SOLE ASSEMBLY WITH THERMOPLASTIC POLYURETHANE COMPONENT THEREON AND AND METHOD OF MANUFACTURING SAME

Abstract

An article of footwear has a sole assembly that includes a midsole. The midsole has a bottom with a bottom surface, and an outer wall with a side surface. At least one of a thermoplastic polyurethane outsole and a thermoplastic polyurethane toe bumper is secured to the midsole. Specifically, a thermoplastic polyurethane outsole can be secured to the bottom surface of the midsole and a thermoplastic polyurethane toe bumper can be secured to the side surface of the midsole. Moreover, at least one of a thermoplastic polyurethane outsole and a thermoplastic polyurethane toe bumper is at least partially transparent. A method of manufacturing an article of footwear includes securing such a thermoplastic polyurethane outsole and/or a thermoplastic polyurethane toe bumper to the midsole.

Description

TECHNICAL FIELD

The present teachings generally include a sole assembly for an article of footwear, and a method of manufacturing an article of footwear.

BACKGROUND

Footwear typically includes a sole configured to be located under a wearer's foot to space the foot away from the ground or floor surface. Soles can be designed to provide a desired level of cushioning. A sole may be an assembly that includes a midsole and an outsole. Athletic footwear in particular sometimes utilizes polyurethane foam or other resilient materials in the sole to provide cushioning.

SUMMARY

An article of footwear has a sole assembly that includes a midsole. The midsole has a bottom with a bottom surface, and an outer wall with a side surface. At least one of a thermoplastic polyurethane outsole and a thermoplastic polyurethane toe bumper is secured to the midsole. Specifically, a thermoplastic polyurethane outsole can be secured to the bottom surface of the midsole and a thermoplastic polyurethane toe bumper can be secured to the side surface of the midsole. Moreover, the thermoplastic polyurethane outsole and/or the thermoplastic polyurethane toe bumper is at least partially transparent. By use of an at least partially transparent thermoplastic polyurethane outsole or toe bumper, various aesthetic features can be achieved. For example, the thermoplastic polyurethane outsole or toe bumper can be dyed one or more colors, a graphic can be laser-etched on an inward-facing or on an outward-facing surface, or a polymeric film with a graphic appearing thereon can be secured to the thermoplastic polyurethane outsole or toe bumper. As used herein, a “graphic” is a design that may include text, figures, or images. Because the thermoplastic polyurethane outsole or toe bumper remains at least partially transparent, the color or colors, the laser-etched graphic, or the graphic on the polymeric film is visible on the article of footwear.

The midsole may be but is not limited to rubber. If the midsole is rubber, a two-sided or double-coated adhesive film can be used to attach the outsole or toe bumper to the midsole. The film has a carrier with a first side and a second side. A first adhesive is on the first side, and a second adhesive is on the second side. The first adhesive is in contact with and is configured to bond to the rubber of the midsole. The second adhesive is in contact with and is configured to bond to the thermoplastic polyurethane of the toe bumper.

The midsole may be configured to have a shape similar to a traditional autoclave-type athletic shoe. For example, the midsole can have a side wall forming the side surface, with the side wall generally orthogonal to the outsole. Such a configuration can be achieved whether the midsole is a rubber component or is a bladder element formed from an upper and lower polymeric sheet.

A method of manufacturing an article of footwear includes securing at least one of a thermoplastic polyurethane toe bumper and a thermoplastic polyurethane outsole to a midsole. Depending on the material of the midsole, the securing may be by one of bonding and radio frequency welding. For example, if the midsole is rubber, the securing may include applying a double-coated adhesive film so that a first side of the double-coated adhesive film bonds to the midsole and a second side of the double-coated adhesive film bonds to the toe bumper or the outsole. The method may include laser-etching a graphic on said at least one of a toe bumper and an outsole. The method may include dyeing the toe bumper and/or the outsole at least one color, or dyeing the toe bumper and/or the outsole a first color on a first side and a second color on a second side. Additionally, the method may include attaching a polymeric film to the toe bumper and/or the outsole prior to securing the toe bumper and/or the outsole to the midsole. The polymeric film can have a graphic appearing thereon. Because the toe bumper and/or the outsole is an at least partially transparent thermoplastic polyurethane, even if dyed, the laser-etched graphic and/or the graphic on the polymeric film is visible.

With the variety of aesthetic features available with the use of the thermoplastic polyurethane outsole and/or the thermoplastic polyurethane toe bumper, the method may include manufacturing the article of footwear according to a customer-selected visual characteristic, such as a particular color or graphic. Accordingly, the method may include receiving a customer selection of a visual characteristic of the toe bumper and/or the outsole, and then providing an article of footwear with the toe bumper and/or the outsole having the selected visual characteristic.

“A,” “an,” “the,” “at least one,” and “one or more” are used interchangeably to indicate that at least one of the item is present; a plurality of such items may be present unless the context clearly indicates otherwise. All numerical values of parameters (e.g., of quantities or conditions) in this specification, including the appended claims, are to be understood as being modified in all instances by the term “about” whether or not “about” actually appears before the numerical value. “About” indicates that the stated numerical value allows some slight imprecision (with some approach to exactness in the value; approximately or reasonably close to the value; nearly). If the imprecision provided by “about” is not otherwise understood in the art with this ordinary meaning, then “about” as used herein indicates at least variations that may arise from ordinary methods of measuring and using such parameters. In addition, a disclosure of a range is to be understood as specifically disclosing all values and further divided ranges within the range.

The terms “comprising,” “including,” and “having” are inclusive and therefore specify the presence of stated features, steps, operations, elements, or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, or components. Orders of steps, processes, and operations may be altered when possible, and additional or alternative steps may be employed. As used in this specification, the term “or” includes any one and all combinations of the associated listed items.

Those having ordinary skill in the art will recognize that terms such as “above,” “below,” “upward,” “downward,” “top,” “bottom,” etc., are used descriptively for the figures, and do not represent limitations on the scope of the invention, as defined by the claims.

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

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic side view illustration of an article of footwear with a sole assembly having an outsole and a toe bumper secured to a midsole.

FIG. 2 is a schematic illustration in perspective view showing the article of footwear of FIG. 1 with the toe bumper and the outsole.

FIG. 3 is a schematic cross-sectional illustration of the article of footwear of FIGS. 1 and 2 taken at lines 3-3 in FIG. 2.

FIG. 4 is a schematic illustration in perspective view showing a thermoplastic polyurethane component for the article of footwear of FIG. 1 or of FIG. 13 with a graphic laser-etched on an outward-facing side.

FIG. 5 is a schematic illustration in perspective view showing a thermoplastic polyurethane component for the article of footwear of FIG. 1 or of FIG. 13 with a graphic laser-etched on an inward-facing side.

FIG. 6 is a schematic illustration in perspective view showing a thermoplastic polyurethane component for the article of footwear of FIG. 1 or of FIG. 13 with a graphic laser-etched on an outward-facing side and dyed two different colors.

FIG. 7 is a schematic illustration in perspective view showing a thermoplastic polyurethane component for the article of footwear of FIG. 1 or of FIG. 13 with a graphic laser-etched on an inward-facing side and dyed two different colors.

FIG. 8 is a schematic illustration in perspective view showing a thermoplastic polyurethane component for the article of footwear of FIG. 1 or of FIG. 13 with a polymeric film having a graphic thereon attached to an inward-facing side.

FIG. 9 is a schematic illustration in exploded perspective view showing the thermoplastic polyurethane component and the polymeric film of FIG. 8.

FIG. 10 is a schematic illustration in perspective view showing a thermoplastic polyurethane component for the article of footwear of FIG. 1 or of FIG. 13 dyed two different colors and with a polymeric film having a graphic thereon attached to an inward-facing side.

FIG. 11 is a schematic illustration in exploded perspective view showing the thermoplastic polyurethane component and the polymeric film of FIG. 10.

FIG. 12 is a schematic illustration in perspective view of a double-coated adhesive film used to attach a toe bumper or an outsole to the midsole of FIGS. 1 and 2.

FIG. 13 is a schematic side view illustration of an alternative article of footwear with a sole assembly having a midsole that is a bladder element and with an outsole and a toe bumper secured to the midsole.

FIG. 14 is a schematic illustration in perspective view showing the article of footwear of FIG. 13 with the toe bumper and the outsole.

FIG. 15 is a schematic illustration in perspective view showing an outer surface of a thermoformed upper polymeric sheet of the bladder element.

FIG. 16 is a schematic illustration in perspective view showing an inner surface of the thermoformed polymeric upper sheet of FIG. 15.

FIG. 17 is a flow diagram of a method of manufacturing the article of footwear of FIG. 1 or of FIG. 13.

DETAILED DESCRIPTION

Referring to the drawings, wherein like reference numbers refer to like components throughout the views, FIG. 1 shows an article of footwear 10 that has a sole assembly 12 with a midsole 14. As further described herein, the midsole 14 is secured to a shoe upper 22, an outsole 24, and a toe bumper 26 are secured to the midsole 14. In the embodiment shown, the midsole 14 provides the general shape of a traditional athletic shoe with a rubber sole as manufactured according to an autoclave process. For example, the outer wall 44 of the midsole 14 surrounds a periphery 68 of the upper 22 and has a side surface 45 generally orthogonal to the outsole 24. However, other types of midsoles can be used within the scope of the present teachings. The midsole 14 has a bottom 31 with a bottom surface 33. The midsole 14 extends the full length of the article of footwear 10, and has a heel region 36, a midfoot region 38, and a forefoot region 40.

As indicated in FIG. 3, an inward-facing side 21 of the outsole 24 is secured to the bottom surface 33. An outward-facing side 25 of the outsole 24 establishes a ground contact surface 35 shown in FIG. 2. The midsole 14 also has an outer wall 44, which may also be referred to as a side wall. The outer wall 44 has an outward-facing side surface 45. An inward-facing side 27 of the toe bumper 26 is secured to the side surface 45. An outward-facing side 29 of the toe bumper 26 has a graphical pattern 23 thereon. The graphic pattern 23 may be laser-etched on the toe bumper 26. The side surface 45 is generally orthogonal to the bottom surface 33.

In the embodiment of FIGS. 1-3, the midsole 14 is rubber, and either or both of the outsole 24, and the toe bumper 26 are an at least partially transparent thermoplastic polyurethane (TPU). In other embodiments, the midsole 14 can be a material other than rubber, and one or both of the toe bumper 26 and the outsole 24 can be a material other than TPU. For example, the outsole 24 can be rubber. In the embodiment of FIGS. 1-3, the midsole 14 has a smooth texture, and is a first color. The outsole 24 is a second color, and has a second texture which may be referred to as a corrugated texture, as a result of tread elements 47 that have a zig-zag pattern, commonly referred to as a herringbone pattern. For example, in one embodiment, the midsole 14 is white and the outsole 24 and toe bumper 26 are blue. If of a TPU material, the outsole 24 and toe bumper 26 remain at least partially transparent even when dyed one or more colors.

By use of a TPU outsole 24 and/or toe bumper 26, a variety of different aesthetic options can be achieved while durability functions of the outsole 24 and toe bumper 26 are also accomplished. These options are shown in FIGS. 4-11 by TPU components 120A-120F, any of which may represent the toe bumper 26 and/or the outsole 24. Different combinations of the TPU components 120A-120F can be used for the toe bumper 26 and the outsole 24. As further explained herein, a customer may select a visual characteristic or feature of either or both of the toe bumper 26 and the outsole 24, and the article of footwear 10 can then be manufactured and/or provided with the toe bumper 26 or outsole 24 having the customer-selected visual characteristic.

FIG. 4 shows a transparent TPU component 120A that has a laser-etched graphic 123A on a first side 125A. A second side 127A does not have a graphic thereon. FIG. 5 shows a similar transparent TPU component 120B that has the laser-etched graphic 123A on a second side 127B. A first side 125B does not have a graphic thereon. Because the TPU material is at least partially transparent, the laser-etched graphic 123A is visible when viewed through the material of the component 120B from the first side 125B.

When the material of the component 120A of FIG. 4 is used for the toe bumper 26, the first side 125A is an outward-facing side, i.e., outward-facing side 29 of FIG. 3, and the second side 127A is an inward-facing side secured to the midsole 14, correlating with inward-facing side 27 of FIG. 3. When the material of component 120A is used for the outsole 24, the first side 125A is an outward-facing side, i.e., outward-facing side 25 of FIG. 3, and the second side 127A is an inward-facing side secured to the midsole 14, correlating with inward-facing side 21 of FIG. 3. In each of these embodiments, the laser-etched graphic 123A is on the outward-facing side.

When the material of the component 120B of FIG. 5 is used for the toe bumper 26, the first side 125B is an outward-facing side, i.e., outward-facing side 29 of FIG. 3, and the second side 127B is an inward-facing side secured to the midsole 14, correlating with inward-facing side 27 of FIG. 3. When the material of component 120B is used for the outsole 24, the first side 125B is an outward-facing side, i.e., outward-facing side 25 of FIG. 3, and the second side 127B is an inward-facing side secured to the midsole 14, correlating with inward-facing side 21 of FIG. 3. In each of these embodiments, the laser-etched graphic 123A is on the inward-facing side 21 or 27. However, because the TPU material is transparent, the laser-etched graphic 123A is visible when looking through the toe bumper 26 or the outsole 24 from the outward-facing side 29 or 25. In FIGS. 4 and 5, the edges of the TPU components 120A, 120B on portions facing away from the perspective view are shown with hidden lines for purposes of clarity in the drawings. In FIG. 5, the graphic 123A is shown with hidden lines for purposes of clarity in the drawings. It should be appreciated, however, that because the TPU material is transparent, the edges and the graphic 123A shown in hidden lines are actually visible from the perspective shown in the drawings.

FIGS. 6 and 7 show embodiments of transparent TPU components 120C, 120D that combine laser-etching and dyeing. FIG. 6 shows a transparent TPU component 120C that has a laser-etched graphic 123B on a first side 125C. A second side 127C does not have a graphic thereon. Alternatively, both sides 125C, 127C may have the same or different laser-etched graphics thereon. FIG. 7 shows a similar transparent TPU component 120D that has a laser-etched graphic 123B on a second side 127D. A first side 125D does not have a graphic thereon. Because the material is transparent, the laser-etched graphic 123B is visible when viewed through the material of the component 120D from the first side 125D. In FIGS. 6 and 7, the edges of the TPU components 120C, 120D on portions facing away from the perspective view are shown with hidden lines for purposes of clarity in the drawings. In FIG. 7, the graphic 123B is shown with hidden lines for purposes of clarity in the drawings. It should be appreciated, however, that because the TPU material is transparent, the edges and the graphic 123B shown in hidden lines are actually visible from the perspective shown in the drawings.

The TPU component 120C of FIG. 6 is dyed a first color extending to approximately a first portion T1 of the thickness T of the component 120C. The TPU component is dyed a second color extending to approximately a remaining portion T2 of the thickness T. Dyeing can be accomplished in stages. First, the undyed TPU component 120C can be placed with the first side 125C down in a first container of dye of the first color, with the dye in the container at a depth T1. The TPU component 120C will remain in the first container until the dye of the first color is absorbed in the portion of the thickness T1. The TPU component 120C can be allowed to dry, and then can be placed with the second side 127C face down in a second container of dye that is the second color, with the dye in the container at a depth T2. The TPU component 120C will remain in the second container until the dye of the second color is absorbed in the portion of the thickness T2. The portion dyed the first color is untouched and unaffected by the dye of the second color. The TPU component 120D of FIG. 7 is dyed in an identical manner as described with respect to the TPU component 120C. The dyeing process can occur either before or after the laser-etching of the graphic 123B on the first side 125C of the TPU component 120C, and either before or after the laser-etching of the graphic 123B on the second side 127D of the TPU component 120D. When looking through the component 120C or 120D from the first side 125C, 125D to the second side 127C, 127D, the second color may affect the appearance as the components 120C, 120D are at least partially transparent.

When the material of the component 120C of FIG. 6 is used for the toe bumper 26, the first side 125C is an outward-facing side, i.e., outward-facing side 29 of FIG. 3, and the second side 127C is an inward-facing side secured to the midsole 14, correlating with inward-facing side 27 of FIG. 3. When the material of component 120C is used for the outsole 24, the first side 125C is an outward-facing side, i.e., outward-facing side 25 of FIG. 3, and the second side 127C is an inward-facing side secured to the midsole 14, correlating with inward-facing side 21 of FIG. 3. In each of these cases, the laser-etched graphic 123B is on the outward-facing side.

When the material of the component 120D of FIG. 7 is used for the toe bumper 26, the first side 125D is an outward-facing side, i.e., outward-facing side 29 of FIG. 3, and the second side 127D is an inward-facing side secured to the midsole 14, correlating with inward-facing side 27 of FIG. 3. When the material of component 120D is used for the outsole 24, the first side 125D is an outward-facing side, i.e., outward-facing side 25 of FIG. 3, and the second side 127D is an inward-facing side secured to the midsole 14, correlating with inward-facing side 21 of FIG. 3. In each of these cases, the laser-etched graphic 123B is on the inward-facing side 21 or 27. However, because the TPU material is transparent, the laser-etched graphic 123B is visible when looking through the toe bumper 26 or the outsole 24 from the outward-facing side 29 or 25.

FIG. 8 shows a TPU component 120E that is dyed a single color throughout its thickness T. Additionally, the TPU component 120E has a polymeric film 129 adhered or otherwise secured to a second side 127E thereof. The polymeric film 129 has a graphic 131, such as a graphical design, text or image, thereon. The TPU component is transparent even when dyed. Therefore the graphic 131 of the polymeric film 129 is visible through the TPU component 120E even when viewed from the first side 125E. FIG. 9 shows the film 129 being moved toward the TPU component 120E in the direction of arrows 133. An upper surface 135 of the polymeric film 129 can have adhesive thereon.

When the material of the component 120E of FIG. 8 is used for the toe bumper 26, the first side 125E is an outward-facing side, i.e., outward-facing side 29 of FIG. 3, and the second side 127E is an inward-facing side secured to the midsole 14, correlating with inward-facing side 27 of FIG. 3. When the material of component 120E is used for the outsole 24, the first side 125E is an outward-facing side, i.e., outward-facing side 25 of FIG. 3, and the second side 127E is an inward-facing side secured to the midsole 14, correlating with inward-facing side 21 of FIG. 3. In each of these cases, the polymeric film 129 with the graphic 131 is on the inward-facing side 21 or 27. However, because the TPU material is transparent, the graphic 131 is visible when looking through the toe bumper 26 or the outsole 24 from the outward-facing side 29 or 25. In FIGS. 8 and 9, the edges of the TPU component 120E on portions facing away from the perspective view are shown with hidden lines for purposes of clarity in the drawings. In FIG. 8, the graphic 131 on the film 129 is shown with hidden lines for purposes of clarity in the drawings. It should be appreciated, however, that because the TPU material is transparent, the edges and the graphic 131 shown in hidden lines are actually visible from the perspective shown in the drawings.

FIG. 10 shows a TPU component 120F that is dyed two different colors according to the dyeing process described with respect to FIG. 6. The TPU component 120F is dyed a first color extending to approximately a first portion T1 of the thickness T of the component 120F. The TPU component 120F is dyed a second color extending to approximately a remaining portion T2 of the thickness T. Additionally, the TPU component 120F has the polymeric film 129 described with respect to FIG. 8 adhered or otherwise secured to a second side 127F thereof. The polymeric film 129 has the graphic 131 thereon. The film 129 can be secured such as by adhesives, as described with respect to FIG. 9, after the dyeing process. The TPU component 120F is transparent even when dyed. Therefore the graphic 131 of the polymeric film 129 is visible through the TPU component 120F even when viewed from the first side 125F. FIG. 11 shows the film 129 being moved toward the TPU component 120F in the direction of arrows 133. An upper surface 135 of the polymeric film 129 can have adhesive thereon.

When the material of the component 120F of FIG. 10 is used for the toe bumper 26, the first side 125F is an outward-facing side, i.e., outward-facing side 29 of FIG. 3, and the second side 127F is an inward-facing side secured to the midsole 14, correlating with inward-facing side 27 of FIG. 3. When the material of component 120F is used for the outsole 24, the first side 125F is an outward-facing side, i.e., outward-facing side 25 of FIG. 3, and the second side 127F is an inward-facing side secured to the midsole 14, correlating with inward-facing side 21 of FIG. 3. In each of these cases, the polymeric film 129 with the graphic 131 is on the inward-facing side 21 or 27. However, because the TPU material is transparent, the graphic 131 is visible when looking through the toe bumper 26 or the outsole 24 from the outward-facing side 29 or 25. In FIGS. 10 and 11, the edges of the TPU component 120F on portions facing away from the perspective view are shown with hidden lines for purposes of clarity in the drawings. In FIG. 10, the graphic 131 on the film 129 is shown with hidden lines for purposes of clarity in the drawings. It should be appreciated, however, that because the TPU material is transparent, the edges and the graphic 131 shown in hidden lines are actually visible from the perspective shown in the drawings.

FIG. 12 shows double-coated adhesive film 150 that can be used to attach a TPU component to a rubber component. The double-coated adhesive film 150 is used to attach the TPU toe bumper 26 to the side surface 45 of the outer wall 44 of the rubber midsole 14, and is used to attach the TPU outsole 24 to the bottom surface 33 of the midsole 14. Specifically, the double-coated adhesive film 150 has a carrier 152. The carrier 152 has a first side 154 and a second side 156. A first adhesive 158 is applied on the first side 154. A second adhesive 160 is applied on the second side 156. The first adhesive 158 is specifically formulated to bond to rubber. The second adhesive 160 is specifically formulated to bond to thermoplastic polyurethane such as during heating by thermal bonding. The double-coated adhesive film 150 is placed between the toe bumper 26 and the midsole 14 so that the first adhesive 158 is in contact with and bonds to the rubber of the midsole 14 on the side wall 44. The second adhesive 160 is in contact with and bonds to the thermoplastic polyurethane of the toe bumper 26 on the inward-facing side of the toe bumper 26. Similarly, the double-coated adhesive film 150 is used to bond the outsole 24 to the bottom surface 33 of the midsole 14 by placing the first adhesive 158 in contact with the midsole 14 and the second adhesive 160 in contact with the outsole 24. The double-coated adhesive film 150 can be applied first to the midsole 14 and then to the respective TPU component, toe bumper 26 or outsole 24, or the double-coated adhesive film 150 can be applied first to the respective TPU component, toe bumper 26 or outsole 24, and then to the midsole 14. The double-coated adhesive film 150, including the adhesives 158, 160 and the carrier 152, is transparent. Accordingly, the double-coated adhesive film 150 does not affect the aesthetics of the toe bumper 26 or the outsole 24.

FIGS. 13 and 14 show another article of footwear 210 to which the TPU toe bumper 26 and the TPU outsole 24 can be secured. The article of footwear 210 has a sole structure 212 with a midsole 214 that is a full-length bladder element rather than a rubber midsole. The midsole 214 is also referred to as a bladder element 214.

The bladder element 214 is a fluid-filled, airtight chamber, as further described herein. The bladder element 214 can be inflated and can resiliently retain a fluid such as air or another gas, and can be at an ambient pressure or pressurized. If the bladder element 214 is inflated with air, it may be referred to as an airbag.

The bladder element 214 is formed from two polymeric sheets, including a first polymeric sheet 16, and a second polymeric sheet 18. The first polymeric sheet 16 is also referred to herein as an upper polymeric sheet 16, and the second polymeric sheet 18 is also referred to herein as a lower polymeric sheet 18. The polymeric sheets 16, 18 are attached to one another as described herein to define a sealed interior cavity 20 that retains the fluid. FIG. 15 shows a tube 17 formed in the upper polymeric sheet 16. The tube 17 is used to fill the bladder element 214. The opening in the tube 17 is then plugged and the tube 17 is trimmed. As further described herein, the bladder element 214 is cooperatively configured to interfit with the footwear upper 22, the outsole 24, and the optional toe bumper 26 to provide the general shape of a traditional athletic shoe with a rubber sole as manufactured according to an autoclave process. In other embodiments, the article of footwear 210 could be for a dress shoe, a work shoe, a sandal, a slipper, a boot, or any other category of footwear. The bladder element 214 provides desirable resiliency and cushioning characteristics and may be lighter in weight than a traditional rubber sole. Moreover, as the bladder element 214, the outsole 24, and the toe bumper 26 can be formed from at least partially transparent materials, the article of footwear 210 has unique characteristics, such as the visibility of the shoe upper 22 through the bladder element 214 from the exterior of the article of footwear 10.

Referring to FIG. 15, the upper polymeric sheet 16 has an outer surface 30 that defines a downwardly-extending recess 32. More specifically, a portion of the outer surface 30 is an upward-facing surface 34 that is generally the shape of a human foot. The surface 34 is configured as a foot support surface with a heel region 36, a midfoot region 38, and a forefoot region 40 generally correlating with a heel, an arch, and a forefoot of a human foot. The foot need not directly contact the upward-facing surface 34, but is supported by the upward-facing surface 34. For purposes of discussion, the heel region 36, the midfoot region 38, and the forefoot region 40 are defined as the rearmost third, the middle third, and the foremost third of the upward-facing surface 34. Heel region 36 generally includes portions of the upper polymeric sheet 16 corresponding with rear portions of a human foot of a size corresponding with the article of footwear 210, including the calcaneus bone. Forefoot region 40 generally includes portions of the upper polymeric sheet 16 corresponding with the toes and the joints connecting the metatarsals with the phalanges of a human foot of a size corresponding with the article of footwear 210. Midfoot region 38 generally includes portions of the upper polymeric sheet 16 corresponding with an arch area of a human foot of a size corresponding with the article of footwear 210. In light of the upward-facing surface 34 having a heel region 36, a midfoot region 38, and a forefoot region 40, the bladder element 214 can be referred to as a full-length bladder element, as the heel region 36, midfoot region 38, and forefoot region 40 together extend the full length of a human foot having dimensions for which the article of footwear 210 is sized.

In the embodiment shown, the upper polymeric sheet 16 is formed from a single, flat sheet, such as by thermoforming, to attain the relatively complex, contoured shape shown in FIGS. 15 and 16. The upper polymeric sheet 16 has an inner wall portion 42, a peripheral outer wall portion 244, and a ridge 46 between the inner wall portion 42 and the outer wall portion 244. The ridge 46 forms the uppermost extent of the sheet 16. The inner wall portion 42 extends generally downward to the upward-facing surface 34 so that the inner wall portion 42 and the upward-facing surface 34 together define the recess 32. The outer wall portion 244 extends generally downward from the ridge 46 further than the recess 32 and the inner wall portion 42, so that a continuous terminal edge 48 of the outer wall portion 244 is below a lowest extent of the recess 32, and extends around an entire periphery of the recess 32. In other words, the portion of the upper polymeric sheet 16 forming the upward-facing surface 34 is elevated relative to the edge 48 in the assembled article of footwear 210. The outer wall portion 244 is also referred to as an outer wall, a side wall, or a sidewall portion.

The bladder element 214 also includes the lower polymeric sheet 18 attached to the upper polymeric sheet 16 by bonding at a flange 106 near the terminal edge 48 of the outer wall portion 244 as further described herein. The upper and lower polymeric sheets 16, 18 define the interior cavity 20. An inner surface of the lower polymeric sheet 18 is joined to an inner surface of the upper polymeric sheet 16 at multiple bonds 60 extending transversely and only partway across the interior cavity 20 from a medial side 62 of the outer wall portion 244 to a lateral side 64 of the outer wall portion 244, as shown in FIG. 14. As used herein, a lateral side of a component for an article of footwear 210, such as the lateral side 64 of the outer wall portion 244 of the upper polymeric sheet 16, is a side that corresponds with an outside area of the foot of the wearer of the article of footwear 10 that is generally further from the other foot of the wearer (i.e., the side closer to the fifth toe of the wearer). The fifth toe is commonly referred to as the little toe. A medial side of a component for an article of footwear, such as the medial side 62 of the outer wall portion 244 of the upper polymeric sheet 16, is the side that corresponds with an inside area of the foot on which the article of footwear 210 is worn and that is generally closer to the other foot of the wearer (i.e., the side closer to the hallux of the foot of the wearer). The hallux is commonly referred to as the big toe.

The recess 32, the ridge 46, and the outer wall portion 244 define an inverted channel 65 at the inner surface 51 of the upper polymeric sheet 16. The inverted channel 65 is part of the interior cavity 20. Because the bonds 60 do not extend completely between the lateral side 64 of the outer wall portion 244 and the medial side 62 of the outer wall portion 244, the inverted channel 65 is in fluid communication with the interior cavity 20 and is a peripheral portion of the interior cavity 20.

The upper polymeric sheet 16 and the lower polymeric sheet 18 are at least partly thermoplastic polyurethane. Examples of polymer materials for the bladder element 214 include thermoplastic polyurethane, polyester, polyester polyurethane, and polyether polyurethane. Moreover, each of the polymeric sheets 16, 18 of the bladder element 214 can be formed of layers of different materials. In one embodiment, the sheets 16, 18 of the bladder element 214 are each formed from thin films having one or more thermoplastic polyurethane (TPU) layers with one or more barrier layers of a copolymer of ethylene and vinyl alcohol (EVOH) that is impermeable to the pressurized fluid contained therein as disclosed in U.S. Pat. No. 6,082,025 to Bonk et al., which is incorporated by reference in its entirety. The polymeric sheets 16, 18 may also be formed from a material that includes alternating layers of thermoplastic polyurethane and ethylene-vinyl alcohol copolymer, as disclosed in U.S. Pat. Nos. 5,713,141 and 5,952,065 to Mitchell et al. which are incorporated by reference in their entireties. Alternatively, the layers may include ethylene-vinyl alcohol copolymer, thermoplastic polyurethane, and a regrind material of the ethylene-vinyl alcohol copolymer and thermoplastic polyurethane. The polymeric sheets 16, 18 of the bladder element 214 may also be flexible microlayer membranes that include alternating layers of a gas barrier material and an elastomeric material, as disclosed in U.S. Pat. Nos. 6,082,025 and 6,127,026 to Bonk et al. which are incorporated by reference in their entireties. Additional suitable materials for the bladder element 214 are disclosed in U.S. Pat. Nos. 4,183,156 and 4,219,945 to Rudy, which are incorporated by reference in their entireties. Further suitable materials for the bladder element 214 include thermoplastic films containing a crystalline material, as disclosed in U.S. Pat. Nos. 4,936,029 and 5,042,176 to Rudy, and polyurethane including a polyester polyol, as disclosed in U.S. Pat. Nos. 6,013,340, 6,203,868, and 6,321,465 to Bonk et al. which are incorporated by reference in their entireties.

In selecting materials for the bladder element 214, engineering properties such as tensile strength, stretch properties, fatigue characteristics, dynamic modulus, and loss tangent can be considered. The thicknesses of polymeric sheets 16, 18 used to form the bladder element 214 can be selected to provide these characteristics. The bladder element 214 is resilient and provides cushioning and flexibility that can be tuned such as by selecting a level of pressurization. In the embodiment shown in FIG. 13, the bladder element 214 is at ambient pressure. Optionally, tensile members and/or reinforcing structures can be integrated with the bladder element 214 to provide desired responsiveness, such as disclosed in U.S. Pat. No. 4,906,502 to Rudy et al., and U.S. Pat. No. 8,061,060 to Swigart et al., which are incorporated by reference in their entireties.

Referring to FIG. 13, the footwear upper 22 has a lower surface 66 secured to the upper surface 34 of the upper polymeric sheet 16 in the recess 32. The footwear upper 22 is also secured to the inner wall portion 42 shown in FIG. 15. The outer wall portion 244 surrounds a periphery 68 of the footwear upper 22. The periphery 68 of the footwear upper 22 is indicated in FIG. 13. Stated differently, the footwear upper 22 is nested in the recess 32 inward of the inner wall portion 42. The upper polymeric sheet 16 is at least partially transparent. A lower extent of the footwear upper 22 is thus visible from an exterior of the article of footwear 210 through the outer wall portion 244 and the inner wall portion 42 to the nested footwear upper 22.

Like the upper polymeric sheet 16, the lower polymeric sheet 18 is also an at least partially transparent material. The outsole 24 provides the ground contact surface 74 of the article of footwear 210, and can be thermoplastic polyurethane with a greater hardness and thickness than the lower polymeric sheet 18 to provide durability, traction and abrasion resistance. An upper surface of the outsole 24 is secured to a lower surface of the lower polymeric sheet 18 after bladder element 214 is formed and inflated. The outsole 24 can be configured so that when it is secured to the lower polymeric sheet 18, the peripheral edge of the outsole 24 is substantially perpendicular to the outer wall portion 244. The outsole 24 is an at least partially transparent thermoplastic polyurethane. In this case, the outsole 24 is secured to the bladder element 214 with adhesives or by radio frequency welding. Alternatively, the outsole 24 can be a rubber material, in which case the double-coated adhesive film 150 of FIG. 12 is used to secure the outsole 24 to the bladder element 214. The pattern of the bonds 60 of the lower polymeric sheet 18 to the upper polymeric sheet 16 is visible through the outsole 24. The pattern of the bonds 60 may be selected to serve both a mechanical function and to be aesthetically pleasing through the outsole 24.

The optional toe bumper 26 is secured to a portion of the upper polymeric sheet 16 that is the outward-facing surface 78 of the outer wall portion 244. Specifically, the toe bumper 26 is secured to the outward-facing surface 78 at the outer wall portion 244 adjacent the forefoot region 40. Like the outsole 24, the toe bumper 26 may also be an at least partially transparent material, and can be a thermoplastic polyurethane with a greater hardness and thickness than the lower polymeric sheet 18 to provide durability and abrasion resistance. In this case, the toe bumper 26 is secured to the bladder element 214 with adhesives or by radio frequency welding.

The thermoplastic polyurethane material used for the outsole 24 and/or the toe bumper 26 can be any of the materials of TPU components 120A-120F, with laser-etching, dyeing, and polymeric film 129 with a graphic 131, or with combinations of these aesthetic features, as described herein. As further explained herein, a customer may select a visual characteristic or feature of either or both of the toe bumper 26 and the outsole 24, and the article of footwear 210 can then be manufactured and/or provided with the toe bumper 26 or outsole 24 having the customer-selected visual characteristic.

FIG. 17 is a flow diagram of a method 300 of manufacturing an article of footwear, such as article of footwear 10 or 210, with a TPU toe bumper 26 and/or a TPU outsole 24. Optionally, the article of footwear 10 or 210 can be made to order with one or more visual characteristics according to a specifically indicated customer preference. In this instance, the method 300 can include step 302, receiving a customer selection of a visual characteristic of said at least one of a toe bumper 26 and an outsole 24. The visual characteristic, for example, can be a color of which all or a portion of the TPU toe bumper and/or outsole 24 is to be dyed, a graphic to be laser-etched on the TPU toe bumper 26 and/or on the outsole 24, or a graphic on a polymeric film 129 to be attached to the TPU toe bumper 26 and/or outsole 24.

In step 304, the article of footwear 10 or 210 is provided with a TPU toe bumper 26 and/or outsole 24, which are according to the customer selected visual characteristic if the method 300 includes step 302, or, otherwise, are according to another production decision.

The article of footwear 10 or 210 provided in step 304 results from one or more substeps 306-316. In step 306, the TPU toe bumper 26 and/or outsole 24 is secured to the midsole 14 or 214, respectively. In the case of a rubber midsole 14, the securing step 306 may include sub-step 308, in which the TPU toe bumper 26 and/or outsole 24 is bonded to the midsole 14 in step 308, such as with the double-coated adhesive film 150. In the case of the polymeric bladder element 214 as the midsole, the securing step 306 may include sub-step 310, in which the TPU toe bumper 26 and/or outsole 24 is secured to the midsole 214 by radio frequency welding.

Optionally, the article of footwear 10 or 210 is provided with a visual characteristic, such as may be received from a customer in step 302. For example, in sub-step 312, a graphic such as 123A or 123B is laser-etched on the toe bumper 26 and/or outsole 24. Additionally or alternatively, in sub-step 314, the toe bumper 26 and/or outsole 24 can be dyed one or more colors, as described with respect to TPU components 120C, 120D, 120E, and 120F. Still further, in sub-step 316, a polymeric film 129 with a graphic appearing thereon, such as polymeric film 150 with graphic 31, is attached to the toe bumper 26 and/or the outsole 24 in sub-step 316.

Accordingly, the articles of footwear 10 or 210 and the method 300 enable a wide variety of aesthetically-pleasing visual characteristics with the use of TPU toe bumpers and/or outsoles.

While the best modes for carrying out the many aspects of the present teachings have been described in detail, those familiar with the art to which these teachings relate will recognize various alternative aspects for practicing the present teachings that are within the scope of the appended claims.

Claims

1. A sole assembly for an article of footwear comprising:

a midsole having a bottom with a bottom surface, and having an outer wall with a side surface; and

at least one of a thermoplastic polyurethane outsole secured to the bottom surface of the midsole and a thermoplastic polyurethane toe bumper secured to the side surface of the midsole; wherein said at least one of a thermoplastic polyurethane outsole and a thermoplastic polyurethane toe bumper is at least partially transparent.

2. The sole assembly of claim 1, wherein the outsole has an inward-facing side secured to the bottom surface of the midsole and an outward-facing side establishing a ground contact surface; and wherein the outsole has a laser-etched graphic on the outward-facing side.

3. The sole assembly of claim 1, wherein the outsole has an inward-facing side secured to the bottom surface of the midsole; and wherein the outsole has a laser-etched graphic on the inward-facing side.

4. The sole assembly of claim 1, wherein the toe bumper has an inward-facing side secured to the side surface of the midsole and an outward-facing side; and wherein the toe bumper has a laser-etched graphic on the outward-facing side.

5. The sole assembly of claim 1, wherein the toe bumper has an inward-facing side secured to the side surface of the midsole; and wherein the toe bumper has a laser-etched graphic on the inward-facing side.

6. The sole assembly of claim 1, wherein said at least one of the outsole and the toe bumper has an inward-facing side and an outward-facing side; and wherein said at least one of the outsole and the toe bumper is dyed a first color on the inward-facing side and a second color on the outward-facing side.

7. The sole assembly of claim 6, wherein said at least one of the outsole and the toe bumper has a thickness; wherein said at least one of the outsole and the toe bumper is dyed a first color extending to approximately a first portion of the thickness; and wherein said at least one of the outsole and the toe bumper is dyed a second color extending to approximately a remaining portion of the thickness.

8. The sole-assembly of claim 6, wherein said at least one of the outsole and the toe bumper has a laser-etched graphic on the outward-facing side.

9. The sole-assembly of claim 6, wherein said at least one of the outsole and the toe bumper has a laser-etched graphic on the inward-facing side.

10. The sole-assembly of claim 6, further comprising:

a polymeric film with a graphic appearing thereon; wherein the polymeric film is attached to said at least one of the outsole and the toe bumper.

11. The sole assembly of claim 10, wherein said at least one of the outsole and the toe bumper has an inward-facing side and an outward-facing side; and

wherein the polymeric film is attached to the inward-facing side and the graphic is visible through said at least one of the outsole and the toe bumper.

12. The sole assembly of claim 11, wherein said at least one of the outsole and the toe bumper is dyed a first color on the inward-facing side and a second color on the outward-facing side.

13. The sole assembly of claim 1, wherein the midsole is rubber.

14. The sole assembly of claim 13, further comprising:

a double-coated adhesive film attaching the toe bumper to the midsole; wherein the film has:

a carrier with a first side and a second side;

a first adhesive on the first side;

a second adhesive on the second side; wherein the first adhesive is in contact with and configured to bond to the rubber of the midsole; and wherein the second adhesive is in contact with and configured to bond to the thermoplastic polyurethane of the toe bumper.

15. The sole assembly of claim 13, further comprising:

a double-coated adhesive film attaching the outsole to the midsole; wherein the film has:

a carrier with a first side and a second side;

a first adhesive on the first side;

a second adhesive on the second side; wherein the first adhesive is in contact with and configured to bond to the rubber of the midsole; and wherein the second adhesive is in contact with and configured to bond to the thermoplastic polyurethane of the outsole.

16. The sole assembly of claim 1, wherein the midsole is a color different than a color of said at least one of the outsole and the toe bumper.

17. The sole assembly of claim 1, wherein the midsole has a first texture; and

wherein said at least one of the outsole and the toe bumper has a second texture different than the first texture.

18. The sole assembly of claim 1, wherein the outsole has a series of tread elements arranged to extend laterally in a zig-zag pattern.

19. The sole assembly of claim 1, wherein the outer wall defines a periphery of the sole assembly; and wherein the outer wall and the bottom surface are substantially orthogonal.

20. The sole assembly of claim 19, in combination with a footwear upper; and wherein the outer wall surrounds a periphery of the footwear upper.

21. The sole assembly of claim 1, wherein the midsole is a bladder element having:

a first polymeric sheet; wherein the outer wall is a peripheral portion of the first polymeric sheet;

a second polymeric sheet attached to the first polymeric sheet at the outer wall such that the first and second polymeric sheets define an interior cavity; and wherein the second polymeric sheet defines the bottom and the bottom surface of the midsole.

22. A sole assembly for an article of footwear comprising:

a midsole having a bottom with a bottom surface, and having an outer wall with a side surface;

a thermoplastic polyurethane outsole secured to the bottom surface;

a thermoplastic polyurethane toe bumper secured to the side surface; wherein the outsole and the toe bumper are at least partially transparent;

wherein at least one of the outsole and the toe bumper has a laser-etched graphic thereon;

wherein at least one of the outsole and the toe bumper has a thickness and is dyed a first color extending to approximately a first portion of the thickness; and

wherein said at least one of the outsole and the toe bumper is dyed a second color extending to approximately a remaining portion of the thickness.

23. The sole assembly of claim 22, wherein the midsole is rubber; and further comprising:

a double-coated adhesive film attaching the outsole to the midsole; wherein the film has:

a carrier with a first side and a second side;

a first adhesive on the first side; a second adhesive on the second side; wherein the first adhesive is in contact with and configured to bond to the rubber of the midsole; and wherein the second adhesive is in contact with and configured to bond to the thermoplastic polyurethane of the outsole.

24. The sole assembly of claim 22, further comprising:

a polymeric film with a graphic appearing thereon; wherein the polymeric film is attached to one of the outsole and the toe bumper

25. A method of manufacturing an article of footwear, comprising:

securing at least one of a toe bumper and an outsole to a midsole; wherein said at least one of the toe bumper and the outsole is thermoplastic polyurethane.

26. The method of claim 25, wherein said securing includes:

applying a double-coated adhesive film so that a first side of the double-coated adhesive film bonds to the midsole and a second side of the double-coated adhesive film bonds to said at least one of a toe bumper and an outsole.

27. The method of claim 25, wherein said securing is by one of bonding and radio frequency welding.

28. The method of claim 25, further comprising:

laser-etching a graphic on said at least one of a toe bumper and an outsole.

29. The method of claim 25, further comprising:

dyeing said at least one of a toe bumper and an outsole at least one color.

30. The method of claim 29, wherein said dyeing said at least one of a toe bumper and an outsole includes dyeing a first color on a first side of said at least one of a toe bumper and an outsole and dying a second color on a second side of said at least one of a toe bumper and an outsole.

31. The method of claim 25, further comprising:

attaching a polymeric film to said at least one of a toe bumper and an outsole; wherein the polymeric film has a graphic appearing thereon.

32. The method of claim 25, further comprising:

receiving a customer selection of a visual characteristic of said at least one of a toe bumper and an outsole;

providing an article of footwear with said at least one of a toe bumper and an outsole; wherein said at least one of a toe bumper and an outsole has said visual characteristic.

33. The method of claim 32, wherein the visual characteristic is one of a color and a graphic.