KR20230142782A - Sole structure for footwear articles - Google Patents

Abstract

A sole structure for an article of footwear includes an upper cushion extending from a first end to a second end; a lower cushion including a tray extending toward a second end of the upper cushion and having a first segment attached to the upper cushion adjacent the first end; and at least one bladder disposed between the tray of the lower cushion and the upper cushion.

Description

Sole structure for footwear articles

Cross-references to related applications:

This PCT International application is filed under 35 U.S.C. U.S. Provisional Patent Application Serial No. 63/146,953 (filed February 8, 2021), the disclosure of which is incorporated herein by reference in its entirety. Priority is claimed for U.S. Patent Application Serial No. 17/666,337 (filing date: February 7, 2022), which claims priority under §119(e).

The present disclosure relates generally to articles of footwear, and more specifically to sole structures for articles of footwear.

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

Articles of footwear typically include an upper structure and a sole structure. The upper may be formed of any material(s) suitable for receiving, securing, and supporting the foot on the sole structure. The upper may work with laces, straps, or other fasteners to adjust its fit around the foot. The bottom portion of the upper closest to the plantar surface of the foot is attached to the sole structure.

Sole structures generally include a layered arrangement extending between the ground surface and the upper. For example, the sole structure includes a midsole and an outsole. The midsole is generally placed between the outsole and the upper to provide cushioning for the foot. The midsole may include a pressurized fluid-filled chamber that elastically compresses under an applied load to cushion the foot by attenuating ground-reaction forces. The outsole provides abrasion resistance and traction with the ground, and may be formed of rubber or other materials that provide durability and wear-resistance as well as improve traction with the ground. .

The drawings described herein are for illustrative purposes only of selected configurations rather than all possible implementations and are not intended to limit the scope of the disclosure.
1 is a side view illustrating the lateral side of an article of footwear including an example sole structure according to the present disclosure.
Figure 2 is a side view showing the medial side of the article of footwear of Figure 1;
FIG. 3 is an exploded perspective view showing the outer side of the sole structure of FIG. 1 viewed from the top.
FIG. 4 is an exploded perspective view showing the inside of the sole structure of FIG. 1 viewed from the bottom.
FIG. 5 is a bottom plan view showing the sole structure of FIG. 1.
FIG. 6 is a cross-sectional view of the sole structure of FIG. 1 taken along line 6-6 in FIG. 5.
FIG. 7 is a cross-sectional view of the sole structure of FIG. 1 taken along line 7-7 in FIG. 5.
FIG. 8 is a cross-sectional view of the sole structure of FIG. 1 taken along line 8-8 in FIG. 5.
FIG. 9 is a cross-sectional view of the sole structure of FIG. 1 taken along line 9-9 in FIG. 5.
Figure 10 is a top plan view showing a cushioning element of the sole structure of Figure 1;
Corresponding reference numerals indicate corresponding parts throughout the drawings.

Example configurations will now be more fully described 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 skilled in the art. To provide a thorough understanding of the subject matter of the disclosure, specific details, such as examples of specific components, devices, and methods, are set forth. It is understood by those skilled in the art that specific details do not have to be used, example configurations may be implemented in many different forms, and specific details and example configurations should not be construed as limiting the scope of the present disclosure. This will be obvious to those skilled in the art.

The terminology used herein is for the purpose of describing specific example configurations and is not intended to be limiting. As used herein, singular nouns are intended to include the plural form as well, unless the context clearly indicates otherwise. The terms “comprise,” “comprising,” “having,” “comprising,” and “having” are inclusive and accordingly refer to features, steps, operations, elements and/or components. Specifies the presence, but does not exclude the presence or addition of one or more other features, steps, operations, elements, components and/or groups thereof. The method steps, processes and acts described herein should not be construed as requiring performance in the specific order in which they are discussed or illustrated unless specifically identified as such. Additional or alternative steps may be used.

When an element or layer is “on,” “connected to,” “connected to,” “attached to,” or “coupled to” another element or layer, it is directly on top of or attached to another element or layer. They may be linked, connected, attached, or joined, or there may also be intermediate intervening elements or layers. In contrast, an element may be referred to as being "directly above," "directly associated with," "directly connected to," "directly attached to," or "directly coupled to" another element or layer. In some cases, intermediate intervening elements or layers may not be present. Other words used to describe relationships between elements should be interpreted in a similar manner (e.g., “between” vs. “directly between…,” “adjacent” vs. “immediately adjacent,” etc.). As used herein, the term “and/or” or “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 used only to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other number-related terms do not imply sequence or order unless clearly indicated by context. Accordingly, a first element, component, region, layer or section discussed below may be called a second element, component, region, layer or section without departing from the teachings of the example configurations.

In one configuration, a sole structure for an article of footwear is provided, comprising: an upper cushion extending from a first end to a second end; a lower cushion including a tray extending toward a second end of the upper cushion and having a first segment attached to the upper cushion adjacent the first end; and at least one bladder disposed between the tray of the lower cushion and the upper cushion.

Implementations of this aspect of the disclosure may include one or more of the following optional features. The plate may be disposed between at least one bladder and the top cushion. A first side of at least one bladder may be attached to the tray, and an opposing second side of at least one bladder may be attached to the plate.

In one configuration, the lower cushion may include a support portion attached to the upper cushion. In this configuration, the tray can be cantilevered from the support.

The at least one bladder may include a first bladder disposed on a medial side of the sole structure and a second bladder disposed on a lateral side of the sole structure. The tray may include a first socket accommodating the first bladder and a second socket accommodating the second bladder. Additionally, or alternatively, at least one of the upper cushion and the lower cushion may include a peripheral side having a plurality of dimples. Dimples may be arranged in multiple columns and rows.

The outsole may be disposed on an opposite side of the lower cushion from at least one bladder. Additionally, or alternatively, the tray of the lower cushion may include a foam material.

In another configuration, a sole structure for an article of footwear is provided, and includes a cushion arrangement, the cushion arrangement having (i) a top surface and a bottom surface formed on opposite sides of the top surface. upper cushion; (ii) a lower cushion having a bottom surface and an upper surface formed on an opposite surface of the lower surface and opposing the lower surface of the upper cushion; and (iii) a socket formed between the lower surface of the upper cushion and the upper surface of the lower cushion. At least one bladder is disposed inside the socket between the upper and lower cushions.

Implementations of this aspect of the disclosure may include one or more of the following optional features. The plate may be disposed between at least one bladder and the top cushion. A first side of the at least one bladder may be attached to the lower cushion and an opposing second side of the at least one bladder may be attached to the plate.

In one configuration, the lower cushion includes a support portion attached to the upper cushion; and a tray cantilevered and supported from this support portion. The tray may define the lower portion of the socket.

The at least one bladder may include a first bladder disposed on a medial side of the sole structure and a second bladder disposed on a lateral side of the sole structure. The upper surface of the lower cushion may include a first socket receiving a first bladder and a second socket receiving a second bladder. Additionally, or alternatively, at least one of the upper cushion and the lower cushion may include a peripheral surface having a plurality of dimples. The dimples of the plurality of dimples may be arranged in a plurality of columns and rows.

The outsole may be disposed adjacent the bottom surface of the lower cushion. Additionally, or alternatively, at least one of the upper cushion and the lower cushion may include a foam material.

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

Referring to FIG. 1 , an article of footwear 10 includes a sole structure 100 and an upper 200 attached to the sole structure 100 . The footwear 10 may further include an anterior end 12 associated with the most forward point of the footwear 10 and a posterior end 14 corresponding to the rearmost point of the footwear 10 . As shown in FIG. 5 , the longitudinal axis A ₁₀ of the footwear 10 extends parallel to the ground surface along the length of the footwear 10 from the front end 12 to the rear end 14 and generally extends along the length of the footwear 10. ) is divided into the inner surface (16) and the outer surface (18). Accordingly, the inner surface 16 and the outer surface 18 respectively correspond to opposite sides of the footwear 10 and extend from the front end 12 to the rear end 14 . As used herein, the longitudinal direction refers to the direction extending from the anterior end 12 to the posterior end 14, while the lateral direction refers to the direction transverse to the longitudinal direction and along the medial side 16. It indicates the direction extending from to the outer surface (18).

Article of footwear 10 may be divided into one or more regions. The regions may include a forefoot region 20, a mid-foot region 22, and a heel region 24. The forefoot region 20 may be subdivided into a toe portion _20T corresponding to the phalanx and a ball portion _20B associated with the metatarsal bone of the foot. The midfoot region 22 may correspond to the arch of the foot, and the heel region 24 may correspond to the rear portion of the foot including the calcaneus bone.

The sole structure 100 includes a midsole 102 configured to provide cushioning and support; and an outsole 104 that defines the ground-engaging surface of the sole structure 100 (i.e., the surface in contact with the ground during the stance phase of the gait cycle). Unlike conventional sole structures that include an integrated midsole and outsole, the sole structure 100 of the present disclosure is constructed as a composite structure that includes a plurality of components bonded together. For example, midsole 102 may include a resilient cushioning element or cushioning arrangement 106; one or more bladders (108); and plate 110. Additionally, outsole 104 may include a plurality of outsole fragments attached to midsole 102 to provide area traction and abrasion resistance.

1 and 2, the cushioning element 106 of the midsole 102 extends from a first end 112 at the front end 12 of the footwear 10 to a second end 114 at the rear end 14 of the footwear 10. ) extends to Here, second end 114 may define a protrusion 116 extending beyond upper 200 at rear end 14 . Additionally, the cushioning element 106 includes a top side 118 opposite the upper 200 and defining the profile of the footbed of the sole structure 100; From this top side 118 a bottom side 120 formed on the opposite side of the cushioning element 106 and defining the profile of the ground-contacting surface of the sole structure 100; and an outer peripheral side 122 extending from the top surface 118 to the bottom surface 120 and defining an outer peripheral profile of the sole structure 100.

Optionally, the peripheral side 122 of the cushioning element 106 may include a plurality of dimples 124 arranged between the top surface 118 and the bottom surface 120 along the heel region 24. In the example shown, the dimples 124 are arranged as an array comprising a plurality of rows and columns of these dimples 124 . The dimples 124, when included, direct airflow along the peripheral side 122 to minimize drag as the article of footwear 10 moves through the swing phase of the gait cycle. Turbulence improves the aerodynamics of the sole structure.

As explained in more detail below, the cushioning element 106 includes a receiving portion 126 formed on the inside of the cushioning element 106 between the top surface 118 and the bottom surface 120 in the forefoot region 20 ( receptacle). The receiving portion 126 is configured to receive and support one or more bladders 108 inside the cushioning element 106. In other words, the cushioning element 106 extends above bladders 108 (i.e., between bladders 108 and upper 200) and below bladders 108 (i.e., between bladders 108). [between 108 and outsole 104] extends.

Although the cushioning element 106 may be formed as a unitary structure comprising a homogeneous elastomeric material, the cushioning element 106 of the examples herein may be defined in terms of a plurality of parts or sub-components. For example, cushioning element 106 may include an upper cushioning member or cushion 130 disposed adjacent upper 200; and a lower cushioning member or cushion 132 disposed adjacent to the outsole 104. The upper cushioning member 130 extends continuously from the first end 112 of the cushioning element 106 to the second end 114 of the cushioning element 106. Conversely, the lower cushioning member 132 can be subdivided into segments and an anterior segment 134 disposed at the first end 112 of the cushioning element 106 and the cushioning element 106 It includes a posterior segment 136 disposed at the second end 114 of. As discussed in more detail below, the anterior segment 134 is spaced apart from the posterior segment by a gap 138 extending from the medial surface 16 to the lateral surface 18 in the midfoot region 22. It can be.

Now, referring to FIGS. 3-9, upper cushioning member 130 extends continuously from first end 112 of cushioning element 106 to second end 114 of cushioning element 106. The upper cushioning member 130 has an upper surface 118 of the cushioning element 106, and a lower side 140 formed on an opposite surface of the upper cushioning member 130 than the upper surface 118. Includes. The upper portion of the outer peripheral side 122 connects the upper surface 118 to the lower surface 140. As shown in FIG. 3 , top surface 118 of upper cushioning member 130 defines insole 142 of sole structure 100 . As shown in FIG. 4 , the lower surface of the upper cushioning member 130 has an upper pocket portion 144 configured to receive the upper portion of the plate 110 when the sole structure 100 is assembled. Includes.

The upper cushioning member 130 defines the upper portion 116a of the posterior projection 116. As shown, upper portion 116a is formed where top surface 118 and peripheral side 122 extend beyond insole 142 at second end 114. Here, the gap between the portion of the outer peripheral side 122 on the inner side 16 and the portion of the outer peripheral side 122 on the outer side 18 is along the direction from the insole 142 to the second end 114. Defines the width of the tapered protrusion 116. In a similar manner, the top surface 118 and the bottom surface 140 of the upper cushioning member 130 have a protrusion 116 having a tapering thickness along the direction from the insole 142 to the second end 114. To provide , they converge with each other.

Still referring to FIGS. 3-9, lower cushioning member 132 and its segments 134, 136 may be described as comprising a bottom surface 120 of cushioning element 106. Additionally, the segments 134 and 136 cooperate to define an upper side 150 of the lower cushioning member 132, which is formed on an opposite side of the lower cushioning member 132 than the bottom surface 120. can do. Lower portions of the outer peripheral side 122 connect the lower surface 120 and the upper surface 150 along each of the segments 134 and 136. When sole structure 100 is assembled, upper surface 150 of lower cushioning member 132 is attached to lower surface 140 of upper cushioning member 130 to form cushioning element 106.

The upper surface 150 of the lower cushioning member 132 includes a lower pocket portion 152 configured to receive the upper portion of the plate 110 when the sole structure 100 is assembled. Since the lower cushioning member 132 can be formed as a fragmentary structure including a front segment 134 and a rear segment 136 that are spaced apart from each other by the gap 138, the lower pocket portion 152 A first portion may be formed within the upper surface 150 of the front segment 134 and a second portion of the lower pocket portion 152 may be formed within the upper surface of the rear segment 136.

The front segment 134 of the lower cushioning member 132 is disposed adjacent the first end 112 of the cushioning element 106. Front segment 134 extends from first end 112 through forefoot region 20 to a terminal end 154 adjacent to and opposite midfoot region 22 . The anterior segment 134 has a support portion 156 extending from the first end 112 through the toe portion _20T and from the support portion 156 through the cheek portion _20B to a distal end 154. It includes a tray 158 extending to ). Generally, the thickness of support portion 156 extends from top surface 150 to bottom surface 120 such that support portion 156 provides cushioning and support through toe portion _20T . In contrast, the tray 158 is formed by a portion of the front segment 134 having a reduced thickness relative to the support portion 156. Tray 158 extends from the posterior wall of support portion 156 to the free-hanging distal end 154 of anterior segment 134. Accordingly, the tray 158 can be described as being cantilevered from the back wall of the support portion 156.

Tray 158 includes one or more recessed sockets 160 formed in upper surface 150 of cushioning element 106. Each of the one or more sockets 160 is configured to receive a corresponding one of the one or more bladders 108 inside the front segment 134 . Accordingly, sockets 160 cooperate with plate 110 and/or upper cushioning member 130 to define a receiving portion 126 of cushioning element 106, as previously discussed. In the example shown, tray 158 is positioned on the upper surface (158) so that when sole structure 100 is assembled, bladders 108 are seated flush with upper surface 150 of lower cushioning member 132. It includes a pair of concavely formed sockets 160 starting from 150. Here, a first of the sockets 160 is disposed adjacent to the inner surface 16 of the sole structure 100 in the ball portion _20B , and a second socket of the sockets 160 is disposed in the ball portion (20B). 20 _B ) is disposed adjacent to the outer surface 18 of the sole structure 100. As shown, when sole structure 100 is assembled, sockets 160 are lateral and medial so that bladders 108 appear uncontracted along distal end 154 and faces 16, 18. It is exposed at the distal end 154 along the peripheral sides 122.

Optionally, the sockets 160 may extend at least partially inward to the rear side wall portion of the support portion 156, which includes a support portion extending at least partially between the inner socket 160 and the outer socket 160. A peninsular region 162 is defined within the posterior side wall portion of 156). Here, the peninsula region 162 may include an opening 164 extending through the thickness of the front segment 134 from the top surface 150 to the bottom surface 120. Distal end 154 may also include a tapered notch 166 extending between sockets 160 across tray 158 and opposite peninsula region 162. Here, when a torsional load is applied to the tray 158 (i.e., during a pivoting or cutting operation), the notch 166 and the hollow peninsula region 162 cooperate to cause the sockets 160 of the tray 158 to interact with each other. It moves relative to the liver.

3-9, the rear segment 136 of the lower cushioning member 130 is opposite the front segment 134 in the midfoot region 22 from the second end 114 of the cushioning element 106. It extends through the heel region 24 to the distal end 168. A portion of the upper surface 150 of the lower cushioning member 132 defined by the rear segment 136 defines a portion of the lower pocket portion 152 in the midfoot region 22 and heel region 24. The lower surface 120 of the posterior segment 136 forms a convex surface with continuous curvature from the second end 114 to the distal end 168. Accordingly, posterior segment 136 is configured to provide rolling and continuous contact during the heel-strike phase of the gait cycle. Here, the rear segment 136 forms the lower part 116b of the projection 116 at the second end 114 of the cushioning element 106. As shown in Figures 1 and 2, the curved bottom surface 120 of the lower cushioning member 132 converges with the inclined top surface 118 of the upper cushioning member 130, forming an insole ( It provides a thickness T ₁₁₆ that tapers along the direction from 142) to the second end 114.

Posterior segment 136 includes an elongated channel 170 formed in bottom surface 120 and extending from distal end 168 of posterior segment 136 into heel region 24 . Channel 170 has a tapered or triangular cross-section between bottom surface 120 and top surface 150 extending from bottom surface 120 to an apex. Channel 170 is positioned at the distal end 168 of the rear segment 136 such that the channel 170 defines a notch 172 extending from the top surface 150 to the bottom surface through the distal end 168. It is formed by passing through. Channel 170 and notch 172 cooperate to form medial and lateral lobes 174 that extend along the length of posterior segment 136 and can be articulated.

As described above, the components 132, 134, 136 of the cushioning element 106 are formed of an elastomeric material, such as foam or rubber, to impart properties of cushioning, sensitivity and energy distribution to the wearer's foot. . In the example shown, the upper cushioning member 130 includes a first foam material, the front segment 134 of the lower cushioning member 132 includes a second foam material, and the rear segment 134 of the lower cushioning member 132 Segment 136 includes a third foam material. For example, the upper cushioning member 130 and the front segment 134 may include a first foam material that provides greater cushioning to impart a distribution, while the rear segment 136 The heel region 24 of the structure 100 includes a foam material with greater stiffness to provide increased stability.

Exemplary elastomeric materials of cushioning element 106 may include materials based on foaming or molding one or more elastomers (eg, thermoplastic elastomers (TPE)). The one or more polymers may include aliphatic polymers, aromatic polymers, or mixtures of the two; and may include homopolymers, copolymers (including terpolymers), or mixtures of the two.

In some embodiments, the one or more polymers may include olefin homopolymers, olefin copolymers, or combinations thereof. Examples of olefin polymers include polyethylene, polypropylene, and combinations thereof. In other embodiments, the one or more polymers include ethylene-vinyl acetate (EVA) copolymers, EVOH copolymers, ethylene-ethyl acrylate copolymers, ethylenically-unsaturated mono-fatty acid copolymers, and combinations thereof. It may contain one or more ethylene copolymers.

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

In still further aspects, the one or more polymers may comprise one or more ionomer polymers. In these embodiments, ionomer polymers may include polymers containing carboxylic acid functionality, sulfonic acid functionality, salts thereof (e.g., sodium, magnesium, potassium, etc.), and/or anhydrides thereof. For example, the ionomer polymer(s) may include one or more fatty acid-modified ionomer polymers, polystyrene sulfonates, ethylene-methacrylic acid copolymers, and combinations thereof.

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

In further aspects, the one or more polymers may comprise one or more polyamide copolymers (e.g., polyamide-polyether copolymers) and/or one or more polyurethanes (e.g., crosslinked polyurethanes and/or thermoplastic polyurethanes). there is. Alternatively, the one or more polymers may include one or more natural and/or synthetic rubbers, such as butadiene and isoprene.

When the elastomeric material is a foamed polymer material, the foamed material is a physical blowing agent whose phase transitions to a gas based on changes in temperature and/or pressure, or when heated above its activation temperature. It can be foamed using a chemical blowing agent that forms gas when heated. For example, the chemical blowing agent can be an azo compound such as azodicarbonamide, sodium bicarbonate, and/or isocyanate.

In some embodiments, the foamed polymeric material may be a crosslinked foam material. In these embodiments, a peroxide-based crosslinking agent, such as dicumyl peroxide, may be used. Additionally, the foamed polymer material may contain one or more fillers such as pigments, modified or natural clays, modified or unmodified synthetic clays, talc fiberglass, powdered glass, modified or natural silica, calcium carbonate, mica, paper, wood chips, etc. You can.

Elastomeric materials can be molded using molding processes. In one example, when the elastomeric material is a molded elastomer, the uncured elastomer (e.g., rubber) is combined with optional fillers and a sulfur-based or peroxide-based curing package in a Banbury mixer. It can be mixed with the same curing package, calendared, molded into shape, placed in a mold and vulcanized.

In another example, when the elastomeric material is a foamed material, the material may be foamed during a molding process, such as an injection molding process. The thermoplastic polymer material may be melted in the barrel of an injection molding system and combined with a physical or chemical blowing agent and an optional crosslinking agent, and then injected into the mold under conditions that activate the blowing agent to form the molded foam.

Optionally, when the elastomeric material is a foamed material, the foamed material may be a compression molded foam. Compression molding is used to change the physical properties of a foam (e.g., density, stiffness, and/or durometer) or to change the physical appearance of a foam (e.g., by fusing two or more pieces of foam and forming a foam). can be used to form a , etc.) or to change both.

The compression molding process preferably involves forming one or more foam preforms, e.g. by injection molding the polymeric material to foam, forming foamed particles or beads, and forming a foamed sheet. It begins with processing such as cutting sheet stock. The compression molded foam is then compressed within the closed mold by placing one or more preforms formed of the foamed polymeric material(s) within the compression mold and applying sufficient pressure to the one or more preforms. It can be manufactured by doing. Once the mold is closed, it modifies the preform(s) by forming a skin on the outer surface of the compression molded foam, fusing the individual foam particles together and densifying the foam(s) or any combination thereof. Sufficient heat and/or pressure is applied to the one or more preforms in the closed mold for a sufficient period of time to permanently increase . After heating and/or applying pressure, the mold is opened and the molded foam article is removed from the mold.

With continued reference to FIGS. 3 and 4 , plate 110 extends from a first end 176 within toe portion _20T to a second end 178 within heel region 24 . The plate 110 includes an upper surface 180 and a lower surface 182 formed on a surface opposite to the upper surface 180. The distance from top surface 180 to bottom surface 182 defines the thickness of plate 110. The outer periphery extends between the top surface 180 and the bottom surface 182, and has an outer peripheral profile of the plate 110 that corresponds to the peripheral profile of the upper and lower pocket portions 144, 152. Define. The plate 110 is an upper cushioning member such that the upper surface 180 of the plate 110 is received within the upper pocket portion 144 and the lower surface 182 of the plate 110 is accommodated within the lower pocket portion 152. It may be buried between (130) and/or the lower buffer member (132). Here, the first end 176 of the plate 110 is received inside the portion of the lower pocket portion 152 defined by the anterior segment 134 and the second end 178 of the plate 110 is posterior. It is received inside the portion of lower pocket portion 152 defined by segment 136. Accordingly, the bottom surface 182 of the plate 110 includes an opening 164 in the front segment 134; and a gap 138 formed between the front segment 134 and the rear segment 136; exposed toward the ground surface (i.e., visible).

Plate 110 includes materials that provide relatively high strength and rigidity, such as polymeric materials and/or composite materials. In some examples, plate 110 is a composite material manufactured using a fiber sheet or textile, such as a pre-impregnated (i.e., “prepreg”) fiber sheet or textile. Alternatively, or additionally, plate 110 may be attached to a substrate or to each other to produce a plate having strands of fibers arranged at predetermined angles or at predetermined positions. It can be manufactured by strands formed from multiple filaments of one or more types of fiber (eg fiber tows) by attaching them. When using fiber strands, the types of fibers included within the strand may include synthetic polymer fibers that can melt and resolidify into other fibers present in the strand; and optionally other components such as stitching thread or substrate or both. Alternatively, or in addition, the fibers of the strand and optionally other components, such as stitching yarn or the substrate or both, may be treated with a resin after attaching the strands of fibers to the substrate and/or to each other. ) can be solidified by applying.

In some embodiments, plate 110 has a substantially uniform thickness. In some examples, the thickness of plate 110 ranges from about 0.6 millimeters (mm) to about 3.0 mm. In one example, the thickness of plate 110 is substantially equal to 1.0 mm. In other implementations, plate 110 may have a greater thickness in one region 20 , 22 , 24 of sole structure 200 than the thickness in other regions 20 , 22 , 24 of sole structure 200 . , the thickness of the plate 110 is non-uniform.

1-4 and 8, one or more bladders 108 are received inside the receiving portion 126 of the cushioning element 106 between the upper cushioning member 130 and the lower cushioning member 132. It is shown to include an inner bladder 108 (medial bladder) and an outer bladder 108 (lateral bladder). More specifically, the bladders 108 are received inside each one of the sockets 160. Accordingly, inner bladder 108 is positioned within first socket 160 closest to the medial surface 16 of sole structure 100, while outer bladder 108 is positioned on the outer surface of sole structure 100 ( It is disposed in the second socket 160 closest to 16).

Each of the bladders 108 has a pair of barrier layers 184a, 184b formed along a peripheral seam and joined together to define an inner chamber 186 of the bladder 108. may include a barrier layer). Here, the upper barrier layer 184a defines the top surface of the bladder 108, and the lower barrier layer 184b defines the bottom surface of the bladder 108. When sole assembly 100 is assembled, lower barrier layer 184b is positioned on the inside of one of the sockets 160 of tray 158 such that bladder 108 is supported on the foam material of front segment 134. is accepted in The top surface of the upper barrier layer 184a is positioned flush with the top surface 150 of the cushioning element 106 and is attached to the bottom surface 182 of the plate 110 inside the gap 138.

As used herein, the term “barrier layer” (e.g., barrier layers 184a, 184b) includes both monolayer and multilayer films. In some embodiments, one or both of the barrier layers 184a, 184b are each manufactured (eg, thermoformed or blow molded) from a single layer film. In other embodiments, one or both of the barrier layers 184a, 184b are each manufactured (eg, thermoformed or blow molded) from a multilayer film (multiple sublayers). In each embodiment, each layer or sublayer can have a film thickness ranging from about 0.2 micrometers to about 1 millimeter. In further embodiments, the film thickness for each layer or sublayer may range from about 0.5 micrometers to about 500 micrometers. In still further embodiments, the film thickness for each layer or sublayer may range from about 1 micrometer to about 100 micrometers.

One or both of the barrier layers 184a, 184b may independently be transparent, translucent, and/or opaque. As used herein, the term “transparent” with respect to a barrier layer and/or a fluid fill chamber means that light can pass through the barrier layer in a substantially straight line so that a viewer can see through the barrier layer. In comparison, in the case of an opaque barrier layer, light does not pass through the barrier layer and no one can ever see clearly through the barrier layer. A translucent barrier layer falls between a transparent barrier layer and an opaque barrier layer, where light passes through the translucent barrier layer, but some of the light is scattered, so the viewer cannot see clearly through the layer.

Barrier layers 184a and 184b may each be made of an elastomeric material containing one or more thermoplastic polymers and/or one or more crosslinkable polymers. In one aspect, the elastomeric material may include one or more thermoplastic elastomeric materials, such as one or more thermoplastic polyurethane (TPU) copolymers, one or more ethylene-vinyl alcohol (EVOH) copolymers, etc.

As used herein, “polyurethane” refers to copolymers (including oligomers) containing urethane groups (-N(C=O)O-). These polyurethanes, in addition to the urethane groups, contain additional compounds such as esters, ethers, ureas, allophanates, biurets, carbodiimides, oxazolidinyl, isocyanurates, uretdione, carbonates, etc. It may contain groups. In one aspect, one or more of the polyurethanes can be produced by polymerizing one or more polyols with one or more isocyanates to produce copolymer chains having (-N(C=O)O-) linkages.

Examples of suitable isocyanates for producing 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 containing trimethyloylpropane (TMP), methylene diphenyl diisocyanate (MDI), xylene diisocyanate (XDI), and tetramethylpropane (TMP). Silylene diisocyanate (TMXDI), hydrogenated xylene diisocyanate (HXDI), naphthalene 1,5-diisocyanate (NDI), 1,5-tetrahydronaphthalene diisocyanate, para-phenylene diisocyanate (PPDI), 3, 3'-dimethyldiphenyl1-4,4'-diisocyanate (DDDI), 4,4'-dibenzyl diisocyanate (DBDI), 4-chloro-1,3-phenylene diisocyanate, and combinations thereof Includes. In some embodiments, the copolymer chains are substantially free of aromatic groups.

In certain embodiments, polyurethane polymer chains are produced from diisocyanates including HMDI, TDI, MDI, H12 aliphatic compounds, and combinations thereof. In one aspect, the thermoplastic TPU may include polyester-based TPU, polyether-based TPU, polycaprolactone-based TPU, polycarbonate-based TPU, polysiloxane-based TPU, or combinations thereof.

In another aspect, the polymer layer may be formed from one or more of the following materials. 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. acrylic nitrile-methyl acrylate copolymer), polyethylene terephthalate, polyether imide, polyacryl imide, and other polymeric materials known to have relatively low gas permeability. In addition to blends of the above materials, blends of the above materials with the TPU copolymers described herein, optionally including combinations of polyimides and crystalline polymers, are also suitable.

Barrier layers 184a, 184b include two or more sublayers (multilayer films) such as those set forth in U.S. Pat. No. 5,713,141 to Mitchell et al. and U.S. Pat. No. 5,952,065 to Mitschell et al., the disclosures of which are incorporated herein by reference in their entirety. It can be included. In embodiments where barrier layers 184a, 184b include two or more sublayers, examples of suitable multilayer films include those disclosed in U.S. Pat. No. 6,582,786 to Bonk et al., the contents of which are incorporated herein by reference in their entirety. Includes microlayer films such as. In further embodiments, barrier layers 184a, 184b each independently comprise alternating sublayers of one or more TPU copolymer materials and one or more EVOH copolymer materials, wherein barrier layers 184a, 184b ) The total number of each sub-layer includes at least 4 sub-layers, at least 10 sub-layers, at least 20 sub-layers, at least 40 sub-layers and/or at least 60 sub-layers.

The fluid filled chamber 186 may be used for thermoforming (e.g., vacuum thermoforming), blow molding, extrusion, injection molding, vacuum molding, rotation molding, transfer molding, pressure molding, or heat sealing. Barrier layers 184a, 184b may be fabricated using any suitable technique, such as sealing, casting, low pressure casting, spin casting, reaction injection molding, radio frequency (RF) welding, etc. In one aspect, the barrier layers 184a, 184b include an inflatable chamber (186) that can optionally include one or more valves (e.g., one-way valves) that allow the chamber 186 to be filled with a fluid (e.g., a gas). 186) (inflatable chamber) can be manufactured by co-extrusion followed by vacuum thermoforming.

Chamber 186 may be provided in a fluid-filled state (such as that provided within footwear 10) or in an unfilled state. Chamber 186 may be filled to contain any suitable fluid, such as a gas or liquid. In one aspect, the gas may include air, nitrogen (N ₂ ), or any other suitable gas. In other aspects, chamber 186 may alternatively include other media such as pellets, beads, shredded recycled materials, etc. (e.g., foamed beads and/or rubber beads). By providing fluid to chamber 186, chamber 186 is thereby pressurized. Alternatively, the fluid provided to chamber 186 may be at atmospheric pressure, such that chamber 186 is not pressurized, but rather simply contains a volume of fluid at atmospheric pressure.

The fluid fill chamber 186 preferably has a low gas permeability rate to preserve its sustained gas pressure. In some embodiments, the fluid filled chamber 186 has a gas permeability rate for nitrogen gas that is about 10 times lower than the nitrogen gas permeability rate for a butyl rubber layer of substantially the same dimensions. In one aspect, the fluid fill chamber 186 has a pressure of 15 cubic centimeters per square meter per atmospheric pressure per day (cm ³ ), for an average film thickness of 500 micrometers (based on the thickness of the barrier layers 184a, 184b). It has a nitrogen gas permeability of less than /m ² ·atm·day). In further aspects, the transmittance is less than or equal to 10 cm ³ /m ² ·atm·day, or less than or equal to 5 cm ³ /m ² ·atm·day, or less than or equal to 1 cm ³ /m ² ·atm·day.

Each chamber 186 of the bladders 108 may contain within itself a tensile element 188 (FIG. 8). Each tensile element 188 may include a series of tensile strands 190 extending between an upper tensile sheet 192 and a lower tensile sheet 192. The upper tensile sheet 192 may be attached to the first barrier layer 184a of the barrier layers, while the lower tensile sheet 192 may be attached to the second barrier layer 184b of the barrier layers. In this way, when chamber 186 receives pressurized fluid, tension strands 190 of tension element 188 are placed in tension. Because the upper tensile sheet 192 is attached to the upper barrier layer 184a and the lower tensile sheet 192 is attached to the lower barrier layer 184b, the tensile strands 190 allow pressurized fluid to flow into the chambers 186. ) maintains the intended shape of the bladders 108 when injected inside.

The outsole 104 is formed of an elastomeric material and is attached to the bottom surface 120 of the lower cushioning member 132. In the example shown, outsole 104 includes a forefoot segment 194 attached to the bottom surface 120 of the forefoot segment 134; and a pair of heel segments 196 respectively attached to the lower surfaces 120 of each of the lobes 174. Optionally, forefoot segment 194 of outsole 104 includes an aperture 198 formed therethrough, such aperture being formed through forward segment 134 of lower cushioning member 132. Corresponds to opening 164. Accordingly, the bottom surface 182 of the plate 110 is exposed through the outsole opening 198 and the cushioning element opening 164.

Upper 200 forms an enclosure having a plurality of components that cooperate to define an internal void 202 and an ankle opening 204, wherein the internal void 202 and the ankle opening cooperate with each other to define the foot. and secures the foot for support on the sole structure 200. Upper 200 may be formed from one or more materials that are sewn or adhesively bonded together to define internal voids 202. Suitable materials for upper 200 include, but are not limited to, textiles, foam, leather, and synthetic leather. The example upper 200 is substantially comprised of one or more devices disposed in different regions of the upper 200 to facilitate movement of the article of footwear 10 between a tightened state and a loose state. It may be formed from a combination of an inelastic or inflexible material and one or more substantially elastic or elastic materials. The one or more elastic materials may include any combination of one or more elastic fabrics, such as, without limitation, spandex, elastane, rubber, or neoprene. The one or more inelastic materials may include any combination of one or more of thermoplastic polyurethane, nylon, leather, vinyl, or another material/fabric that does not impart elastic properties.

The following items provide exemplary configurations for the articles of footwear and sole structures described above.

Item 1. A sole structure for an article of footwear, the sole structure comprising: an upper cushion extending from a first end to a second end; a lower cushion including a tray extending toward a second end of the upper cushion and having a first segment attached to the upper cushion adjacent a first end; and at least one bladder disposed between the tray of the lower cushion and the upper cushion.

Item 2. The sole structure of item 1, wherein the sole structure further comprises a plate disposed between the at least one bladder and the upper cushion.

Item 3. The sole of item 2, wherein a first side of the at least one bladder is attached to the tray and an opposing second side of the at least one bladder is attached to the plate. struct.

Item 4. The sole structure of any one of items 1 to 3, wherein the lower cushion includes a support portion attached to the upper cushion, and wherein the tray is cantilevered from the support portion.

Item 5. The method of any one of items 1 to 4, wherein the at least one bladder includes a first bladder disposed on an inner surface of the sole structure and a second bladder disposed on an outer surface of the sole structure. A sole structure for a footwear article.

Item 6. The sole structure of item 5, wherein the tray includes a first socket to receive the first bladder and a second socket to receive the second bladder.

Item 7. The sole structure of any one of items 1 to 6, wherein at least one of the upper cushion and the lower cushion includes a peripheral side having a plurality of dimples.

Item 8. The sole structure of item 7, wherein the dimples are arranged in a plurality of columns and rows.

Item 9. The sole structure of any of items 1-8, wherein the sole structure further includes an outsole disposed on an opposite surface of the lower cushion from the at least one bladder.

Clause 10. The sole structure of any of clauses 1-9, wherein the tray of the lower cushion comprises a foam material.

Item 11. A sole structure for an article of footwear, the sole structure comprising a cushion arrangement, the cushion arrangement comprising: (i) an upper cushion having a top surface and a lower surface formed on an opposite surface of the top surface; (ii) a lower cushion having a lower surface and an upper surface formed on an opposite surface of the lower surface and opposing the lower surface of the upper cushion; and (iii) a socket formed between the lower surface of the upper cushion and the upper surface of the lower cushion. At least one bladder is disposed inside the socket between the upper and lower cushions.

Item 12. The sole structure of item 11, wherein the sole structure further comprises a plate disposed between the at least one bladder and the upper cushion.

Item 13. The article of item 12, wherein a first side of the at least one bladder is attached to the lower cushion and an opposing second side of the at least one bladder is attached to the plate. Sole structure.

Item 14. The method according to any one of items 11 to 13, wherein the lower cushion includes: a support portion attached to the upper cushion; and a tray cantilevered from the support portion and defining a lower portion of the socket.

Item 15. The method of any one of items 11 to 14, wherein the at least one bladder includes a first bladder disposed on an inner surface of the sole structure and a second bladder disposed on an outer surface of the sole structure. A sole structure for a footwear article.

Item 16. The sole structure of item 15, wherein the upper surface of the lower cushion includes a first socket receiving the first bladder and a second socket receiving the second bladder.

Item 17. The sole structure of any of items 11-16, wherein at least one of the upper cushion and the lower cushion includes a peripheral surface having a plurality of dimples.

Item 18. The sole structure of item 17, wherein the dimples of the plurality of dimples are arranged in a plurality of columns and rows.

Item 19. The sole structure of any of items 11-18, wherein the sole structure further comprises an outsole disposed adjacent a bottom surface of the lower cushion.

Item 20. The sole structure of any of items 11-19, wherein at least one of the upper cushion and the lower cushion comprises a foam material.

The foregoing description has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular configuration are generally not limited to a particular configuration, but may be interchanged where applicable and may be used in a selected configuration even if not specifically shown or described. Additionally, the same thing may vary in many ways. The above variations should not be considered a departure from the present disclosure, and all such modifications are intended to be included within the scope of the present disclosure.

Claims (20)

A sole structure for a footwear article, wherein the sole structure includes
an upper cushion extending from a first end to a second end;
a lower cushion including a tray extending toward a second end of the upper cushion and having a first segment attached to the upper cushion adjacent a first end; and
A sole structure for an article of footwear, comprising: at least one bladder disposed between a tray of the lower cushion and the upper cushion. 2. The sole structure of claim 1, wherein the sole structure further includes a plate disposed between the at least one bladder and the upper cushion. 3. The sole structure of claim 2, wherein a first side of the at least one bladder is attached to the tray and an opposing second side of the at least one bladder is attached to the plate. 2. The sole structure of claim 1, wherein the lower cushion includes a support portion attached to the upper cushion, and the tray is cantilevered from the support portion. The sole of claim 1, wherein the at least one bladder includes a first bladder disposed on an inner surface of the sole structure and a second bladder disposed on an outer surface of the sole structure. struct. 6. The sole structure of claim 5, wherein the tray includes a first socket receiving the first bladder and a second socket receiving the second bladder. 2. The sole structure of claim 1, wherein at least one of the upper cushion and the lower cushion includes a peripheral side surface having a plurality of dimples. 8. The sole structure of claim 7, wherein the dimples are arranged in a plurality of columns and rows. 2. The sole structure of claim 1, wherein the sole structure further includes an outsole disposed on an opposing surface of the lower cushion from the at least one bladder. 2. The sole structure of claim 1, wherein the tray of the lower cushion comprises a foam material. A sole structure for a footwear article, wherein the sole structure includes
Includes a cushion arrangement unit, wherein the cushion arrangement unit
i. an upper cushion having a top surface and a lower surface formed on an opposite side of the top surface;
ii. a lower cushion having a lower surface and an upper surface formed on an opposite surface of the lower surface and opposing the lower surface of the upper cushion; and
iii. A socket formed between the lower surface of the upper cushion and the upper surface of the lower cushion, and
A sole structure for an article of footwear, wherein at least one bladder is disposed inside the socket between the upper cushion and the lower cushion. 12. The sole structure of claim 11, wherein the sole structure further includes a plate disposed between the at least one bladder and the upper cushion. 13. The sole structure of claim 12, wherein a first side of the at least one bladder is attached to the lower cushion and an opposing second side of the at least one bladder is attached to the plate. . The cushion according to claim 11, wherein the lower cushion includes: a support portion attached to the upper cushion; and a tray cantilevered from the support portion and defining a lower portion of the socket. 12. The sole of claim 11, wherein the at least one bladder includes a first bladder disposed on an inner surface of the sole structure and a second bladder disposed on an outer surface of the sole structure. struct. 16. The sole structure of claim 15, wherein the upper surface of the lower cushion includes a first socket receiving the first bladder and a second socket receiving the second bladder. 12. The sole structure of claim 11, wherein at least one of the upper cushion and the lower cushion includes a peripheral surface having a plurality of dimples. 18. The sole structure of claim 17, wherein the dimples of the plurality of dimples are arranged in a plurality of columns and rows. 12. The sole structure of claim 11, wherein the sole structure further includes an outsole disposed adjacent a bottom surface of the lower cushion. 12. The sole structure of claim 11, wherein at least one of the upper cushion and the lower cushion comprises a foam material.