam material. The foam material in the pod body of at least one pod in the plurality of pods may have a density that is different than the density of the foam material in the pod body of at least one other pod in the plurality of pods. The chassis may encapsulate each pod in the plurality of pods.

In some aspects, an article of footwear includes an upper and a sole structure coupled with the upper. The sole structure defines a forefoot region, a midfoot region that corresponds with a portion of the article of footwear that is configured to encase an arch of a foot, and a heel region that is proximate and adjoining the midfoot region. The footwear also includes a first foam material and a second foam material within the sole structure. The first foam material has a density that is different than a density of the second foam material. At least one of the first and second materials is directly attached to the upper. The footwear further includes a plurality of ground contacting regions and a heel support plate that extends along a portion of the upper in the heel region.

In some embodiments, the heel support plate extends upwardly away from a ground surface. In some embodiments, the heel support plate is substantially ovular in shape and includes a flange extending from an upper edge. In some embodiments, a chassis is attached to a bottom surface of at least one of the first foam material or the second foam material. In some embodiments, the chassis is indirectly coupled with the upper by way of attachment between the chassis and the first foam material or the second foam material. In some embodiments, the chassis is a unitary piece that is integrally formed of rubber. In some embodiments, the chassis includes a chassis stem, a first chassis leg extending from the chassis stem through at least one of the heel region or the forefoot region of the sole structure, a second chassis leg extending from the chassis stem through at least one of the heel region or forefoot region of the sole structure, and a continuous elongated groove positioned between the first chassis leg and the second chassis leg. In some embodiments, the continuous elongated groove extends along substantially an entire length of the first chassis leg and the second chassis leg. In some embodiments, at least one of the first foam material and the second foam material is a supercritical foam formed by a supercritical foaming process. In some embodiments, one of the first foam material or the second foam material extends along substantially an entire longitudinal length of one or more of the forefoot region, the midfoot region, and the heel region. In some embodiments, the first foam material is positioned in the heel region and the second foam material is positioned in the midfoot region. In some embodiments, the first foam material or the second foam material occupies at least 50% of a surface area of a bottom surface of the upper within one or more of the heel region, the midfoot region, and forefoot region.

In some aspects, an article of footwear includes an upper and a sole structure coupled with the upper. The sole structure defines a forefoot region, a midfoot region that corresponds with a portion of the article of footwear that is configured to encase an arch of a foot, and a heel region that is proximate and adjoining the midfoot region. The sole structure includes a first foam material and a second foam material. The first foam material is a supercritical foam and has a density that is different from a density of the second foam material. The sole structure also includes a chassis that is not directly attached to the upper. The chassis is attached to a bottom surface of the first foam material or the second foam material. The chassis is made of rubber and comprises a plurality of ground contacting regions.

In some embodiments, the chassis includes a chassis stem, a first chassis leg extending from the chassis stem through at least one of the heel region or the forefoot region of the sole structure, a second chassis leg extending from the chassis stem through at least one of the heel region or forefoot region of the sole structure, and a continuous elongated groove positioned between the first chassis leg and the second chassis leg. In some embodiments, the continuous elongated groove extends along substantially an entire length of the first chassis leg and the second chassis leg. In some embodiments, the continuous elongated groove is an opening that extend through an entire thickness fo the chassis. In some embodiments, the continuous elongated groove forms a portion of the chassis having a reduced thickness. In some embodiments, the plurality of ground contacting regions are positioned along each of the first leg and the second leg. In some embodiments, at least one of the first foam material or the second foam material extends across substantially an entire width from a lateral side to a medial side of the article of footwear. In some embodiments, one of the first foam material or the second foam material extends along substantially an entire longitudinal length of one or more of the forefoot region, the midfoot region, and the heel region.

In some aspects, an article of footwear includes an upper and a sole structure coupled with the upper. The sole structure defines a forefoot region, a midfoot region that corresponds with a portion of the article of footwear that is configured to encase an arch of a foot, and a heel region that is proximate and adjoining the midfoot region. The sole structure includes a first foam material and a second foam material. The first foam material is a supercritical foam and has a density that is different from a density of the second foam material. The sole structure also includes a chassis that comprises a first leg, a second leg, and a continuous elongated groove that extends along a length of the first leg and the second leg. At least one of the first foam material or the second foam material is visible through the continuous elongated groove.

In some embodiments, the first leg and the second leg comprise a plurality of ground contacting regions. In some embodiments, the chassis is attached to a bottom surface of at least one of the first foam material or the second foam material. In some embodiments, the chassis is made of rubber. In some embodiments, a heel support plate extends along the upper in a heel region of the article of footwear. In some embodiments, the heel support plate is formed separately from the chassis.

Other aspects of the articles of footwear described herein, including features and advantages thereof, will become apparent to one of ordinary skill in the art upon examination of the figures and detailed description herein. Therefore, all such aspects of the articles of footwear are intended to be included in the detailed description and this summary.

The following discussion and accompanying figures disclose various embodiments or configurations of a shoe having an upper and a sole structure. Although embodiments are disclosed with reference to a sports shoe, such as a running shoe, tennis shoe, basketball shoe, etc., concepts associated with embodiments of the shoe may be applied to a wide range of footwear and footwear styles, including cross-training shoes, football shoes, golf shoes, hiking shoes, hiking boots, ski and snowboard boots, soccer shoes and cleats, walking shoes, and track cleats, for example. Concepts of the shoe may also be applied to articles of footwear that are considered non-athletic, including dress shoes, sandals, loafers, slippers, and heels.

The term “about,” as used herein, refers to variations in the numerical quantity that may occur, for example, through typical measuring and manufacturing procedures used for articles of footwear or other articles of manufacture that may include embodiments of the disclosure herein; through inadvertent error in these procedures; through differences in the manufacture, source, or purity of the ingredients used to make the compositions or mixtures or carry out the methods; and the like. Throughout the disclosure, the terms “about” and “approximately” refer to a range of values ±5% of the numeric value that the term precedes.

The present disclosure is directed to an article of footwear or specific components of the article of footwear, such as an upper or a sole or a sole structure. The sole structure defines a forefoot region, a midfoot region, and a heel region. The sole structure is coupled with the upper. The sole structure includes a plurality of pods and a chassis. The plurality of pods are connected to the upper. More specifically, the top surface of each pod is connected to the bottom surface of the upper. The chassis is connected to the plurality of pods. More specifically, the bottom surface of each pod is connected to at least the top surface of the chassis. In an embodiment, the chassis is not connected directly to the upper.

While only a single shoe is depicted, i.e., a shoe that is worn on a left foot of a user, it should be appreciated that the concepts disclosed herein are applicable to a pair of shoes (not shown), which includes a left shoe and a right shoe that may be sized and shaped to receive a left foot and a right foot of a user, respectively. For ease of disclosure, however, a single shoe will be referenced to describe aspects of the disclosure, but the disclosure below with reference to the article of footwear is applicable to both a left shoe and a right shoe. However, in some embodiments there may be differences between a left shoe and a right shoe other than the left/right configuration. Further, a left shoe may include one or more additional elements that a right shoe does not include, or vice versa.

Referring initially to, the article of footwearcomprises sole structureand an upper. The upperwill be discussed in more detail below. The sole structureis coupled with the upper. The sole structureincludes a chassishaving a chassis stem, a first chassis leg, a second chassis leg(shown in), and a continuous elongated groove. The continuous elongated groovehas a first end, a second end, a heel joint, and a toe joint. The sole structurealso includes a plurality of pods. The plurality of podsincludes a first pod, a second pod, and third pod. The chassisis coupled with the plurality of pods. The plurality of podsis connected directly with the upper. The chassismay be connected directly to the upper. However, in some embodiments, it is preferred that the chassisis not connected directly to the upper, but rather the chassisis only indirectly coupled with the upperby way of attachment between the chassisand the plurality of podsand further attachment between the plurality of podsand the upper. When fully assembled, the upperincludes an interior surface, an exterior surface, and an interior cavity. The interior surfacefaces inward and generally defines the interior cavity, and the exterior surfaceof the upperfaces outward and generally defines an outer perimeter or boundary of the upper. As will be discussed in greater detail below, the pods in the plurality of podsmay be customized so that a given plurality of podsmay have specific properties that are tailored to meet the needs of a given user.

Referring now to, the article of footwearhas a heel region, a midfoot region, and a forefoot region. The forefoot regiongenerally corresponds with portions of the article of footwearthat encase portions of the foot that includes the toes, the ball of the foot, and joints connecting the metatarsals with the toes or phalanges. The midfoot regionis proximate and adjoining the forefoot region, and generally corresponds with portions of the article of footwearthat encase the arch of the foot, along with the bride of a foot. The heel regionis proximate and adjoining the midfoot regionand generally corresponds with portions of the article of footwearthat encase rear portions of the foot, including the heel or calcaneus bone, the ankle, or the Achilles tendon.

The forefoot regionextends from a toe endto a widest portionof the article of footwear. The widest portionis defined or measured along a first linethat is perpendicular with respect to a longitudinal axisthat extends from a distal portion of the toe end to a distal portion of a heel end, which is opposite the toe end. The midfoot regionextends from the widest portionto a thinnest portionof the article of footwear. The thinnest portionof the article of footwearis defined as the portion of the article of footwearhaving the least width, as measured along a second linethat is perpendicular with respect to the longitudinal axis. The heel regionextends from the thinnest portionto the heel endof the article of footwear.

The heel region, the midfoot region, the forefoot region, a medial side, and a lateral sidedefine boundaries or areas of the article of footwear, and generally characterize sections of the article of footwear. Certain aspects of the disclosure may refer to portions or elements that are coextensive with one or more of the heel region, the midfoot region, the forefoot region, the medial side, or the lateral side. Further, both the upperand the sole structuremay be characterized as having portions within the heel region, the midfoot region, the forefoot region, or along the medial sideor the lateral side. Therefore, the upperand the sole structure, or individual portions of the upperand the sole structure, may include portions thereof that are disposed within the heel region, the midfoot region, the forefoot region, or along the medial sideor the lateral side.

When a user is wearing the article of footwear(configured as a pair of shoes), the lateral sidecorresponds with an outside-facing portion of the article of footwearwhile the medial sidecorresponds with an inside-facing portion of the article of footwear. As such, a left shoe and a right shoe have opposing lateral sidesand medial sides, such that the medial sidesare closest to one another when a user is wearing the shoes, while the lateral sidesare the sides that are farthest from one another. As will be discussed in greater detail below, the medial sideand the lateral sideadjoin one another along a longitudinal central plane or axisat opposing, distal ends of the article of footwear. As will also be further discussed herein, the longitudinal central plane or axismay demarcate a central, intermediate axis between the medial sideand the lateral sideof the article of footwear. Put differently, the longitudinal plane or axismay extend between a toe endof the article of footwearand a heel endof the article of footwear. The longitudinal axismay continuously define a middle of the sole structure, or the upperof the article of footwear, i.e., the longitudinal plane or axismay be a straight axis extending from the heel endof the heel regionto the toe endof the forefoot region.

Still referring to, the medial sidebegins at the toe endand bows outward along the forefoot regiontoward the midfoot region. At the first line, the medial sidebows inward, toward the central, longitudinal axis. The medial sideextends from the first line, i.e., the widest portion, toward the second line, i.e., the thinnest portion, entering into the midfoot regionupon crossing the first line. After reaching the second line, the medial sidebows outward, away from the longitudinal, central axis, at which point the medial sideextends into the heel region, i.e., upon crossing the second line. The medial sidethen bows outward and then inward toward the heel end, and terminates at a point where the medial sidemeets the longitudinal, center axis.

The lateral sidealso begins at the toe endand bows outward along the forefoot regiontoward the midfoot region. The lateral sidereaches the first line, at which point the lateral sidebows inward, toward the longitudinal, central axis. The lateral sideextends from the first line, i.e., the widest portion, toward the second line, i.e., the thinnest portion, entering into the midfoot regionupon crossing the first line. After reaching the second line, the lateral sidebows outward, away from the longitudinal, central axis, at which point the lateral sideextends into the heel region, i.e., upon crossing the second line. The lateral sidethen bows outward and then inward toward the heel end, and terminates at a point where the lateral sidemeets the longitudinal, center axis.

It should be understood that numerous modifications may be apparent to those skilled in the art in view of the foregoing description, and individual components thereof, may be incorporated into numerous articles of footwear. Accordingly, aspects of the article of footwearand components thereof, may be described with reference to general areas or portions of the article of footwear, with an understanding the boundaries of the heel region, the midfoot region, the forefoot region, the medial side, or the lateral sideas described herein may vary between articles of footwear. However, aspects of the article of footwearand individual components thereof, may also be described with reference to exact areas or portions of the article of footwearand the scope of the appended claims herein may incorporate the limitations associated with these boundaries of the heel region, the midfoot region, the forefoot region, the medial side, or the lateral sidediscussed herein.

Referring again to, the sole structureincludes a chassisthat is attached to a bottom surface of each pod of the plurality of pods. As best shown in, the chassisis configured in an elongated fork structure. The elongated fork structure of the chassisincludes the chassis stem, the first chassis leg, and the second chassis leg. The chassis stemis positioned in the heel regionof the sole structureand includes a heel jointthat connects the first chassis legand the second chassis leg. The chassis stemmay be integral with the first chassis legand the second chassis leg. The chassis stemextends upwardly (i.e. away from the ground) from the heel joint. In a particular embodiment, the chassis stemextends upwardly, around at least a portion of a podthat is disposed in the heel region. A portion of the chassis stemmay be connected to at least one pod. In other embodiments, the entirety of the chassis stemmay be connected to one or more pods.

The elongated fork structure of the chassisincludes the first chassis leg. The first chassis legextends from the chassis stem. The first chassis legextends along the bottom surface of the plurality pods, and through the heel region, the midfoot region, and the forefoot regionof the sole structure. The first chassis legdefines at least a portion of the bottom-most surface of the article of footwear, and may define at least a portion of the bottom-most surface of the article of footwearin each of the heel region, the midfoot region, and the forefoot region. In some embodiments, the first chassis legmay be integral with the chassis stem. Alternatively, the first chassis legmay be formed separately from and coupled to the chassis stem, in any suitable manner. The first chassis legmay be disposed substantially on a medial portion of the sole structure. Alternatively, the first chassis legmay be disposed substantially on a lateral portion of the sole structure.

The elongated fork structure of the chassisalso includes the second chassis leg. The second chassis legmay be substantially similar to the first chassis leg. The second chassis legextends from the chassis stem. The second chassis legis positioned opposite the first chassis leg, such that if the first chassis legis disposed substantially on a medial portion of the bottom surface of the sole structure, then the second chassis legis disposed substantially on a lateral portion of the sole structure. In certain embodiments, the inverse arrangement of the first chassis legand the second chassis legis possible. Like the first chassis leg, the second chassis legextends from the chassis stemand through the heel region, the midfoot region, and the forefoot regionof the sole structure. The second chassis legdefines at least a portion of the bottom-most surface of the article of footwear, and may define at least a portion of the bottom-most surface of the article of footwearin each of the heel region, the midfoot region, and the forefoot regionof the sole structure. The second chassis legmay be integral with the chassis stem. In a particular embodiment, the entire chassis(including at least the stem, first leg, and the second leg) may be formed as a single unitary piece that is integrally formed from a single material. Alternatively, the second chassis legmay be formed separately and coupled to the chassis stem, in any suitable manner.

The chassismay include the toe joint. In embodiments that include the toe joint, the toe jointis positioned between the first chassis legand the second chassis legin the forefoot regionof the sole structure. The toe jointmay be substantially similar to the portion of the chassis stemthat forms the heel jointbetween the first chassis legand the second chassis legin the heel regionof the sole structure. Alternatively, no toe jointmay be provided. In this instance, the first chassis legand the second chassis legremain distanced from each other throughout the entirety of the midfoot regionand the forefoot region.

The elongated fork structure of the chassisalso includes the continuous elongated groove. The continuous elongated grooveis positioned between the first chassis legand the second chassis leg. The continuous elongated groovehas a first endthat is located in the heel region, adjacent to the portion of the chassis stemthat forms the heel joint. The continuous elongated grooveextends along substantially the entire length of the first chassis legand the second chassis leg. The continuous elongated grooveseparates substantially all of the length of the first chassis legfrom substantially all of the length of the second chassis leg. The continuous elongated groovemay have second endthat is located in the forefoot regionof the sole structure, adjacent to the toe joint.

The second endof the continuous elongated groovemay be adjacent to the toc joint, when provided, such that the continuous elongated grooveis fully enclosed within and surrounded by the chassis(in the longitudinal direction), as measured along the central, longitudinal axis. Alternatively, the second endof the continuous elongated groovemay be open/exposed in the forefoot region, such that the chassisdoes not fully enclose the length of the continuous elongated groove. In one embodiment, the width of the continuous elongated groovetappers proximate both the first endand the second end. In other embodiments, the width of the elongated groovetapers at the first end(in the heel region) but remains substantially uniform at the second end(in the forefoot region). Alternatively, the width of the elongated groovemay remain substantially uniform at both the first endand the second end. Additionally, the continuous elongated groovemay be wider in the midfoot regionand/or forefoot regionthan in the heel region.

The continuous elongated groovemay be configured as an opening that can extend through the entire thickness of the chassis. Alternatively, the continuous elongated groovemay be configured as an area that does not extend through the entire thickness of the chassis, but instead forms a portion of the chassishaving a reduced thickness. The thickness of the chassismay be reduced by any suitable amount, throughout the elongated groove. For example, the thickness of the chassismay be reduced by at least 50%, or at least 60%, or at least 70%, or at least 90%, or at least 95%, throughout the elongated groove. In an embodiment, at least a portion of one or more of the pods may be visible through a portion of the continuous elongated groove.

Still referring to, the chassismay also include additional optional components, such as a plurality of ground contacting regions(which themselves may include traction pads), a heel support plate, and/or a support fin.

When present, the ground contacting regionsare disposed on portions of the bottom surface of the chassis. Put another way, when an article of footwearis worn by a user, portions of the bottom surface of the chassis(i.e. ground contact regions) directly interface with the ground on which the user walks or stands. The first chassis legand/or the second chassis legmay comprise a plurality of ground contacting regions. Specifically, both the first chassis legand the second chassis legmay each comprise a plurality of ground contacting regions. The chassismay also comprise one or more traction pads. The traction pads may be positioned in some or all of the ground contacting regions. The traction pads may be integrally formed with the chassis. Alternatively, the traction pads may be coupled to the chassisin any suitable manner. The ground contacting portionsof the traction pads, i.e. the bottom surface of the traction pads, may include “high abrasion” textures or other features that are suitable for improving grip between the article of footwearand the ground. The chassismay be formed from one or more materials to impart durability, wear-resistance, abrasion resistance, or traction to the sole structure. For example, the chassis may be formed from rubber.

Still referring to, the chassismay also include additional optional components, such as a plurality of ground contacting regions(which themselves may include traction pads), a heel support plate, and/or a support fin.

When present, the heel support platethat extends upwardly, i.e., away from the ground, from the chassis stem. The heel support platemay extend along and around at least a portion of at least one pod. The heel support platemay extend along at least some of the upperin the heel region. The heel support platemay be attached to a portion of at least one pod. Additionally, the heel support platemay be distanced from, and therefore not attached directly to, the upper. Beneficially, this may allow a heel portion of the upperto have some space in which to expand, potentially to accommodate different foot sizes of different users, while simultaneously providing a region of rigidity and support to a heel portion of the upper. The heel support platemay further have a flange extending from the upper-most edge of the heel support plate. The heel support platemay have any suitable shape. The heel support platemay have a substantially ovular or a substantially rectangular shape. The heel support platemay be formed from any suitable material. For example, the heel support platemay be formed from the same material as the chassis. In a particular embodiment, the heel support platemay be integral with the chassis. Alternatively, the heel support platemay be formed separately from and then subsequently attached to the chassis.

When present, the support finextend upwardly from the first chassis legin the midfoot regionof the sole structure. The support finmay be positioned on lateral sideof the article of footwear. Alternatively, the support finmay be positioned on medial sideof the article of footwear. Some articles of footwear may have multiple support fins, such that a support finmay be positioned on both the lateral sideand the medial sideof the article of footwear. The support finmay have any suitable shape. In a particular embodiment, the support finmay have a substantially triangular shape. Alternatively, support finmay have a shape that is commonly associated with the dorsal appendage of a dolphin or shark, i.e., a fin. The support finmay be made from any suitable material. In an embodiment, the support finmay be made from the same material as the chassis. The support finmay be integral with the chassis. Alternatively, the support finmay be formed separately from and subsequently attached to the chassis. In certain embodiments, the support finmay be attached to at least a portion of one or more pods. Additionally, the support finmay be distanced from, and therefore not attached directly to, the side of the upper. Beneficially, this may allow the upperto have space in which to expand, potentially to accommodate different foot sizes of different users, while simultaneously providing a region of rigidity and support to a side of the upper.

Referring now to, a portion of the chassiscomprising the elongated fork structure is shown. The elongated fork structure provides the article of footwearnumerous benefits. For example, the elongated fork structure provides an article of footwearwith improved flexibility. With particular reference to, the elongated fork structure provides the article of footwearwith greater lateral/medial torsional flexibility, which may be particularly beneficial in athletic shoes. Referring now to, the elongated fork structure provides the article of footwearwith greater flexibility for movement in the vertical direction in the forefoot region, while simultaneously providing greater rigidity and support in the heel region. Additionally, the elongated fork structure of the chassisaccording to the present disclosure may have relatively few components, may require relatively few materials to manufacture, and reduce assembly time; all of which may beneficially reduce the cost of manufacturing related footwear.

Turning back to, the sole structureincludes the plurality of pods. The plurality of podshave at least a first pod, a second pod, and third pod. The chassisis coupled with the plurality of pods. The plurality of podsis coupled with the upper.

Each pod in the plurality of podsmay have two portions: (1) a pod body, and (2) an optional coating. As used herein, the term “pod body” refers to all portions of the podother than an optional coating. The pod body forms at least the significant majority of the mass of the podand provides the podwith its general shape. In podsthat have an optional coating, the coating is disposed around the outside surface of its pod body. In podsthat do not have a coating, the pod body makes up the entirety of the pod, i.e., the podconsists only of a pod body. For these pods, the terms “pod body” and “pod” become synonymous and can be used interchangeably.

Each podis formed from a foam material. More specifically, each pod body is formed from a foam material. The foam material(s) may include any suitable compositions. For example, foam material may be constructed from ethylene-vinyl acetate (EVA), interpolymers that include EVA, or a similar type of material. In some embodiments, the foam material may be an EVA-Solid-Sponge (“ESS”) material, an EVA foam (e.g., PUMA® ProFoam Lite™, IGNITE Foam), polyurethane, polyether, an olefin block copolymer, a thermoplastic material (e.g., a thermoplastic polyurethane, a thermoplastic elastomer, a thermoplastic polyolefin, etc.), or a supercritical foam. The foam material may comprise only a single polymeric material or may comprise a blend of materials, such as an EVA copolymer, a thermoplastic polyurethane, a polyether block amide (PEBA) copolymer, and/or an olefin block copolymer.

A foam material may be formed by a supercritical foaming process, such that the foam material form a supercritical foam. The supercritical foam may have micropore foams or particle foams, such as a TPU, EVA, PEBAX®, or mixtures thereof, manufactured using a process that is performed within an autoclave, an injection molding apparatus, or any sufficiently heated/pressurized container that can process the mixing of a supercritical fluid (e.g., CO, N, or mixtures thereof) with a material (e.g., TPU, EVA, polyolefin elastomer, or mixtures thereof) that is preferably molten. During an exemplary process, a solution of supercritical fluid and molten material is pumped into a pressurized container, after which the pressure within the container is released, such that the molecules of the supercritical fluid rapidly convert to gas to form small pockets within the material and cause the material to expand into a foam, which may be used in a pod of the present disclosure. In some embodiments, pods of the present disclosure may be formed using alternative methods known in the art, including the use of an expansion press, an injection machine, a pellet expansion process, a cold foaming process, a compression molding technique, die cutting, or any combination thereof. For example, a podmay be formed using a process that involves an initial foaming step in which supercritical gas is used to foam a material and then compression molded or die cut to a particular shape.

Some pod bodies may consist only of a single foam material. However, in some podseach individual pod body may comprise a combination of multiple foam materials.

In podshaving an optional coating, the optional coating may be a skin layer disposed around the outside of the pod body. Alternatively, the coating may be added to the outside of the pod body by spraying, extrusion coating, painting, dipping, or any other suitable method. The coating may be made of any materials suitable for a particular application. For example, the coating may include a foam material as described here, where the foam material of the coating is different than the foam material of the pod body. The coating may alter or improve a target property of the pod. For example, the coating may provide the podwith any or all of: a harder outer surface, an improved resistance to water, an improved resistance to stains, a higher melting temperature, a higher flashpoint, better bonding properties, and/or a preferable appearance.

A sole structuremay have podsmade from a number of different foam materials. For example, one podmay be made of a foam material that is different from the foam material of any of the other pods. Further, a sole structure may have a plurality of podsin which every podis made from a foam material that is different than the foam material of every other pod. Put another way, in such an embodiment, each podis made of a unique foam material. For example, in the article of footwearshown in, the first podmay be formed from a first foam material, the second podmay be formed from a different second form material, and the third podmay formed from still another different third foam material.

It is often especially useful if the different foam materials used to make a plurality of podsvary in density, hardness, and/or elasticity. Referring now to, a weightand three different types of foam material, formed into wedge shapes (,, andrespectively), are shown. The weightis shown resting on the top surface of each wedge (,, andrespectively) of foam material. The foam material in wedgeis less dense than the foam material in wedge, which in turn is less dense than the foam material in wedge. The differences in density cause the weightto compresses the wedgeto a greater degree than it does the wedge. The weightcompresses the wedgeeven less than it does the wedge, the weight appearing to have little if any compressive impact upon wedge. As such, the foam material of wedgemay be particularly useful in components of an article of footwear that tend to be load bearing and therefore need to provide support, whereas the foam material of wedgemay be particularly useful in components of an article of footwear that tend to experience high amounts of impact force and therefore need to provide cushioning. A particular foam material may have a density within the range between about 0.05 grams per cubic centimeter (g/cm) and about 0.50 g/cm, or between about 0.20 g/cmand about 0.40 g/cm. The foam material of particular pods may have a Shore A hardness between about 45 and about 60.