Sole Structure for Article of Footwear

This application is a continuation of U.S. application Ser. No. 18/189,513, filed Mar. 24, 2023, which is a continuation of U.S. application Ser. No. 16/950,792, filed Nov. 17, 2020, which claims priority to U.S. Provisional Application No. 62/937,462, filed Nov. 19, 2019, the contents of which 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 abrasion-resistance and 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 increase durability of the sole structure, as well as 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 may incorporate tensile members within the bladder to retain the shape of the bladder when pressurized. Generally, bladders 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.

In one aspect of the disclosure, a bladder for an article of footwear is provided. The bladder extends from an anterior end to a posterior end and includes a first chamber disposed in an interior region of the bladder and including a first interior void having a first pressure, and a second chamber at least partially surrounding the first chamber and including a second interior void having a second pressure.

Implementations of the disclosure may include one or more of the following optional features.

In some examples, the bladder has a first width adjacent to the anterior end of the bladder, a second width adjacent to the posterior end of the bladder, and a third width in an intermediate portion that is less than the first width and the second width.

In some configurations, the second chamber includes an anterior portion having a first cross-sectional area, a posterior portion having a second cross-sectional area, and an intermediate portion connecting the anterior portion and the posterior portion and having a third cross-sectional area. Here, the third cross-sectional area may be less than the first cross-sectional area. Optionally, the third cross-sectional area may be less than the second cross-sectional area. In some examples, the third cross-sectional area may be less than the first cross-sectional area and the second cross-sectional area.

In some implementations, the bladder includes a web area disposed between and connecting the first chamber and the second chamber.

In some examples, the bladder includes a first barrier layer and a second barrier layer joined together at discrete locations to define the first chamber and the second chamber. Optionally, at least one of the first barrier layer and the second barrier layer is transparent. In some examples, at least one of the first barrier layer and the second barrier layer is translucent.

In some configurations, the second chamber completely surrounds the first chamber.

In some examples, the second chamber partially surrounds the first chamber.

In some implementations, the second chamber includes a plurality of lobes, each lobe having a first end, a second end, and an intermediate portion disposed between the first end and the second end and being larger than the first end and the second end. Here, each lobe may taper from the intermediate portion to the first end and the second end. For each lobe, a thickness of the intermediate portion may be greater than thicknesses of the first end and the second end. Additionally or alternatively, for each lobe, a width of the intermediate portion is greater than widths of the first end and the second end. In some examples, a cross-sectional area of the intermediate portion is greater than the cross-sectional areas of the first end and the second end. Optionally, a plurality of the lobes are arranged in series around the first chamber.

In some examples, the plurality of lobes includes a medial anterior lobe and a lateral anterior lobe. Here, the medial anterior lobe and the lateral anterior lobe may be in direct fluid communication with each other.

In some implementations, the plurality of lobes includes a posterior lobe disposed at the posterior end of the bladder. Here, the posterior lobe may extend from a first end on a medial side of the bladder to a second end on a lateral side of the bladder. In some configurations plurality of lobes includes a lateral intermediate lobe and a medial intermediate lobe in direct fluid communication with the posterior lobe. Here, the lateral intermediate lobe and the medial intermediate lobe may be smaller than the posterior lobe. In some examples, a cross-sectional area of an interior void of the second chamber is greater at the intermediate portion of the posterior lobe than at the intermediate portions of each of the lateral intermediate lobe and the medial intermediate lobe. In some examples, a thickness of the intermediate portion of the posterior lobe defines a maximum thickness of the bladder.

In some implementations, the plurality of lobes includes a lateral intermediate lobe and a medial intermediate lobe disposed between the anterior end and the posterior end of the bladder.

In some examples, the first pressure is different than the second pressure. In some examples, the second pressure is greater than the first pressure. In some configurations, the first pressure ranges from 0 psi to 20 psi. In some implementations, the first pressure ranges from 5 psi to 15 psi. In some examples, the first pressure ranges from 7 psi to 10 psi. In some examples, the second pressure ranges from 0 psi to 35 psi. In some configurations, the second pressure ranges from 15 psi to 30 psi. In some implementations, the second pressure ranges from 20 psi to 25 psi. In some examples, the first pressure and the second pressure are atmospheric pressure.

In some configurations, a first thickness of the first chamber is greater than a second thickness of the second chamber at the anterior end and less than a third thickness of the second chamber at the posterior end.

Another aspect of the disclosure includes a sole structure including the bladder of any of the preceding clauses.

Another aspect of the disclosure is directed towards an article of footwear including the bladder described in the preceding paragraphs.

In another aspect of the disclosure, a sole structure is provided. The sole structure has a chassis including a bottom surface forming a first portion of the chassis and a recessed surface offset from the bottom surface to define a recess in a second portion of the chassis. The sole structure further includes a bladder disposed within the recess of the chassis and including a first chamber disposed in an interior region of the recess and a second chamber disposed in a peripheral region of the recess. The second chamber at least partially surrounds the first chamber and is fluidly isolated from the first chamber.

Implementations of the disclosure may include one or more of the following optional features.

In some examples, the second chamber completely surrounds the first chamber.

In some implementations, the second chamber partially surrounds the first chamber.

In some configurations, the first chamber has a different pressure than the second chamber.

In some examples, the chassis includes a cushioning element forming the bottom surface and the interior region of the recesses surface, and a cradle at least partially defining the peripheral region of the recessed surface, the cradle being formed of a different material than the cushioning element.

In some configurations, the recessed surface includes a plurality of supports each configured to interface with a respective lobe of the bladder. Here, a first one of the supports may be formed of a first material and a second one of the supports may be formed of a second material that is different than the first material. Optionally, the plurality of supports includes an interior support interfacing with the first chamber and a plurality of peripheral supports each interfacing with a respective lobe of the second chamber.

In some examples, the sole structure includes an outsole having a first portion attached to the chassis and a second portion attached to the bladder. Here, the second portion of the outsole optionally includes an interior portion attached to the first chamber and a peripheral portion attached to the second chamber and independently movable relative to the interior portion.

Referring to, an article of footwearincludes a sole structureand an upperattached to the sole structure. 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 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. The footwearmay further include an anterior endassociated with a forward-most point of the forefoot region, and a posterior endcorresponding to a rearward-most point of the heel region. A longitudinal axis Aof the footwearextends along a length of the footwearfrom the anterior endto the posterior end, and generally divides the footwearinto a lateral sideand a medial side, as shown in. Accordingly, the lateral sideand the medial siderespectively correspond with opposite sides of the footwearand extend through the regions,,.

The article of footwear, and more particularly, the sole structure, may be further described as including an interior regionand a peripheral region, as indicated in. The peripheral regionis generally described as being a region between the interior regionand an outer perimeter of the sole structure. Particularly, the peripheral regionextends from the forefoot regionto the heel regionalong each of the lateral sideand the medial side, and wraps around each of the forefoot regionand the heel region. Thus, the interior regionis circumscribed by the peripheral region, and extends from the forefoot regionto the heel regionalong a central portion of the sole structure.

With reference to, the sole structureincludes a midsoleconfigured to provide cushioning characteristics to the sole structure, and an outsoleconfigured to provide a ground-engaging surfaceof 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 bladderand a chassis, where the chassisis attached to the upperand provides an interface between the upper, the bladder, and the outsole.

With reference to, the bladderof the midsolemay be described as extending along a longitudinal axis Afrom a first, anterior endto a second, posterior enddisposed at an opposite end of the bladderthan the anterior end. When incorporated into the article of footwear, the anterior endof the bladderis disposed within the heel regionor the midfoot regionand faces the anterior endof the footwear, while the posterior endis disposed at the posterior endof the footwear. The bladdermay be further described as including an intermediate regiondisposed between the anterior endand the posterior end. The geometry and features of the bladdermay also be described relative to the peripheral regionand the interior regionof the article of footwear.

As shown in the cross-sectional views of, the bladdermay be formed by an opposing pair of barrier layers,, which can be joined to each other at discrete locations to define an overall shape of the bladder. Alternatively, the bladdercan be produced from any suitable combination of one or more barrier layers.

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.

One or both of the barrier layers,can independently be transparent, translucent, and/or opaque. As used herein, the term “transparent” for a barrier layer and/or a fluid-filled chamber means that light passes through the barrier layer in substantially straight lines and a viewer can see through the barrier layer. In comparison, for an opaque barrier layer, light does not pass through the barrier layer and one cannot see clearly through the barrier layer at all. A translucent barrier layer falls between a transparent barrier layer and an opaque barrier layer, in that light passes through a translucent layer but some of the light is scattered so that a viewer cannot see clearly through the layer.

The barrier layers,can each be produced from an elastomeric material that includes one or more thermoplastic polymers and/or one or more cross-linkable polymers. In an aspect, the elastomeric material can include one or more thermoplastic elastomeric materials, such as one or more thermoplastic polyurethane (TPU) copolymers, one or more ethylene-vinyl alcohol (EVOH) copolymers, and the like.

As used herein, “polyurethane” refers to a copolymer (including oligomers) that contains a urethane group (—N(C═O)O—). These polyurethanes can contain additional groups such as ester, ether, urea, allophanate, biuret, carbodiimide, oxazolidinyl, isocynaurate, uretdione, carbonate, and the like, in addition to urethane groups. In an aspect, one or more of the polyurethanes can be produced by polymerizing one or more isocyanates with one or more polyols to produce copolymer chains having (—N(C═O)O—) linkages.

Examples of suitable isocyanates for producing the polyurethane copolymer chains include diisocyanates, such as aromatic diisocyanates, aliphatic diisocyanates, and combinations thereof. Examples of suitable aromatic diisocyanates include toluene diisocyanate (TDI), TDI adducts with trimethyloylpropane (TMP), methylene diphenyl diisocyanate (MDI), xylene diisocyanate (XDI), tetramethylxylylene diisocyanate (TMXDI), hydrogenated xylene diisocyanate (HXDI), naphthalene 1,5-diisocyanate (NDI), 1,5-tetrahydronaphthalene diisocyanate, para-phenylene diisocyanate (PPDI), 3,3′-dimethyldiphenyl-4,4′-diisocyanate (DDDI), 4,4′-dibenzyl diisocyanate (DBDI), 4-chloro-1,3-phenylene diisocyanate, and combinations thereof. In some embodiments, the copolymer chains are substantially free of aromatic groups.

In particular aspects, the polyurethane polymer chains are produced from diisocynates including HMDI, TDI, MDI, H12 aliphatics, and combinations thereof. In an aspect, the thermoplastic TPU can include polyester-based TPU, polyether-based TPU, polycaprolactone-based TPU, polycarbonate-based TPU, polysiloxane-based TPU, or combinations thereof.

In another aspect, the polymeric layer can be formed of one or more of the following: EVOH copolymers, poly (vinyl chloride), polyvinylidene polymers and copolymers (e.g., polyvinylidene chloride), polyamides (e.g., amorphous polyamides), amide-based copolymers, acrylonitrile polymers (e.g., acrylonitrile-methyl acrylate copolymers), polyethylene terephthalate, polyether imides, polyacrylic imides, and other polymeric materials known to have relatively low gas transmission rates. Blends of these materials, as well as with the TPU copolymers described herein and optionally including combinations of polyimides and crystalline polymers, are also suitable.

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

The bladdercan be produced from the barrier layers,using any suitable technique, such as thermoforming (e.g. vacuum thermoforming), blow molding, extrusion, injection molding, vacuum molding, rotary molding, transfer molding, pressure forming, heat sealing, casting, low-pressure casting, spin casting, reaction injection molding, radio frequency (RF) welding, and the like. In an aspect, the barrier layers,can be produced by co-extrusion followed by vacuum thermoforming to form the profile of the bladder, which can optionally include one or more valves(e.g., one way valves) that allows the bladderto be filled with the fluid (e.g., gas).

The bladderdesirably has a low gas transmission rate to preserve its retained gas pressure. In some embodiments, the bladderhas a gas transmission rate for nitrogen gas that is at least about ten (10) times lower than a nitrogen gas transmission rate for a butyl rubber layer of substantially the same dimensions. In an aspect, bladderhas a nitrogen gas transmission rate of 15 cubic-centimeter/square-meter·atmosphere·day (cm/m·atm·day) or less for an average film thickness of 500 micrometers (based on thicknesses of barrier layers,). In further aspects, the transmission rate is 10 cm/m·atm·day or less, 5 cm/m·atm·day or less, or 1 cm/m·atm·day or less.