Dynamically-controlled cushioning system for an article of footwear

Abstract

An article of footwear with a dynamically-controlled cushioning system is disclosed. The cushioning system includes a sealed, fluid-filled bladder formed with a plurality of separate cushioning chambers, and a control system. The control system, which includes a CPU, pressure sensors and valves, controls fluid communication between the chambers to dynamically adjust the pressure in the cushioning chambers for various conditions such as the activity that the footwear is used in, the weight of the individual and the individual's running style. Certain adjustments can be made while the footwear is in use.

Description

FIELD OF THE INVENTION

This invention relates to a cushioning system for an article of footwear. In particular, the cushioning system includes a fluid-filled bladder having separate reservoir chambers. The chambers are in fluid communication with each other, and a control device dynamically-distributes and regulates pressure within the chambers based on sensed and user input criteria.

BACKGROUND OF THE INVENTION

Articles of footwear, such as the modern athletic shoes, are highly refined combinations of many elements which have specific functions, all of which work together for the support and protection of the foot. Athletic shoes today are as varied in design and purpose as are the rules for the sports in which the shoes are worn. Tennis shoes, racquetball shoes, basketball shoes, running shoes, baseball shoes, football shoes, walking shoes, etc. are all designed to be used in very specific, and very different, ways. They are also designed to provide a unique and specific combination of traction, support and protection to enhance performance.

Moreover, physical differences between wearers of a specific shoe, such as differences in each user's weight, foot size, shape, activity level, and walking and running style, make it difficult to economically optimize a mass produced shoe's performance to a particular individual.

Closed-celled foam is often used as a cushioning material in shoe soles and ethylene-vinyl acetate copolymer (EVA) foam is a common material. In many athletic shoes, the entire misdeal is comprised of EVA. While EVA foam can be cut into desired shapes and contours, its cushioning characteristics are limited. One of the advantages of fluid, in particular gas, filled bladders is that gas as a cushioning component is generally more energy efficient than close-celled foam. Cushioning generally is improved when the cushioning component, for a given impact force, spreads the impact force over a longer period of time, resulting in a smaller impact force being transmitted to the wearer's body. Thus, fluid-filled bladders are routinely used as cushions in such shoes to increase shoe comfort, enhance foot support, decrease wearer fatigue, and reduce the risk of injury and other deleterious effects. In general, such bladders are comprised of elastomeric materials which are shaped to define at least one pressurized pocket or chamber, and usually include multiple chambers arranged in a pattern designed to achieve one or more of the above-stated characteristics. The chambers may be pressurized with a variety of different mediums, including air, various gases, water, or other liquids.

Numerous attempts have been made to improve the desirable characteristics associated with fluid-filled bladders by attempting to optimize the orientation, configuration and design of the chambers. In U.S. Pat. No. 2,080,469 to Gilbert, bladders have been constructed with a single chamber that extends over the entire area of the sole. Alternatively, bladders have included a number of chambers fluidly interconnected with one another. Examples of these types of bladders are disclosed in U.S. Pat. No. 4,183,156 to Rudy, and U.S. Pat. No. 900,867 to Miller. However, these types of bladder constructions have been known to flatten and “bottom out” when they receive high impact pressures, such as experienced in athletic activities. Such failures negate the intended benefits of providing the bladder.

In an effort to overcome this problem, bladders have been developed with the chambers fluidly connected to each other by restricted openings. Examples of these bladders are illustrated in U.S. Pat. No. 4,217,705 to Donzis, U.S. Pat. No. 4,129,951 to Petrosky, and U.S. Pat. No. 1,304,915 to Spinney. However, these bladders have tended to either be ineffective in overcoming the deficiencies of the non-restricted bladders, or they have been too expensive to manufacture.

Bladders are also disclosed in patents that include a number of separate chambers that are not fluidly connected to each other. Hence, the fluid contained in any one chamber is precluded from passing into another chamber. One example of this construction is disclosed in U.S. Pat. No. 2,677,906 to Reed. Although this design obviates “bottoming out” of the bladder, it also requires each chamber to be individually pressurized, thus, the cost of production can be high.

Another problem with these known bladder designs is that they do not offer a way for a user to individually adjust the pressure in the chambers to optimize their shoes' performance for their particular sport or use. Several inventors have attempted to address this issue by adding devices that make the chamber pressure adjustable. For example, U.S. Pat. No. 4,722,131 to Huang discloses an open system type of air cushion. The air cushion has two cavities, with each cavity having a separate air valve. Thus, each cavity can be inflated to a different pressure by pumping in or releasing air as desired.

However, in such systems, a separate pump is required to increase the pressure in the cavities. Such a pump would have to be carried by the user if it is desired to inflate the cavities away from home, inconveniencing the user. Alternatively, the pump could be built into the shoe, adding weight to the shoe and increasing the cost and complexity. Additionally, open systems tend to lose pressure rapidly due to diffusion through the bladder membrane or leakage through the valve. Thus, the pressure must be adjusted often.

A significant improvement over this type of design is found in U.S. Pat. No. 5,406,719 to Potter (“Potter”), the disclosure of which is hereby incorporated by reference. Potter controllably links a plurality of chambers within a bladder with at least one variable-volume fluid reservoir such that the pressure in each chamber may be manually adjusted by a user modulating selected control links and the volume of the reservoir. The chambers may be oriented to allow chambers of different pressure in areas corresponding with different areas of the foot. For example, to correct over-pronation, pressure in chambers located on the medial side of the shoe can be selectively increased by the user.

The system in Potter is also closed to the atmosphere. Accordingly, pressure in the system may be higher than ambient pressure. Moreover, dirt and other debris cannot enter the system.

However, since Potter requires manual adjustment, the pressure in the various chambers cannot be dynamically modulated or adjusted during use of the shoe. Accordingly, considerable user effort is required to “fine tune” the performance of the shoe for a particular use and individual, and such adjustments must be re-done by the user when the sport or activity changes.

In recent years, consumer electronics have become increasingly more reliable, durable, light-weight, economical, and compact. As a result, the basic elements of a miniaturized fundamental control system, such as a central processing unit, input/output device, data sensing devices, power supplies, and micro actuators are now commercially available at reasonable prices. Such systems are small, light-weight, and durable enough to be attached to an article of footwear, such as a shoe, without compromising the shoe's performance.

A control system to permit dynamic adjustment to the pressure in a single chamber cushioning bladder is disclosed in U.S. Pat. No. 5,813,142 to Demon (“Demon”), the disclosure of which is hereby incorporated by reference. In Demon, a plurality of single-chamber independent bladders are secured within a shoe and in fluid communication with ambient air through fluid ducts. A control system monitors the pressure in each bladder. Each duct includes a flow regulator, that can be actuated by the control system to any desired position such that the fluid duct can be modulated to any position between and including being fully open and fully closed. The control system monitors the pressure in each of the bladders, and opens the flow regulator as programmed based on detected pressure in each bladder.

Despite the benefits of using an on-board control system to dynamically modulate bladder pressure in each bladder of Demon, the specific implementation of this concept taught by Demon adversely affects performance of the bladder as a cushion, thereby significantly limiting the commercial viability of the concept. For example, the plurality of bladders in Demon each have their own reservoir, which is preferably ambient air. Accordingly, the static pressure in each bladder cannot exceed ambient pressure. In practice, it is desirable for the static pressure in the bladder to be higher than ambient pressure. Such higher pressure urges the bladder to return to its neutral position following impact, prevents bottoming out of the bladder, and improves the cushioning ability, or feel, of the bladder.

Also, like other bladder configurations that exhaust to ambient air, the bladders in Demon are prone to collect dirt and other debris through their exit/inlet port, particularly when a user wears the shoe outdoors, such as when running on wet pavement. Moreover, Demon neither teaches nor suggests dynamically-modulating pressure between at least two chambers within the same bladder thereby allowing the control system to optimize performance within all areas of the bladder without compromising the integrity of the system, and without requiring multiple bladders within the same shoe.

Accordingly, despite the known improvements to bladder designs, there remains a need for a cost effective, closed-system, multi-chamber bladder that allows pressure in each chamber to be dynamically distributed, adjusted, and regulated between each chamber based on real-time sensed and user input criteria to optimize the desirable characteristics of the bladder while the shoe is being worn by its user.

In addition to other benefits that will become apparent in the following disclosure, the present invention fulfills this need.

SUMMARY OF THE INVENTION

The present invention is a cushioning system for an article of footwear that includes a fluid-filled bladder having a plurality of separate sealed cushioning chambers. Separate reservoir chambers can also be placed in fluid communication with the cushioning chambers. The chambers are in fluid communication with each other, and a control device dynamically-distributes and regulates pressure within the chambers based on sensed and user input criteria by modulating the level of fluid communication between each of the chambers and, if installed, the reservoir chambers.

In a preferred embodiment, the control system includes a central processing unit (CPU), pressure sensing devices, and electronically-actuated, CPU-commanded valves that work in conjunction to control fluid communication between the chambers, and if desired, with a variable volume reservoir to optimize performance of the cushioning system for a particular wearer and activity.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional view through a shoe of the present invention, incorporating a bladder in accordance with a preferred embodiment of the present invention.

FIG. 2A is a top plan view of a bladder of the present invention;

FIG. 2B is a cross-sectional view taken along line 2B-2B of FIG. 2A;

FIG. 3 is a cross-sectional view taken along line 3-3 of FIG. 2A;

FIG. 4 is a top plan view of another embodiment of bladder of the present invention;

FIG. 5 is a cross-sectional view taken along line 5-5 of FIG. 4;

FIG. 6 is a cross-sectional view taken along line 6-6 of FIG. 4;

FIG. 7 is a cross-sectional view taken along line 7-7 of FIG. 4;

FIG. 8 is a schematic side view of a portion of a shoe, illustrating control knobs; and,

FIG. 9 is a schematic view of a control system in accordance with the present invention.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

A cushioning system 8 for use in an article of footwear 9 is disclosed in FIGS. 1 to 9. The cushioning system 8 includes a bladder 10 having a plurality of chambers 12a-j in fluid connection with each other at plenum 20 with each chamber entrance having an individually operable regulator, such as a modulating valve 29. A control system monitors pressure in the chambers and dynamically operates the regulators to change the level of fluid communication between the chambers, thereby changing their respective pressures, to optimize performance of the bladder while the article of footwear is being worn.

A. Bladder Assembly

In a preferred embodiment of the invention (FIGS. 1-3), a bladder 10 is a thin, elastomeric member defining a plurality of chambers 12 or pockets. The chambers 12 are pressurized to provide a resilient support. Bladder 10 is particularly adapted for use in the midsole of the shoe, but could be included in other parts of the sole or have applicability in other fields of endeavor. In a midsole, bladder would preferably be encapsulated in an elastomeric foam 11 (FIG. 1). As is well known in the art, the foam need not fully encapsulate the bladder. Moreover, the bladder can be used to form the entire midsole or sole member.

Preferably, bladder 10 is composed of a resilient, plastic material including polyester polyurethane, polyether polyurethane, such as a cast or extruded ester base polyurethane film having a shore “A” harness of 80 to 95 (e.g., Tetra Plastics TPW-250) which is inflated with hexafluorethane (e.g., Dupont F-116) or sulfer hexafluoride. Other suitable materials and fluids having the requisite characteristics can be used, such as those disclosed in U.S. Pat. No. 4,183,156, to Rudy, which is incorporated by reference. Among the numerous thermoplastic urethanes which are particularly useful in forming the film layers are urethanes such as Pellethane, (a trademarked product of the Dow Chemical Company of Midland, Mich.), Elastollan (a registered trademark of the BASF Corporation) and ESTANE (a registered trademark of the B. F. Goodrich Co.), all of which are either ester or ether based and have proven to be particularly useful. Thermoplastic urethanes based on polyesters, polyethers, polycaprolactone and polycarbonate macrogels can also be employed. Further suitable materials could include thermoplastic films containing crystalline material, such as disclosed in U.S. Pat. Nos. 4,936,029 and 5,042,176 to Rudy, which are incorporated by reference; polyurethane including a polyester polyol, such as disclosed in U.S. Pat. No. 6,013,340 to Bonk et al., which is incorporated by reference; or multi-layer film formed of at least one elastomeric thermoplastic material layer and a barrier material layer formed of a copolymer of ethylene and vinyl alcohol, such as disclosed in U.S. Pat. No. 5,952,065 to Mitchell et al., which is incorporated by reference. Further, the bladders 10 can also be fabricated by blow molding or vacuum forming techniques.

As a bladder midsole, bladder 10 defines a forefoot support 14, a heel support 16, a medial segment 18 interconnecting the two supports. Chambers 12 each define a support portion 13 and a channel portion 15. The support portions 13 are raised to provide a resilient resistance force for an individual's foot. The channel portions 15 are relatively narrow in comparison to the support portions 13, and are provided to facilitate the unique manufacturing process described below. Forefoot and heel supports 14, 16 are comprised primarily of support portions so that a cushioned support is provided under the plantar areas receiving the greatest impact pressure during use of the shoe. Channel portions 15, while extending partially into the forefoot and heel supports 14, 16, are concentrated in medial segment 18.

In forefoot support 14, the support portions 13 are arranged parallel to one another in a lateral direction across the sole to provide a suitable flexibility in the forefront sole portion and to apportion the cushioned resistance as desired. Nonetheless, different chamber arrangements could be used.

In the illustrated athletic shoe, forefoot portion 14 includes chambers 12a-g. Chambers 12a-g are of varying sizes, with the chambers nearer to the front (e.g., chamber 12a) defining a larger volume than those closer to medial segment 18 (e.g., chamber 12g). As will be described more fully below, all of the chambers 12a-g are initially pressurized to the same level. However, due to the different volumes of chambers, they will each possess a unique resistance. In other words, the chambers with smaller volumes will provide a firmer support than the chambers with larger volumes, because the movement of a side wall defining a smaller chamber will involve a greater percentage of the volume of air being displaced than the same movement in a larger chamber. Hence, for example, chamber 12g will provide a firmer support than chamber 12a.

Channel portions 15a-g of chamber 12a-g, in general extend rearwardly from support portions 13a-g to plenum 20 located transversely across medial segment 18. Channel potions 15 are essential to the unique manufacturing process described in U.S. Pat. No. 5,406,719 to Potter, the disclosure of which is hereby incorporated by reference. Preferably, channel portion 15 are provided along the sides of forefoot portion 14, so that the needed cushioned support is not taken from the central portions of the sole where it is most needed. In the illustrated embodiment, channel portions 15 for adjacent chambers 12 are placed on opposite sides of the sole. Of course, other arrangements could be used.

Additionally, in forefoot portion 14, void chambers 22 are defined adjacent the more rearward chambers 12e-g. A void chamber 22 is a chamber that has not been pressurized. Void chambers 22 exist because of the need to limit the volume of the chambers 12e-g to provide a certain firmness in these portions of the bladder. Nevertheless, void spaces are not essential to the present invention and could be eliminated. In a midsole usage (FIG. 1), the resilient foam 11 would fill in the void space and provide ample support to the user's foot.

In a manner similar to forefoot support 14, heel support 16 includes a row of chambers 12h-j. In the illustrated bladder, three chamber 12h-j are provided. The support portions 13h-j of these chambers are arranged parallel to one another in a generally longitudinal direction across the sole to ensure that all three chambers provide cushioned support for all impacts to the user's heel. Nonetheless, as with the forefoot portion, different chamber arrangements could be used. Additionally, each chamber 12h-j includes a channel portion 15 which extends from the support potion 13 to plenum 20. In the same manner as in forefoot support 14, chambers 12h-j provide different resistance forces in the support of the heel. For example, the smaller chamber 12h will provide a firmer resistance than the larger chambers 12i or 12j. The firmer chamber 12h would act as a medial post in reducing pronation.

Chambers 12h-j are initially pressurized in the same internal pressure as chambers 12a-g. One preferred example of internal pressure for athletic footwear is 30 psi. Of course, a wide variety of other pressures could be used. Alternatively, chambers 12a-j can be pressurized to different internal pressures. As one preferred example, the pressure in the forefoot portion could be set at 35 psi, while the heel portion could be pressurized to 30 psi. The particular pressure in each section though will depend on the intended activity and size of the chambers, and could vary widely from the given examples. Finally, by individually controlling the control valves during inflation, individual chambers can be inflated to different pressures.

In the fabrication of the bladder 10, two elastomeric sheets 24, 26 are preferably secured together to define the particular weld pattern illustrated in FIGS. 2-3; that is, that the two opposed sheets 24, 26 are sealed together to define wall segments 28 arranged in a specific pattern (FIG. 2A). The welding is preferably performed through the use of radio frequency welding, the process of which is well known. Of course, other methods of sealing the sheets could be used. Alternatively, the bladder could also be made by blow molding, vacuum forming, or injection molding, the processes of which are also well known.

When the bladder is initially welded (or otherwise formed), the plenum 20 is fluidly coupled with all of the channel portions of the chambers 12a-j, so that all of the chambers are in fluid communication with one another. Each channel portion includes a modulating valve 29a-k that is preferably electronically actuated and can be commanded open, closed, or to an infinite position between these two points, thereby regulating change in pressure into and out of its respective chamber 12a-j.

An injection pocket 32 is provided to supply bladder 10 with a quantity of fluid. Injection pocket 32 is in fluid communication with a pressurizing channel 34, which in turn is fluidly coupled to plenum 20 (FIGS. 2A and 2B). Chambers 12a-j, therefore, are initially pressurized by inserting a needle (not shown) through one of the walls defining an injection pocket 32, and injecting a pressurized fluid therein. The pressurized fluid flows from pocket 32, through channel 34, into plenum 20, through channel portions 15a-j and into the supporting portion 13a-j of all of the chambers 12a-j. Once the predetermined quantity of fluid has been inserted into the bladder, or alternatively when the desired pressure has been reached, channel 34 is temporarily clamped. Preferred fluids include, for example, hexafluorethane, sulfur hexafluoroide, nitrogen, air, or other gases such as disclosed in the aforementioned '156, '945, '029, or '176 patents to Rudy, or the '065 patent to Mitchell et al.

Walls 24, 26 are welded, or otherwise heat sealed, forming a seal around plenum 20 (FIG. 1) to completely seal the chambers in fluid communication with each other at plenum 20. Once the seal has been made, the needle is removed and channel 34 remains on uninflated void area. Hence, as can be readily appreciated, this unique independent chamber design can be fabricated by the novel process in a easy, quick, and economical manner.

B. Control System Assembly

Referring specifically to FIG. 9, the control system 200 is shown and includes a central processing unit (“CPU”) 202, power source 204, a plurality of pressure sensing devices 206a-k, and the modulating valves 29a-k. Preferably, the system also includes an input device 208, but it is not required.

One pressure sensing device 206a-k is positioned adjacent to each modulating valve 29a-k such that the pressure in adjacent chamber 12a-k is detected. The pressure sensing devices 206a-j transmit sensed information to the CPU 202, where it is processed according to preset programming to modulate the respective modulating valves in response to the detected pressures in each chamber. Such control systems and programming logic are known. For example, in U.S. Pat. No. 5,813,142, the pressure sensing devices 206a-k include pressure sensing circuitry, which converts the change in pressure detected by variable capacitor into digital data. Each variable capacitor forms part of a conventional frequency-to-voltage converter (FVC) which outputs a voltage proportional to the capacitance of the variable capacitor. An oscillator is electrically connected to each FVC and provides an adjustable reference oscillator. The voltage produced by each pressure sensing device is provided as an input to multiplexer which cycles through the channels sequentially connecting the voltage from each FVC to analog-to-digital (A/D) converter which coverts the analog voltage into digital date for transmission to the CPU via data lines. These components and this circuitry is well known to those skilled in the art and any suitable component or circuitry might be used to perform the same function.

The control system 200 also includes a programmable microcomputer having conventional RAM and ROM, and received information from pressure sensing device 206a-j indicative of the relative pressure sensed by each pressure sensing device 206a-j. The CPU 202 receives digital data from pressure sensing circuitry proportional to the relative pressure sensed by pressure sensing devices. The control system 200 is also in communication with modulating valves 29a-j to vary the opening of each such valves and thus the level of fluid communication of each chamber with the other chambers. As the modulating valves are preferably solenoids (and thus electrically controlled), the control system is in electrical communication with modulating valves.

In a preferable embodiment, the control system also includes a user input devices 208, which allows the user to control the level of cushioning of the shoe. Such devices are known in the art. For example, as shown in FIG. 8, a knob 210a-c on the article of footwear 9 is adjusted by the user to indicate a particular sport or activity to be engaged in by the user, the user's weight, and or the type of pronation desired to be corrected. The CPU 202 detects the commanded signal from the input device 208, and adjusts the pressure in the various chambers 12a-j accordingly.

The CPU programming may be pre set during manufacturing, or include a communications interface 212 for receiving updated programming information remotely. Such communications ports and related systems are known in the industry. For example, the interface 212 may be a radio frequency transceiver for transmitting updated programming to the CPU. An associated receiver would be installed on the shoe and in electrical communication with the CPU. The interface may alternately, or additionally, have a serial or parallel data port, infrared transceiver, or the like.

C. Variable Volume Reservoir

If desired, one or more variable volume reservoirs 516 as disclosed more fully in U.S. Pat. No. 5,406,719 can be inserted into the bladder and placed in fluid communication with the plenum 20. Such reservoirs 516 preferably include a pressure sensing device 206l-o and a modulating valve 29l-o, within a channel connecting the reservoir with the plenum 20. The volume of the reservoir can be modulated electronically through solenoid 517a-d, which causes flat screw 526 to actuate. The control system 200 detects the sensed pressure in the reservoir, and can command the solenoid 517a-d and modulating valve 29l-o as needed to increase the pressure in any of the chambers 512a-d.

In particular, and as best shown in FIGS. 4-7, the pressurizing of the various chambers 512a-d may be selectively varied in a known manner in a closed cushioning system. Referring specifically to FIG. 4, an alternative preferred cushioning element, or bladder, is shown. Bladder 510 preferably includes four separate gas-filled post support storage chambers 512a-d. Chambers 512 compress and stiffen when a load is applied in order to provide cushioning but do not collapse upon themselves. Forward medial support chamber 512b and rearward medial support chamber 512c are disposed on the medial side in the heel region, and extend approximately ½ of the width of the bladder. Lateral chamber 512d also is disposed in the heel region, and extends from the medial side for approximately ⅔ of the width of the bladder. Chambers 512b-d are spaced from each other.

Chambers 512b and 512c are linked by interconnecting tube or port 514g which may be selectively opened or closed by pinch-off valve 518g, the operation of which is discussed in greater detail below. Chambers 512c and 512d also may be linked by port 515 to facilitate initial pressurization of the chambers. However, as shown in FIG. 4, if desired, port 515 may be permanently sealed to prevent fluid communication between chamber 512c and chamber 512d. Chamber 512a forms the forward portion of cushioning element 510, and extends generally across the width of the sole. Chamber 512a is formed as a separate element from chambers 512b-d, with foam element 513 disposed therebetween, and if desired can be linked directly in fluid communication with any chambers 512b-d.

Foam element 513 forms the arch portion of the cushioning element and includes cylindrical opening 520a-d formed partially or fully therethrough. Variable volume reservoir chambers 516a-d are disposed within openings 520a-d, respectively. Chambers 516a-d have a bellows shape which allows the chambers to collapse upon themselves to reduce the volume. Front medial reservoir chamber 516a is linked in fluid communication with front support chamber 512 by interconnecting tube or port 514a, and with rear medial compressible reservoir 516c by interconnecting tube 514c. Rear medial reservoir chamber 516 is linked in fluid communication with forward medial post chamber 512b by interconnecting tube 514c. Front lateral reservoir chamber 516b is linked in fluid communication with front support chamber 512a by interconnecting tube 514b, and with rear lateral reservoir chamber 516d by inter-connecting tube 514d. Rear lateral reservoir chamber 516d is further linked in fluid communication with lateral support chamber 512d by interconnecting tube 514f. The opening and closing of each of interconnecting tubes 514a-g is controlled by a corresponding valve 518a-g, described further below.

Cushioning is provided by the confined gas in chambers 512a-d, and any load on any part of a given chambers will instantaneously increase the pressure equally throughout the whole chamber. The chamber will compress to provide cushioning, stiffening but not collapsing, due to the increase in pressure of the contained gas. When open, interconnecting tubes 514 do not restrict the fluid communication between support chambers 5132 and reservoirs 516, and two support chambers and/or reservoirs connected by an open tube function dynamically as a single chamber. Thus, when all of tubes 514 are open, cushioning element 510 functions as a substantially unitary bladder providing cushioning throughout the misdeal.

Valves 518a-g may comprise any suitable valve known in the art, for example, a pinch-off valve including a screw as shown in FIGS. 5 and 6. With reference to FIG. 4, valves 518a-g, for example, valve 518c, includes hollow rivet 522 disposed in a hole extending partially throughout foam element 513 from one end thereof, and includes an actuator 519a-g in electrical communication with and commanded by the CPU 202. Rivet 522 disposed in a hole extending partially through foam element 513 from one end 522a extending radially therethrough at the inner end. The inner wall of rivet 522 is screw-threaded, and adjusting screw 524 is disposed therein and includes actuator 525 in electrical communication with and commanded by the CPU. Screws 524 preferably are made of light weight plastic.

Interconnecting tubes 514 are disposed within indented portion 522a. The fluid communication may be controlled by adjusting the extent to which screws 524 extend within region 522b. When screws 524 are disposed out of contact with tubes 514, there is substantially free fluid communication between reservoirs 516 and/or support chambers 512. When screws 524 are in the innermost position, they fully contact and pinch-off tubes 514, preventing fluid communication substantially completely.

As discussed, reservoirs 516a-d are disposed within cylindrical holes 520a-d formed in foam element 513. The interior of holes 520 are screw-threaded and form containing chambers for reservoirs 516. Flat screws 526 are disposed in respective holes 520a-d. Downward rotation of screws 526 brings the screws into contact with and compresses reservoir chambers 516. Accordingly, each reservoir 516 can be adjusted to and maintained at a desired volume by simple rotation of the corresponding flat screw 526 which causes the reservoir to collapse. When reservoirs 516 are at their maximum volume, the top of screws 526 are level with the top of holes 520. Screws 526 are made of a light weight material, such as plastic, and are manipulated by actuators 527, that are in electrical communication with and commanded by the CPU 202. Pressure sensing devices 206k-n are disposed in each reservoir and transmit pressure information to the CPU 202.

Due to the light-weight nature of both screws 526, chambers 518 and foam element 513, only a minimal downward force is needed to collapse reservoirs 516 and retain reservoirs 516 at the desired volume. Thus, only a minimal torque is needed to rotate screws 526 to the desired level. If a sock liner is provided, corresponding hooks could be provided therethrough as well to provide ease of access.

By making use of reservoirs 516a-d and tubes 514, the degree of pressurization and thus the stiffness of each support chamber 512a-d can be adjusted to provide customized cushioning at different locations of the shoe, without requiring gas to be added to or leaked from the bladder. For example, if it is desired to increase the resistance to compression in the medial rear portion of the shoe, the pressure in one or both of support chambers 512b and 512c may be increased by the CPU 202 commanding the appropriate actuators until desired pressure is obtained in the appropriate chambers in the following manner. Screw 524 of valve 518a would be commanded by the CPU to rotate into contact with connecting tube 514a, fully compressing the tube and preventing the fluid communication therethrough so as to isolate medial front reservoir 516a from support chamber 512a. Reservoir 516a would be collapsed by the CPU 202 commanding the rotation of the corresponding flat screw 526, forcing gas therefrom and into reservoir 516c and medial support chambers 512b and 512c. Therefore, reservoir 516c also would be collapsed forcing gas therefrom and into medial support chambers 512b and 512c. Screw 524 of pinch-off valve 518e would be commanded by the CPU to rotate so as to compress the connecting tube, isolating reservoirs 516a and 516c from support chambers 512b and 512c.

The mass of the gas in chambers 512b and 512c has been increased, and since chambers 512b and 512c are now isolated from the other support chambers of the bladder, their effective volume is reduced. Thus, the pressure in chambers 512b and 512c is increased. As a result, when chambers 512b and 512c are loaded, element 510 has an increased resistance to compression and is stiffer at the location of support chambers 512b and 512c. If desired, the resistance to compression of chambers 512b and 512c can be further increased by the CPU 202 commanding the closing of tube 514c, making the chambers independent of each other and decreasing their effective volumes further. Thus, when a load is localized at one or the other of chambers 512b or 512c, the stiffness of the loaded chamber is increased since fluid communication to the other chamber is prevented. For most people, during walking or running the foot rolls forwardly from the heel. Thus, chamber 512c experiences maximum loading separately from chamber 512b. As the foot rolls forwardly, the stiffness of each chamber is increased as it receives the maximum load beyond the maximum stiffness when the chambers are in communication. Accordingly, the overall stiffness experienced by the wearer is increased.

The pressure in both of chambers 512b and 512c could be further increased by the CPU 202 commanding the reopening of interconnecting tube 514a and rotation of flat screws 526 into their uppermost position to allow fluid communication from support chamber 512a into collapsible reservoirs 516a and 516c. The process described above is then repeated to force the gas from reservoirs 516a and 516c into chambers 512b and 512c to further increase their stiffness. The CPU 202 can dynamically modify the process, while the shoes are being worn by their user, until any desired stiffness is obtained. In a similar manner, the effective volumes of chambers 512a and/or 512d can be adjusted by the CPU 202 commanding and performing similar manipulations on reservoirs 516b and 516d. In fact, by making use of all four reservoirs 516., gas may be transferred from any one of chambers 512 to any of the other chambers to increase or decrease the stiffness of the bladder at a desired location, to thereby tune the overall cushioning characteristics of the midsole for a particular activity or for a specific gait characteristic of the wearer.

For example, a wearer who tends to strike the ground at the midfoot or the forefoot may prefer that forefoot chamber 512a be more compliant. In this case, the fluid pressure could be transferred to the three rearward chambers. Similarly, a wearer who strikes the ground at the lateral rear may prefer that chamber 512d be less resistant and that forefoot chamber 512a be more resistant, in which case the fluid pressure could be transferred to chamber 512a from chamber 512d.

Furthermore, the overall pressure in chambers 512a-d and thus element 510 as a whole, can be reduced by increasing the available volume to include reservoirs 516a-d. For example, connectors 514a, 514b, 514e, and 514f could be closed to isolate reservoirs 516a-d from support chambers 512a-d. Reservoirs 516a-c could be compressed to force fluid into reservoir 516d. Thereafter, connector 514d could be closed to isolate reservoir 516d. Reopening connectors 514a, 514b, and 514e and allowing reservoirs 516a-c to expand by rotating flat screws 526 into their uppermost positions would lower the pressure in support chambers 512a-c. The process could then be repeated for reservoir 516c to further lower the overall pressure in bladder 510.

Although as shown in FIG. 4, cushioning element 510 includes two separate bladder elements, that is, chamber 512a is formed as a separate element from chambers 512c-d, cushioning element 510 could be a single integral element in which chamber 512a could extend rearwardly to the forward boundary of chambers 512b and 512d, with foam element 513 eliminated. However, the portion of chamber 512a which would be disposed in the arch area of the shoe would be thinner than the remainder of chamber 512a, so as to allow pinch-off valves 518 to be disposed either above or below chamber 512a, and would include cylindrical holes formed therethrough for placement of reservoir chambers 516. Separate wall elements having internal threading could be disposed in the holes to allow for the use of flat screws 526. In this construction, chamber 512a would still be isolated by an internal wall from fluid communication with chambers 512b and 512d. Of course, bladder 510 could be formed as a single-element, including reservoirs 516.

D. Operation of the Cushioning System

A user wears the shoes containing the dynamically controlled cushioning system much like a regular pair of shoes. However, he or she can quickly adjust the cushioning of the shoes by manipulating one or more of the control knobs 210a-c.

For example, in a running shoe application, as a person increases speed, the impact force will increase. The chambers receiving the increased impact force will increased in stiffness by increasing pressure from the variable reservoir 516 or by closing the valves for those chambers, or both. Similarly, in a basketball shoe, when landing on the heel chambers after a jump, the pressure on those chambers in increased by using the variable reservoirs or by closing the valves leading to those chamber, or both.

To decrease stiffness of the chambers, for example, in both the forefoot and heel chambers, such as in a walking shoe application, the forefoot and heel chambers can be made to be fluidly linked, thus increasing the total volume which results in a less stiff feel. A user can dynamically control the softness level by adjusting one or more of the control knobs.

Similarly, the side-to-side stiffness can be easily adjusted to correct a wearer's over or under-pronation. For example, if a wearer walks or runs in an over-pronated manner, pressure in the chambers on the medial side may be increased, either automatically by the CPU 202, or by a user selecting an appropriate setting on a control knob 210c (FIG. 8), to make that side of the cushioning support more stiff, and thereby reducing the wearer's tendency to over-pronate. To correct under-pronation, pressure in the chambers on the lateral side of the shoe may be increased in a similar manner.

The present invention provides for an infinite number of variations of pressure and thus stiffness at various locations in the midsole, without requiring that gas be supplied to or released from the bladder. That is, the variations in pressure are achieved in a closed system. Thus, the attendant drawbacks of open air systems such as leakage or the requirement for an external pump are avoided. It is preferred that reservoir chambers 516 be placed in the arch of midfoot area as shown. This area receives relatively low loads and a closed reservoir in this location which would yield limited cushioning would not pose a problem, especially where foam element 513 is used. However it is possible to locate the reservoirs and control system components at any convenient location, even outside of the midsole such as on the upper. Although one particular configuration of the various support chambers, reservoirs and control system is shown, other configurations could be used. For example, chamber 512a or 512d could be broken into several smaller chambers linked in fluid communication by interconnecting tubes.

In view of the wide variety of embodiments to which the principles of the invention can be applied, it should be apparent that the detailed embodiments are illustrative only and should not be taken as limiting the scope of the invention. Rather, the claimed invention includes all such modifications as may come within the scope of the following claims and equivalents thereto.

Claims

1. An article of footwear having a dynamically-controlled cushioning system, the system comprising:

a control system attached to the article of footwear;

a fluid-filled bladder received within a sole of the article of footwear, said bladder being closed to ambient air, and having a plurality of separate cushioning chambers in fluid communication with each other, each said chamber having: a pressure detector in communication with said control system for detecting pressure in said chamber; and a regulator in communication with, and actuated by, said control system for regulating the level of fluid communication of the chamber with other chambers;

said control system modulating the level of fluid communication between said chambers by actuating said regulators in a predetermined sequence to maintain a predetermined pressure in each chamber.

2. (canceled)

3. (canceled)

4. (canceled)

5. (canceled)

6. (canceled)

7. (canceled)

8. (canceled)

9. A method of dynamically controlling a pressure in a cushioning system of an article of footwear, comprising:

operating a regulator to allow the entry of fluid from a fluid reservoir of a cushioning system into a first chamber of the cushioning system or the exit of fluid from the first chamber of the cushioning system to the fluid reservoir; and

operating an actuator to change a volume of the fluid reservoir to expel fluid from the fluid reservoir into the first chamber or draw fluid from the first chamber into the fluid reservoir.

10. The method recited in claim 9, further comprising operating a second regulator to allow the entry of fluid from a second chamber of the cushioning system into the first chamber or the exit of fluid from the first chamber to the second chamber.

11. The method recited in claim 9, further comprising:

receiving input from a user; and

operating the regulator based upon the data input.

12. The method recited in claim 11, wherein the data input corresponds to one or more of an anticipated use of the article of footwear, a weight of the user, and a pronation characteristic of a user.