CN108348037B

CN108348037B - Article of footwear and method of making the same

Info

Publication number: CN108348037B
Application number: CN201680064329.1A
Authority: CN
Inventors: 潘梅拉·S·格林
Original assignee: Nike Innovate CV USA
Current assignee: Nike Innovate CV USA
Priority date: 2015-11-03
Filing date: 2016-11-02
Publication date: 2021-12-21
Anticipated expiration: 2036-11-02
Also published as: CN108348037A; CN108348038B; EP3370558A1; EP3788901A1; CN108348038A; WO2017079252A1; EP3370557A4; EP3370557B1; EP3370558B1; EP3370558A4; EP3370557A1; WO2017079254A1; EP3788901B1

Abstract

An article of footwear is disclosed that includes a sole structure having a bladder element that includes a plurality of cushioning components. Each cushioning component includes a closed fluid-filled chamber. The cushioning components may include a first cushioning component and a second cushioning component. The first cushioning component has a single central opening extending completely therethrough and a continuous fluid-filled chamber surrounding the central opening. The second cushioning component has a plurality of connectors located within an outer periphery of the second cushioning component. The connector connects a first side of the second cushioning component to a second side of the second cushioning component opposite the first side. A method of manufacturing an article of footwear having such a cushioning component is disclosed.

Description

Article of footwear and method of making the same

Cross Reference to Related Applications

This application claims priority to U.S. patent application No. 14/931280 filed on 3/11/2015, which is incorporated herein by reference in its entirety. This application claims priority to U.S. patent application No. 14/931287 filed on 3/11/2015, which is incorporated herein by reference in its entirety.

Technical Field

The present teachings generally include an article of footwear having a sole structure with a bladder element and methods of making the sole structure of the article of footwear.

Background

Footwear typically includes a sole that is configured to be positioned under a foot of a wearer to space the foot from a ground or floor surface. Athletic shoes, in particular, sometimes utilize polyurethane foam or other resilient material in the sole to provide cushioning. Fluid-filled bladders are sometimes included in the sole to provide the desired impact force absorption, motion control, and resiliency.

Drawings

Fig. 1 is a schematic illustration in side view of an article of footwear having a sole structure and a bladder element shown in hidden lines;

fig. 2 is a schematic view of the bladder element of fig. 1 in plan view, showing the perimeter of the sole structure in phantom;

fig. 3 is a schematic cross-sectional view of a first cushioning component of the bladder element of fig. 2 taken at line 3-3 in fig. 2;

fig. 4 is a schematic illustration in partial plan view of an alternative configuration of a cushioning component of the bladder element of fig. 2;

FIG. 5 is a schematic cross-sectional view of the cushioning component of FIG. 4, taken at line 5-5 in FIG. 4;

fig. 6 is a schematic cross-sectional view of another alternative configuration of the cushioning component of the bladder element of fig. 2;

fig. 7 is a schematic cross-sectional view of the second cushioning component of the bladder element of fig. 2 taken at line 7-7 in fig. 2, showing the tubular post;

fig. 8 is a schematic cross-sectional view of the bladder element of fig. 2 taken at the same line as fig. 7 before the bladder element is punched at the center of the tubular column of the bladder element;

fig. 9 is a schematic cross-sectional view of the bladder element of fig. 2 taken at line 9-9 in fig. 2;

FIG. 10 is a schematic cross-sectional view of the sole structure of FIG. 1 taken at line 10-10 in FIG. 1;

fig. 11 is a schematic illustration in plan view of a bladder element for the sole structure of fig. 1, according to an alternative aspect of the present teachings;

fig. 12 is a schematic cross-sectional view of the bladder element of fig. 11 taken at line 12-12 in fig. 11;

fig. 13 is a schematic cross-sectional view of a mold assembly for thermoforming the bladder element of fig. 1 from a polymeric sheet on the same cross-section as fig. 3.

Detailed Description

An article of footwear is disclosed that includes a sole structure having a bladder element that includes a plurality of cushioning components. Each cushioning component includes a closed fluid-filled chamber. The cushioning components include a first cushioning component and a second cushioning component. The first cushioning component has a single central opening extending completely therethrough and a continuous fluid-filled chamber surrounding the central opening. The second cushioning component has a plurality of connectors located within an outer periphery of the second cushioning component. The connector connects a first side of the second cushioning component to a second side of the second cushioning component opposite the first side.

In one embodiment, the cushioning components are spaced apart from one another such that an outer surface of each of the cushioning components is substantially separated from an outer surface of an adjacent cushioning component.

In one embodiment, the first cushioning component is a regular ring or an irregular ring.

In one embodiment, the connector is a tubular post. The at least one tubular post may include an opening extending completely through the at least one tubular post. The tubular post having an opening extending completely therethrough may be hollow.

In one embodiment, the connector is a tether positioned within the fluid-filled cavity of the second cushioning component.

In one embodiment, the cushioning components include a third cushioning component and a fourth cushioning component. The third cushioning component includes a single central opening extending completely therethrough and a continuous fluid-filled chamber surrounding the central opening of the third cushioning component. The fourth cushioning component includes a plurality of connectors positioned within an outer perimeter of the fourth cushioning component and connecting a first side of the fourth cushioning component to a second side of the fourth cushioning component, the second side being opposite the first side of the fourth cushioning component. The first cushioning component is located between a medial end of the sole structure and the third cushioning component. The third cushioning component is located between the lateral extremity of the sole structure and the first cushioning component. The second cushioning component is located between a medial end of the sole structure and the fourth cushioning component. The fourth cushioning component is located between the lateral extremity of the sole structure and the second cushioning component.

In one embodiment, the cushioning component further includes a fifth cushioning component having a single central opening extending completely therethrough and a continuous fluid-filled chamber surrounding the central opening of the fifth cushioning component. A fifth cushioning component is located rearward of the third cushioning component and within a midfoot portion of the sole structure.

In one embodiment, both the first cushioning component and the second cushioning component are positioned within a forefoot portion of the sole structure, and the second cushioning component is positioned forward of the first cushioning component.

In one embodiment, the second cushioning component is located in a heel portion of the article of footwear and includes a tubular portion extending along a periphery of the sole structure in the heel portion.

In one embodiment, the cushioning member includes a tubular cushioning member that extends lengthwise along a medial end of the sole structure within a midfoot portion of the sole structure.

In one embodiment, the bladder element includes a channel connecting adjacent cushioning components and establishing fluid communication between adjacent cushioning components. At least one of the passages may be sealed such that adjacent cushioning components connected by the sealed passage are isolated from fluid communication with each other by the sealed passage. Adjacent cushioning components connected by sealed channels may have different inflation pressures.

In one embodiment, a gap is disposed between adjacent cushioning components and extends from a medial end to a lateral end of the sole structure.

In some embodiments, substantially separating the cushioning component allows at least some of the outer surface of the cushioning component to be surrounded by or encapsulated in foam. The gaps between the lengths of tubing may be filled with foam or may be free of foam or other structure. The foam-filled or empty gaps allow for increased fore-aft flexibility of the sole structure as compared to a bladder element in which the outer surfaces of adjacent cushioning components are not substantially separated.

An article of footwear is disclosed that includes a sole structure having a bladder element that includes a cushioning component. The cushioning component includes a fluid-filled cavity and a plurality of tubular posts positioned within an outer periphery of the cushioning component. The tubular post connects a first side of the cushioning component to a second side of the cushioning component opposite the first side such that the fluid-filled cavity surrounds the tubular post. At least one tubular post includes an opening extending completely therethrough.

In one embodiment, the article of footwear further includes an additional cushioning component. The additional cushioning component includes a single central opening extending completely therethrough, with a continuous fluid-filled chamber surrounding the central opening. The bladder element further includes a channel connecting the cushioning component to the additional cushioning component.

In one embodiment, the cushioning component is located in one of a forefoot portion of the sole structure and a heel portion of the sole structure. For example, the cushioning component may be located in a heel portion of the sole structure and may include a tubular portion extending along an edge of the sole structure in the heel portion.

In one embodiment, the passage is sealed to isolate the fluid-filled cavity of the cushioning component from fluid communication with the fluid-filled cavity of the additional cushioning component through the sealed passage.

A method of manufacturing a sole structure for an article of footwear includes forming a bladder element having a plurality of cushioning components. Each cushioning component includes a fluid-filled chamber. The cushioning component includes a first cushioning component having a single central opening extending completely therethrough and having a continuous fluid-filled cavity surrounding the central opening. The cushioning component further includes a second cushioning component having a plurality of connectors positioned within an outer periphery of the second cushioning component and connecting a first side of the second cushioning component to a second side of the second cushioning component opposite the first side. The second cushioning component is substantially separate from the first cushioning component.

In one embodiment of the method, the plurality of connectors are hollow tubes, and forming the bladder element includes positioning the polymeric sheet in a mold assembly and thermoforming the polymeric sheet in the mold assembly to include the tubular columns. The method further includes punching holes at the tubular post of the polymer sheet so that the tubular post is hollow.

In one embodiment of the method, forming the bladder element includes forming a channel connecting adjacent cushioning components to establish fluid communication between the adjacent cushioning components, and forming a plenum disposed at a periphery of the bladder element and in fluid communication with the adjacent cushioning components via the channel. The method further includes inflating the bladder element to a first inflation pressure through the inflation port, closing one of the channels to form a first sealed portion of the bladder element, and inflating the remaining unsealed portion of the bladder element to a second inflation pressure through the inflation port, thereby establishing different inflation pressures in different cushioning components separated from each other by the closed channels.

In one embodiment, the method further comprises at least partially covering an outer surface of the at least one cushioning component with foam.

The above features and advantages and other features and advantages of the present teachings are readily apparent from the following detailed description of the modes for carrying out the present teachings when taken in connection with the accompanying drawings.

"a/an", "the", "at least one", and "one or more" are used interchangeably to indicate the presence of at least one item. There may be a plurality of such items, unless the context clearly indicates otherwise. Unless otherwise expressly or clearly indicated by context, all numbers in this description (including the appended claims) to parameters (e.g., amounts or conditions) are to be understood as modified in all instances by the term "about", whether or not the term "about" actually appears before the value. "about" means that the numerical value allows some slight imprecision (with some approach to exactness in the value; approximately or reasonably close the value; nearly). "about" as used herein means the changes that may result from at least the conventional methods of measurement and use of these parameters, provided the imprecision provided by "about" is not otherwise understood in the art with its ordinary meaning. Moreover, the disclosed ranges should be understood to specifically disclose all values within the range and further divided ranges. All references mentioned are incorporated herein in their entirety.

The terms "comprising", "including" and "having" are inclusive and therefore specify the presence of stated features, steps, operations, elements, or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, or components. The order of the steps, procedures, and operations may be varied, where practicable, and additional or alternative steps may be employed. As used in this specification, the term "or" includes any and all combinations of the associated listed items. The term "any" is understood to include any feasible combination of the referenced items, including "any one" of the referenced items. The term "any" is understood to include any feasible combination of the claims that are referenced in the appended claims, including the claims that are referenced in "any one of the claims.

Those of ordinary skill in the art will recognize that terms such as "above," "below," "upward," "downward," "top," "bottom," and the like are used descriptively with respect to the figures, and do not represent limitations on the scope of the invention, as defined by the claims.

Referring to the drawings, wherein like reference numbers refer to like components throughout the several views, fig. 1 shows an article of footwear 10 in an exterior view. As shown, article of footwear 10 is an athletic shoe. In other embodiments, article of footwear 10 may be another type of footwear, such as a dress shoe, a work shoe, a sandal, a slipper, or a boot.

An article of footwear 10 includes an upper 12 configured with a cavity to receive a foot 14 of a wearer. Upper 12 may be a variety of flexible materials such as textiles and fabrics and may include a plastic support component. Upper 12 may be multiple pieces that are stitched, knitted, or bonded to one another. Upper 12 may include a lacing system or may be a pull-on sock. Upper 12 may also include a support element, such as a heel. Upper 12 is shown worn on foot 14, which is shown in phantom.

Article of footwear 10 includes a sole structure 16, with sole structure 16 being operatively secured to upper 12 and providing cushioning between foot 14 and ground G. Article of footwear 10 and sole structure 16 have a forefoot portion 18, a midfoot portion 20, and a heel portion 22. The forefoot portion 18 generally includes portions of the sole structure 16 corresponding with the toes and the joints connecting the metatarsals with the phalanges of the foot 14. The midfoot portion 20 generally corresponds with the arch area of the foot 14 and extends from the forefoot portion 18 to the heel portion 22. Heel portion 22 generally corresponds with a rear portion of foot 14, including the calcaneus bone, with foot 14 corresponding in size with article of footwear 10. Heel portion 22 is defined as being approximately in the rear third of sole structure 16. The midfoot portion 20 is defined as the middle third of the sole structure 16. The forefoot portion 18 is defined as the front third of the sole structure 16. The perimeter P of the sole structure 16 surrounds the forefoot portion 18, the midfoot portion 20, and the heel portion 22. The article of footwear 10 is shown for a left foot. A pair of shoes includes article of footwear 10 and an article of footwear for the right foot, which is a mirror image of article of footwear 10.

The sole structure 16 has a lateral side 24, best shown in figure 1, and a medial side 26, shown in figure 2. Lateral side 24 includes all portions of sole structure 16 on a side of longitudinal centerline L closest to a lateral side of foot 14. Medial side 26 includes all portions of sole structure 16 on a side of longitudinal midline L closest to a medial side of foot 14. The lateral side 24 of the sole structure 16 is the side that corresponds with the side of the foot 14 that is generally further from the other foot of the wearer (i.e., the side closer to the fifth toe of the wearer). The fifth digit is commonly referred to as the little digit. The medial side 26 of the sole structure 16 is the side that corresponds with the medial area of the foot 14 and is generally closer to the other foot of the wearer (i.e., the side closer to the hallux of the foot of the wearer). The hallux is commonly referred to as the big toe.

The sole structure 16 includes a fluid-filled bladder element 30, the fluid-filled bladder element 30 being shown and described in further detail with respect to fig. 2. In fig. 1, the sole structure 16 also includes foam 32 that covers at least some of the outer surface of the bladder element 30. For example, foam 32 may be, but is not limited to, an Ethylene Vinyl Acetate (EVA) foam or a polyurethane foam. In addition to the foam 32, the sole structure 16 may include an outsole or discrete outsole element (not shown) attached directly to the bladder element 30 between the foam 32 and the ground G or between the bladder element 30 and the ground G. For example, the outsole or outsole element may be rubber or another relatively durable material for providing traction and grip. Alternatively, foam 32 may be used as an integral midsole and outsole. Sole structure 16 may also include various support elements such as one or more plates that may also be encapsulated in foam 32. Further, foam may not be used. For example, the bladder element 30 may instead be attached directly to the upper 12, or a layer may be attached to the upper 12 and the bladder element 30 may be attached to the ground-facing side of the layer. For example, the layer may be a midsole layer or a layer having a different stiffness. In such embodiments, the outsole element may be attached to or manufactured integrally with the bladder element 30.

The bladder element 30 is a polymeric material capable of retaining a pressurized fluid. For example, the bladder element 30 may include a thermoplastic polyurethane material (TPU). Alternatively, the TPU may be recyclable and regrind, and may be made from recycled TPU, allowing the material of the bladder element 30 to be recycled and reused.

The bladder element 30 may be blow molded or alternatively may be thermoformed from an upper sheet and a lower sheet. The sheet may have alternating layers of TPU and gas barrier material. In any embodiment, the bladder element 30 is configured to retain a fluid within the fluid-filled cavity. As used herein, "fluid" includes a gas, including air, an inert gas (e.g., nitrogen), or another gas. Thus, "fluid filled" includes "gas filled". Various materials for the bladder element 30 may be substantially transparent or may have a colored color. For example, the bladder element 30 can be made of any of a variety of polymeric materials capable of maintaining a fluid at a predetermined pressure, the fluid including a fluid that is a gas, such as air, nitrogen, or another gas. For example, the bladder element 30 may be a TPU material, urethane, polyurethane, polyester polyurethane, and/or polyether polyurethane.

Also, in one embodiment, the bladder element 30 may be formed from one or more sheets having different layers of material. The sheet may be a laminated film formed from a film having one or more first layers comprising thermoplastic polyurethane layers alternating with one or more second layers (also referred to herein as barrier layers, gas barrier polymers, or gas barrier layers). The second layer may comprise a copolymer of ethylene and vinyl alcohol (EVOH) that is impermeable to the pressurized fluid contained therein, as disclosed in U.S. patent No. 6,082,025 to Bonk et al, which is hereby incorporated by reference in its entirety. The first layer may be configured to form an outer surface of the polymer sheet. That is, the outermost first layer may be an outer surface of the bladder element 30. The bladder element 30 may also be formed from a material that includes alternating layers of thermoplastic polyurethane and ethylene-vinyl alcohol copolymer, as disclosed in U.S. patent nos. 5,713,141 and 5,952,065 to Mitchell et al, which are incorporated herein by reference in their entirety. Alternatively, the layers may include ethylene vinyl alcohol copolymer, thermoplastic polyurethane, and regrind material of ethylene vinyl alcohol copolymer and thermoplastic polyurethane. The bladder element 30 may also be a flexible microlayer membrane that includes alternating layers of a gas barrier polymer material (e.g., a second layer) and an elastomeric material (e.g., a first layer), as disclosed in U.S. patent nos. 6,082,025 and 6,127,026 to Bonk et al, which are hereby incorporated by reference in their entirety. With such alternating layers, the bladder element 30 or any additional bladder element described herein, for example, can have a nitrogen transmission rate of less than 10 cubic centimeters per square meter per atmosphere per day or less than 1 cubic centimeter per square meter per atmosphere per day. Other suitable materials for the bladder element 30 are disclosed in U.S. patent nos. 4,183,156 and 4,219,945 to Rudy, which are hereby incorporated by reference in their entirety. Further suitable materials for the bladder element 30 include thermoplastic films comprising crystalline materials (as disclosed in U.S. patent nos. 4,936,029 and 5,042,176 to Rudy) and polyurethanes comprising polyester polyols (as disclosed in U.S. patent nos. 6,013,340, 6,203,868, and 6,321,465 to Bonk et al), which are incorporated herein by reference in their entirety. Engineering properties such as tensile strength, tensile properties, fatigue characteristics, dynamic modulus, and loss tangent may be considered in selecting a material for the bladder element 30. When the bladder element 30 is formed from a sheet, the thickness of the sheet used to form the bladder element 30 can be selected to provide these characteristics.

The bladder element 30 includes a plurality of cushioning components. More specifically, the bladder element 30 includes

cushioning components

34A, 34B, 34C, 35A, 35B, 35C, and 36. Each of the

cushioning components

34A, 34B, 34C, 35A, 35B, 35C, and 36 includes a closed fluid-filled chamber. Cushioning component 34A includes a fluid-filled chamber 38A. Cushioning component 34B includes a fluid-filled chamber 38B. The cushioning component 34C includes a fluid-filled cavity 38C. Cushioning component 35A includes a fluid-filled chamber 38D. Cushioning component 35B includes a fluid-filled chamber 38E. Cushioning component 35C includes a fluid-filled chamber 38F. Cushioning component 36 includes a fluid-filled chamber 38G.

Cushioning

components

34A, 34B, and 34C each have a single central opening extending completely therethrough. As used herein, a "central opening" need not be positioned at the exact center of the cushioning component. More specifically, if the cushioning component is a regular ring, the cushioning component will have a central axis and the central opening will be centered on the central axis. If the cushioning component is an irregular ring, the central opening does not have a central axis, and although it is defined by the material of the cushioning component, the central opening is therefore not centered within the cushioning component.

Cushioning component 34A has a single central opening 40A extending completely therethrough. The fluid-filled cavity 38A is a continuous fluid-filled cavity that completely surrounds the central opening 40A. Cushioning component 34B has a single central opening 40B extending completely therethrough. The fluid-filled cavity 38B is a continuous fluid-filled cavity that completely surrounds the central opening 40B. Cushioning component 34C has a single central opening 40C extending completely therethrough. The fluid-filled cavity 38C is a continuous fluid-filled cavity that completely surrounds the central opening 40C.

Each of the

cushioning components

34A, 34B, 34C is a ring. As shown, each of the

cushioning components

34A, 34B, 34C is an irregular ring. Optionally, one or more of the

cushioning components

34A, 34B, 34C may be configured as a regular ring. As used herein, an "irregular ring" is a surface or entity (e.g., like a doughnut) formed by a closed shape (e.g., without limitation, a circle, an ellipse, a square, or a rectangle) rotated about a line that lies in the same plane as the closed shape but does not intersect the closed shape, wherein the closed shape varies as it rotates about the line, the distance from the line varies as the closed shape rotates about the line, or both. A "regular ring" is a surface or entity (e.g., like a doughnut) formed by rotation of a closed shape (such as, but not limited to, a circle, oval, square, or rectangle) about a line that lies in the same plane as, but does not intersect, the closed shape, wherein neither the closed shape nor the distance from the line changes as the closed shape rotates about the line.

Fig. 4 is an example of a cushioning component 34AA, which cushioning component 34AA is a regular loop and may be used in place of cushioning component 34A. Cushioning component 34AA is a closed circle in cross-section (and has a flange 79 as described herein) rotated about line L3 shown in fig. 5 to form the ring of fig. 4. Accordingly, cushioning component 34AA is equidistant from line L3 on any cross-section of cushioning component 34AA through a plane including line L3, and thus line L3 is the central axis of cushioning component 34 AA. Alternatively, if cushioning component 34AA is blow-molded, it does not include flange 79.

Fig. 6 is another example of a cushioning component 34BB that may be used in place of cushioning component 34 and cushioning component 34 AA. The cushioning member 34BB is substantially closed rectangular in cross section, and rotates around a line L3 similarly to the cushioning member 34A and is a regular ring. Each of the

cushioning components

34A, 34B, 34C is an irregular ring because none of them is disposed equidistant from the central axis such as line L3. Furthermore, each is an irregular ring because the closed shape of the part in cross-section varies and is not uniform across all cross-sections taken in a plane including the axis through the central opening. For example, as is evident in fig. 2, the cross-section of the cushioning component 34C is wider at the

corners

42A, 42B than along the relatively

straight portions

44A, 44B.

By configuring each of the

cushioning components

34A, 34B, 34C as a regular or irregular ring, a relatively large cushioning area is provided, while the overall height of the cushioning component is relatively small compared to its width. For example, if cushioning component 34A does not have a central opening 40A, it will tend to inflate into a spherical shape, making it much higher in the center. Further, the central opening 40A allows the cushioning component 34A to deflect downward and inward toward the central opening 40A.

The

cushioning components

35A, 35B, and 35C of fig. 2 may be configured differently from the

cushioning components

34A, 34B, and 34C. More specifically, each of the

buffer members

35A, 35B, and 35C has a plurality of connecting pieces 44. As shown in fig. 7 with respect to cushioning component 35A, connector 44 is positioned within outer periphery 45A of cushioning component 35A. Connector 44 connects a first side 50A of cushioning component 35A to a second side 52A of cushioning component 35A opposite first side 50A. In the embodiment of fig. 2, the connector 44 is a tubular post and may be referred to as such. The material of the bladder element 30 forms a tubular column 44. The tubular posts 44 are hollow in that each tubular post includes an opening 46 extending completely through the tubular post 44. The tubular post 44 may be initially formed as a hollow post with the opening 46 extending completely therethrough during the shaping of the bladder element 30 (e.g., by blow molding or thermoforming the bladder element 30). Alternatively, the material of the bladder element 30 may initially extend across the tubular post 44 at the central region 48, as shown in fig. 8. A hole 51, shown in fig. 7, is then punched through the bladder element 30 at the center of each tubular post 44 so that the tubular posts 44 are hollow and the openings 46 extend completely through the tubular posts 44. For example, the bladder element 30 may be formed from a first polymeric sheet 70 and a second polymeric sheet 72 positioned between a first mold half 74 and a second mold half 76 of a mold assembly 78.

Sheets

70, 72 are vacuum formed and thermoformed to

mold surfaces

74A, 76A shown in fig. 13 and to form compression with each other at peripheral flange 79 shown in fig. 3 to form all

cushioning components

34A, 34B, 34C, 35A, 35B and 36. In such an embodiment, the

tabs

70, 72 are initially bonded to one another at the central region 48 of each tubular post 44, as shown in FIG. 8. Similarly, the

sheets

70, 72 are initially bonded to one another in the area of the

central openings

40A, 40B, 40C, and the

central openings

40A, 40B, 40C are punched out.

Tubular posts 44 of

cushioning components

35B and 35C are configured in a manner similar to that described with respect to tubular posts 44 of cushioning component 35A. Cushioning

components

35B and 35C are configured similarly to cushioning component 35A, with tubular posts 44 located within

outer peripheries

45B, 45C of

cushioning components

35B, 35C, respectively, and connecting a first side to a second side of each of

cushioning components

35B, 35C, as shown with respect to cushioning component 35A.

Referring to fig. 2, cushioning component 35C is located in sole structure 16 and heel portion 22 of article of footwear 10. Cushioning component 35C includes extended

tubular portions

60A, 60B, with

tubular portions

60A, 60B extending along perimeter P of sole structure 16 in heel portion 22. More specifically, tubular portion 60A extends along perimeter P at a lateral end 60 of sole structure 16, and tubular portion 60B extends along perimeter P at a medial end 62 of sole structure 16. The height of the

tubular portions

60A, 60B may be higher than the portion of the cushioning component 35C having the tubular post 44, thereby providing greater support and deflection capability at the perimeter P.

The bladder element 30 includes a tubular cushioning member 36, the cushioning member 36 extending lengthwise along a medial end 62 of the sole structure 16 generally at the midfoot portion 20 of the sole structure 16. Cushioning member 36 thereby provides cushioning and support to the arch region of foot 14.

Cushioning member 34A is located between inner end 62 and cushioning member 34B. Cushioning member 34B is located between outer end 60 and cushioning member 34A. Cushioning member 35A is located between inner end 62 and cushioning member 35B. Cushioning member 35B is located between outer end 60 and cushioning member 35A. Cushioning

components

34A and 35A are generally medial of longitudinal centerline L of sole structure 16, and

cushioning components

34B, 35B are generally lateral of longitudinal centerline

L. Cushioning components

34A, 34B, 35A, and 35B are positioned in forefoot portion 18 of sole structure 16. Cushioning member 36 is located between inner end 62 and cushioning member 34C. Cushioning member 34C is located between outer end 60 and cushioning member 36. Cushioning

components

34C and 36 are located in midfoot portion 20 of sole structure 16. Cushioning component 35C is located in heel portion 22 of sole structure 16.

In the embodiment of fig. 2, cushioning component 34A may be referred to as a first cushioning component and cushioning component 35C may be referred to as a second cushioning component. Alternatively, the cushioning component 35A may be referred to as a second cushioning component, the cushioning component 34B may be referred to as a third cushioning component, the cushioning component 35B may be referred to as a fourth cushioning component, and the cushioning component 34C may be referred to as a fifth cushioning component. Any one of the

buffer members

35A, 35B, and 35C may be simply referred to as a buffer member, and any one of the

buffer members

34A, 34B, and 34C may be referred to as an additional buffer member. The cushion member 34A is located rearward of the cushion member 35A. The cushion member 34B is located rearward of the cushion member 35B. The cushion member 34C is located rearward of the cushion member 34B. The cushion member 35C is located rearward of the cushion member 35B.

The

cushioning members

34A, 34B, 34C, 35A, 35B, 35C, and 36 are substantially separated from each other. As used herein, the outer surfaces of adjacent ones of the cushioning components are "substantially separated" from one another if the outer surfaces are connected to one another only by inflation channels or by tubular cushioning components. In other words, adjacent cushioning components may be indirectly connected to each other through channels that establish fluid communication or through tubular cushioning components, but the outer surfaces of adjacent cushioning components are not directly connected to each other, nor are they indirectly connected to each other through webbing formed from the material used to form the cushioning components. Adjacent ones of the

cushioning components

34A, 34B, 34C, 35A, 35B, 35C, and 36 are disconnected from each other along more than fifty percent of their perimeters. Also, the outer surface of any one of the

cushioning components

34A, 34B, 34C, 35A, 35B, 35C, and 36 is not connected to the outer surface of an adjacent cushioning component directly or through webbing. As described herein, adjacent cushioning components are only indirectly connected by channels such as

channels

80A, 80B, 80C, 80D, 80E, and 80F. The bladder element typically has webbing located between the inflated portions. The webbing is an uninflated portion of a polymeric material (e.g., a sheet) used to form the bladder element. The bladder element 30 does not have such webbing, but rather provides a gap between the length of each adjacent cushioning component. The cushioning component provides cushioning support in the bladder element 30 where it is desired to be positioned under the foot 14, while the polymeric material is not present in other areas to minimize material waste and enhance flexibility as described herein.

The

channels

80A, 80B, 80C, 80D, 80E, and 80F connect

adjacent cushioning components

34A, 34B, 34C, 35A, 35B, 35C, and 36 along portions of their peripheries to establish fluid communication between the connected

adjacent cushioning components

34A, 34B, 34C, 35A, 35B, 35C, and 36 when the

channels

80A, 80B, 80C, 80D, 80E, and 80F are unsealed. In the embodiment of FIG. 2, channel 80A connects cushioning component 34A to cushioning component 35A. Channel 80B connects cushioning component 34B to cushioning component 35B. Channel 80C connects cushioning component 34C to cushioning component 34B. Channel 80D connects cushioning component 34A to cushioning component 34B. Channel 80E connects cushioning component 34C to cushioning component 35C. Passage 80F connects cushioning component 36 to passage 80E, thereby placing cushioning component 36 in fluid communication with

cushioning components

34C and 35C. One or more of the

passages

80A, 80B, 80C, 80D, 80E, and 80F may be sealed to isolate adjacent cushioning components connected by the sealed passages from fluid communication with each other.

The bladder element 30 includes an inflation port 82 disposed at a forward-most perimeter 83 of the bladder element 30. Alternatively, the inflation port 82 can be disposed at another location along the periphery of the bladder element 30. In the illustrated embodiment, the inflation port 82 is connected to the cushioning components 35A and is in fluid communication with all of the

cushioning components

34A, 34B, 34C, 35A, 35B, 35C, and 36 via the

passages

80A, 80B, 80C, 80D, 80E, and 80F when the

passages

80A, 80B, 80C, 80D, 80E, and 80F are unsealed.

The

channels

80A, 80B, 80C, 80D, 80E, and 80F and the inflation port 82 are formed simultaneously with the

cushioning components

34A, 34B, 34C, 35A, 35B, 35C, and 36 by thermoforming or blow molding the polymeric material used to form the bladder element 30. Accordingly, the

cushioning components

34A, 34B, 34C, 35A, 35B, 35C, 36, the

channels

80A, 80B, 80C, 80D, 80E, and 80F, and the inflation port 82 are formed simultaneously with each other and of the same material. The inflation port 82 and the

channels

80A, 80B, 80C, 80D, 80E, and 80F are positioned and configured to enable the bladder element 30 to inflate and maintain different fluid pressures in different portions of the bladder element 30.

For example, the bladder element 30 may be first inflated to a first inflation pressure through the inflation port 82. Next, the channel 80E between the

cushioning components

34C and 35C may be sealed (i.e., closed) closed, such as by heat bonding the walls of the channel 80E together to form a seam 84A. The sealing of the passage 80E is indicated at the seam 84A of fig. 9. Closed channel 80E forms the final first inflation pressure of cushioning component 35C in heel portion 22. The inflation fluid in the remainder of the bladder element 30 (i.e., all of the bladder element 30 between the inflation port 82 and the closed channel 80E, referred to as the first remaining unsealed portion) can be released through the inflation port 82, or can remain in the bladder element 30 as inflation continues. The first remaining unsealed portion of the bladder element 30 is then further inflated through the inflation port 82 to a final second inflation pressure. All portions of the bladder element 30 to the seam 84A will thus be at the second inflation pressure. Optionally, the second channel 80F may then be sealed, such as by heat bonding the walls of the channel 80F together to form a seam 84B. The final second inflation pressure of cushioning members 36 is established, for example, by thermal bonding of closed passages 80F. The inflation fluid in the remaining portion of the bladder element 30 between the

seams

84A, 84B and the inflation port 82 (referred to as a second remaining unsealed portion) may be released through the inflation port 82 or may remain in the bladder element 30 as inflation continues. The second remaining unsealed portion of the bladder element 30 can then be further inflated through the inflation port 82 to a final third inflation pressure. The inflation port 82 can then be closed, for example, by thermally bonding the walls of the inflation port 82 to one another. This establishes the third inflation pressure as the final inflation pressure of

cushioning components

34A, 34B, 34C, 35A, and 35B. Optionally, additional subsequent inflation may occur with any or all of the remaining

passages

80A, 80B, 80C, and 80D sealed at

seams

84C, 84D, 84E, and 84F, respectively, to establish different inflation pressures in the different remaining

cushioning components

34A, 34B, 34C, 35A, and 35B. In yet another alternative, none of the

channels

80A, 80B, 80C, 80D, 80E, and 80F may be closed, or one or more of the

channels

80A, 80B, 80C, 80D, 80E, and 80F may be closed, depending on the desired final inflation pressure and the desired capacity of fluid communication within the bladder element 30, but the inflation pressures in the different portions separated by the closed channels may be the same, such that the closed channels function only to prevent fluid communication between the portions separated by the closed channels.

In the arrangement of the bladder element 30 with the

cushioning components

34A, 34B, 34C, 35A, 35B, and 36 as described, various gaps are provided between

adjacent cushioning components

34A, 34B, 34C, 35A, 35B, and 36. For example,

cushioning components

34A and 35A are substantially separated from each other and

cushioning components

34B and 35B are substantially separated from each other such that gap G1 extends from outer end 60 to inner end 62 between substantially separated

cushioning components

34A and 35A and between substantially separated

cushioning components

34B and 35B. The gap G1 is traversed only by the

channels

80A, 80B. The

channels

80A and 80B are relatively narrow in width compared to the

cushioning components

34A, 34B, 35A, 35B and extend generally longitudinally between the

cushioning components

34A, 34B, 35A, 35B. Accordingly, the

channels

80A, 80B do not significantly reduce the flexibility of the sole structure 16 in the front-to-rear direction at the gap G1.

Similarly, additional gap G2 is provided to extend from outer end 60 to inner end 62 between substantially separated

adjacent cushioning components

36 and 34A and between substantially separated

adjacent cushioning components

34C and 34B. Gap G2 is traversed only by channel 80C. The channel 80C is relatively narrow in width compared to the

cushioning components

34A, 34B, 34C, and 36, and extends generally longitudinally between the

cushioning components

34B, 34C. Accordingly, the channel 80C does not significantly reduce the flexibility of the sole structure 16 in the front-to-rear direction at the gap G2.

Another gap G3 extends generally longitudinally between substantially

separate cushioning components

35A and 35B and continues between substantially

separate cushioning components

34A, 34B, interrupted only by channel 80D. The gap G3 allows the sole structure 16 to increase flexibility in the lateral direction between the

cushioning components

34A, 34B and between the

cushioning components

35A, 35B. The width of channel 80D is relatively narrow in comparison to

cushioning components

34A, 34B, 35A, 35B, and therefore does not significantly reduce the flexibility of the sole structure in the lateral direction.

Accordingly, gaps G1 and G2 serve as flexion regions where sole structure 16 flexes in the fore-aft direction, and gap G3 serves as flexion regions where sole structure 16 flexes in the lateral direction. Any foam 32 that covers the outer surfaces of the

cushioning components

34A, 34B, 34C, 35A, 35B, 35C, and 36 and fills the gaps G1, G2, G3 can be configured to have greater flexibility than the inflated bladder element 30. For example, fig. 10 shows foam 32 covering

outer surfaces

90A, 90B of

cushioning components

34B, 35B.

Fig. 11 illustrates another embodiment of a bladder element 130 that can be used in place of the bladder element 30 in the sole structure 16 of fig. 1. The bladder element 130 has many of the same features as described with respect to the bladder element 30 and these features are described with the same reference numerals as shown and described with reference to fig. 2. The bladder element 130 includes

cushioning components

135A, 135B, and 135C in place of the

cushioning components

35A, 35B, and 35C, respectively. Each of

cushioning components

135A, 135B, and 135C may be referred to as a second cushioning component and have a plurality of connections 144 positioned within an outer perimeter of the second cushioning component and connecting a first side of the cushioning component to a second side of the cushioning component. For example, as shown with respect to cushioning component 135A in fig. 12. Link 144 is a tether of tether element 192. Tether element 192 includes a first panel 194A attached to an inner surface of upper panel 170 of cushioning component 135A and a second panel 194B attached to an inner surface of lower panel 172 of cushioning component 135A. For example, adhesive bonding or thermal bonding may be used to secure the first and

second panels

194A, 194B to the upper and

lower sheets

170, 172. Tether 144 connects first plate 194A to second plate 194B and thereby connects first side 150 of cushioning component 135A to second side 152 of cushioning component 135A. Tether element 192 (including tether 144 and

plates

194A, 194B) is located within fluid-filled chamber 138D of cushioning component 135A. The inner cavity 138D is inflated with fluid, which exerts an outward force on the

sheets

170, 172 and the

plates

194A, 194B. Tether 144 extends across interior cavity 138D and is placed in tension by the outward force of the pressurized fluid on

sheets

170, 172, thereby preventing outward expansion of cushioning component 135A and maintaining the desired shape of cushioning component 135A. The peripheral adhesive connects the

polymer sheets

170, 172 to form a seal at the peripheral flange 145A that prevents fluid from escaping, and the tether element 192 prevents the cushioning component 135A from expanding or otherwise inflating outward due to the pressure of the fluid. That is, tether element 192 effectively limits the expansion of interior cavity 138D to maintain the desired shape of the surface of cushioning component 135A.

The tether 144 may be formed of any generally elongated material exhibiting a length that is significantly greater than the width and thickness. Accordingly, suitable materials for the tether 144 include various strands, filaments, fibers, yarns, cords, and ropes made of rayon, nylon, polyester, polyacrylic, silk, cotton, carbon, glass, aramid (e.g., para-aramid), ultra-high molecular weight polyethylene, liquid crystal polymer, copper, aluminum, and steel. Filaments have an indefinite length and may be used alone as tethers 144, while fibers have a relatively short length and are generally subjected to a spinning or twisting process to produce strands of the appropriate length. The individual filaments used in the tether 144 may be formed from a single material (i.e., a single component filament) or from multiple materials (i.e., a bi-component filament). Similarly, different filaments may be formed of different materials. As an example, the yarns used as tethers 144 may include filaments that are each formed of a common material, may include filaments that are each formed of two or more different materials, or may include filaments that are each formed of two or more different materials. Similar concepts are applicable to cords, cables or ropes. For example, the thickness of the tether 144 may also vary significantly from 0.03 millimeters to over 5 millimeters. The tether 144 may have various shapes in cross-section perpendicular to its length (e.g., circular, square, rectangular, oval, or other closed shapes in cross-section). The tethers 144 are arranged in rows that extend longitudinally along the length of the

panels

194A and 194B. Only one row is shown in the cross-sectional view of fig. 12.

Cushioning

components

135B and 135C are configured in a similar manner, and tether elements 192 within

cushioning components

135B and 135C are shown in hidden lines in fig. 11. Cushioning

components

135A, 135B, and 135C are substantially separate from cushioning components 134A, 134B, 134C, and 136 and from each other in substantially the same manner as described with respect to

cushioning components

35A, 35B, and 35C of fig. 2.

While several modes for carrying out many aspects of the present teachings have been described in detail, those familiar with the art to which these teachings relate will recognize various alternative aspects for practicing the present teachings that are within the scope of the appended claims. It is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative only and not limiting.

Claims

1. An article of footwear comprising:

a sole structure having a bladder element that includes a plurality of cushioning components, each of the cushioning components including an enclosed fluid-filled chamber; wherein the buffer member includes:

a first cushioning component having:

a single central opening extending completely through the first cushioning component, wherein the single central opening is free of foam or other structure; and

a continuous fluid-filled cavity surrounding the central opening; and

a second cushioning component having a plurality of connectors positioned within an outer periphery of the second cushioning component and connecting a first side of the second cushioning component to a second side of the second cushioning component, the second side opposite the first side;

wherein the cushioning components are spaced apart from each other such that an outer surface of each of the cushioning components is substantially separated from an outer surface of an adjacent cushioning component,

wherein a first plurality of the plurality of connectors is a tubular post, and wherein at least one of the tubular posts includes an opening extending completely through the at least one of the tubular posts.

2. The article of footwear of claim 1, wherein a second plurality of connectors of the plurality of connectors is a tether positioned within the fluid-filled cavity of the second cushioning component.

3. The article of footwear of claim 1, wherein:

the buffer parts comprise a third buffer part and a fourth buffer part;

the third buffer member includes:

a single central opening extending completely through the third cushioning component; and

a continuous fluid-filled cavity surrounding the central opening of the third cushioning component;

the fourth cushioning component comprising a plurality of connectors positioned within an outer perimeter of the fourth cushioning component and connecting a first side of the fourth cushioning component to a second side of the fourth cushioning component, the second side being opposite the first side of the fourth cushioning component;

the first cushioning component is positioned between a medial end of the sole structure and the third cushioning component;

the third cushioning component is positioned between a lateral end of the sole structure and the first cushioning component;

the second cushioning component is positioned between the medial end of the sole structure and the fourth cushioning component; and is

The fourth cushioning component is positioned between the lateral end of the sole structure and the second cushioning component.

4. The article of footwear of claim 3, wherein:

the cushioning components include a fifth cushioning component having:

a single central opening extending completely through the fifth cushioning component; and

a continuous fluid-filled cavity surrounding the central opening of the fifth cushioning component;

the fifth cushioning component is located rearward of the third cushioning component and is positioned within a midfoot portion of the sole structure.

5. The article of footwear of any of claims 1-4, wherein the cushioning component includes a tubular cushioning component that extends lengthwise along a medial end of the sole structure in a midfoot portion of the sole structure.

6. The article of footwear of any of claims 1-4, wherein:

both the first cushioning component and the second cushioning component are positioned in a forefoot portion of the sole structure; and is

The second cushioning component is positioned forward of the first cushioning component.

7. The article of footwear of claim 5, wherein:

8. The article of footwear of any of claims 1-4 and 7, wherein the bladder element includes a channel connecting adjacent cushioning components and establishing fluid communication between the adjacent cushioning components.

9. The article of footwear recited in claim 5, wherein the bladder element includes a channel that connects adjacent cushioning components and establishes fluid communication between the adjacent cushioning components.

10. The article of footwear recited in claim 6, wherein the bladder element includes a channel that connects adjacent cushioning components and establishes fluid communication between the adjacent cushioning components.

11. The article of footwear of claim 8, wherein:

at least one of the channels is sealed such that the adjacent cushioning components connected by the sealed channel are isolated from fluid communication with each other by the sealed channel.

12. The article of footwear of claim 11, wherein the adjacent cushioning components connected by the sealed channel have different inflation pressures.

13. The article of footwear of any of claims 1-4, 7, and 9-12, wherein a gap is disposed between adjacent cushioning components and extends from a medial end to a lateral end of the sole structure.

14. The article of footwear of claim 5, wherein a gap is disposed between adjacent cushioning components and extends from a medial end to a lateral end of the sole structure.

15. The article of footwear of claim 6, wherein a gap is disposed between adjacent cushioning components and extends from a medial end to a lateral end of the sole structure.

16. The article of footwear of claim 8, wherein a gap is disposed between adjacent cushioning components and extends from a medial end to a lateral end of the sole structure.

17. The article of footwear of any of claims 1-4, 7, 9-12, and 14-16, wherein the first cushioning component is a regular ring or an irregular ring.

18. The article of footwear according to claim 5, wherein the first cushioning component is a regular ring or an irregular ring.

19. The article of footwear according to claim 6, wherein the first cushioning component is a regular ring or an irregular ring.

20. The article of footwear according to claim 8, wherein the first cushioning component is a regular ring or an irregular ring.

21. The article of footwear according to claim 13, wherein the first cushioning component is a regular ring or an irregular ring.

22. The article of footwear recited in claim 1, wherein the second cushioning component is located in a heel portion of the article of footwear and includes a tubular portion extending along a periphery of the sole structure in the heel portion.

23. An article of footwear comprising:

a sole structure having a bladder element including cushioning components, wherein the cushioning components are all spaced apart from one another such that an outer surface of each of the cushioning components is substantially separated from an outer surface of an adjacent cushioning component; wherein the buffer member includes:

a first cushioning component having:

a continuous fluid-filled cavity surrounding the central opening; and

a second cushioning component having a plurality of connectors and a fluid-filled cavity, the plurality of connectors being tubular posts positioned within an outer periphery of the second cushioning component and connecting a first side of the second cushioning component to a second side of the second cushioning component, the second side being opposite the first side, such that the fluid-filled cavity surrounds the tubular posts; and is

Wherein at least one of the tubular posts includes an opening extending completely through the tubular post.

24. The article of footwear recited in claim 23, wherein the bladder element further includes a channel connecting the second cushioning component to the first cushioning component.

25. The article of footwear recited in claim 24, wherein the channel is sealed to isolate the fluid-filled cavity of the second cushioning component from fluid communication with the fluid-filled cavity of the first cushioning component through the sealed channel.

26. The article of footwear of any of claims 23-25, wherein the first cushioning component and the second cushioning component are located within one of a forefoot portion of the sole structure and a heel portion of the sole structure.

27. The article of footwear of claim 26, wherein:

the second cushioning component is located in the heel portion of the sole structure and includes a tubular portion that extends along an edge of the sole structure in the heel portion.

28. A method of manufacturing a sole structure for an article of footwear, comprising:

forming a bladder element having a plurality of cushioning components, each of the cushioning components including a fluid-filled cavity;

wherein the buffer member includes:

a first cushioning component having:

a continuous fluid-filled cavity surrounding the central opening; and

a second cushioning component having a plurality of connectors positioned within an outer periphery of the second cushioning component and connecting a first side of the second cushioning component to a second side of the second cushioning component, the second side opposite the first side; wherein the second cushioning component is substantially separate from the first cushioning component and the cushioning components are all spaced apart from each other such that an outer surface of each of the cushioning components is substantially separate from an outer surface of an adjacent cushioning component,

wherein:

the connecting piece is a hollow pipe; and is

Shaping the bladder element comprises:

positioning a polymer sheet in a mold assembly; and

thermoforming the polymeric sheet in the mold assembly to include a tubular post; and the method further comprises:

punching holes at the tubular post within the polymeric sheet such that the tubular post is hollow.

29. The method of claim 28, wherein the forming the bladder element comprises:

forming channels connecting adjacent cushioning components to establish fluid communication therebetween;

a shaped inflation port disposed at a periphery of the bladder element and in fluid communication with the adjacent cushioning component via the channel; and is

The method further comprises:

inflating the bladder element to a first inflation pressure through the inflation port;

closing one of the channels to form a first sealed portion of the bladder element; and

inflating the remaining unsealed portion of the bladder element to a second inflation pressure through the inflation port, thereby establishing different inflation pressures in different cushioning components separated from each other by the closed channel.

30. The method according to any one of claims 28-29, further comprising:

at least partially covering an outer surface of at least one of the cushioning components with foam.