ARTICLE OF FOOTWEAR HAVING A SOLE STRUCTURE

Abstract

A sole structure for an article of footwear, the sole structure including a forefoot region and a heel region. The sole structure further includes a chassis plate, an outsole plate extending from the forefoot region to the heel region, the outsole plate including a recess disposed in a top surface, wherein the outsole plate is disposed below the chassis plate, and a cushioning element disposed within the recess.

Description

CROSS-REFERENCE TO RELATED APPLICATION(S)

This application is a continuation of U.S. application Ser. No. 18/178,342, filed on Mar. 3, 2023, which claims priority to U.S. Provisional Application No. 63/316,632, filed Mar. 4, 2022, each of which is incorporated by reference herein in its entirety.

FIELD

The present disclosure relates generally to articles of footwear, and more particularly to a sole structure for an article of footwear.

BACKGROUND

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

Articles of footwear conventionally include an upper and a sole structure. The upper may be formed from any suitable material(s) to receive, secure, and support a foot on the sole structure. The upper may cooperate with laces, straps, or other fasteners to adjust the fit of the upper around the foot. A bottom portion of the upper, proximate to a bottom surface of the foot, attaches to the sole structure.

Sole structures generally include a layered arrangement extending between a ground surface and the upper. One layer of the sole structure includes an outsole that provides abrasion-resistance and traction with the ground surface. The outsole may be formed from polymers or other materials that impart durability and wear-resistance, as well as enhancing traction with the ground surface. Another layer of the sole structure includes a midsole disposed between the outsole and the upper. The midsole provides cushioning for the foot and is, generally, at least partially formed from a polymer foam material that compresses resiliently under an applied load to cushion the foot by attenuating ground-reaction forces. The midsole may define a bottom surface on one side that opposes the outsole and a footbed on the opposite side that may be contoured to conform to a profile of the bottom surface of the foot. Sole structures may also include a comfort-enhancing insole and/or a sockliner located within a void proximate to the bottom portion of the upper.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings described herein are of selected embodiments for illustrative purposes only. Accordingly, the drawings do not include all possible implementations, and are not intended to limit the scope of the present disclosure.

FIG. 1 illustrates an exemplary article of footwear including a sole structure, according to an embodiment of the disclosure;

FIG. 2 illustrates an exploded view of the sole structure of the article of footwear of FIG. 1;

FIG. 3a illustrates a top-down view of an outsole plate of the sole structure of the article of footwear of FIG. 1;

FIG. 3b illustrates a bottom view of a studded moderator plate of the sole structure of the article of footwear of FIG. 1;

FIG. 4 illustrates a partially exploded view of the sole structure of the article of footwear of FIG. 1;

FIG. 4a illustrates a top-down view of a forefoot cushioning element of the sole structure of the article of footwear of FIG. 1;

FIG. 4b illustrates a cross-sectional view of the sole structure of the article of footwear of FIG. 4;

FIG. 4c illustrates a cross-sectional view taken along line A-A of a cushioning element of the sole structure of the article of footwear of FIG. 4;

FIG. 4d illustrates a cross-sectional view taken along line B-B of a cushioning element of the sole structure of the article of footwear of FIG. 4;

FIG. 5 illustrates a top-down view of a forefoot cushioning element disposed in an outsole plate of the sole structure of the article of footwear of FIG. 1,

FIG. 6 illustrates a perspective view of the sole structure of the article of footwear of FIG. 1;

FIG. 7 illustrates an exploded view of an alternative embodiment of the sole structure of the article of footwear;

FIG. 8 illustrates a top-down view of an alternative embodiment of a forefoot cushioning element of the sole structure of the article of footwear of FIG. 7;

FIG. 9 illustrates a perspective view of a moderator plate of the sole structure of the article of footwear of FIG. 7;

FIG. 10 illustrates a bottom view of a moderator plate and a gasket of the sole structure of the article of footwear of FIG. 7;

FIG. 11 illustrates a perspective view of a gasket of the sole structure of the article of footwear of FIG. 7;

FIG. 12 illustrates a perspective view of the sole structure of the article of footwear of FIG. 7;

FIG. 13 illustrates a bottom view of the sole structure of the article of footwear of FIG. 7;

FIG. 14 illustrates an exploded view of an alternative embodiment of the sole structure of the article of footwear;

FIG. 15 illustrates an exploded view of an alternative embodiment of the sole structure of the article of footwear;

FIG. 16 illustrates a cross-sectional view of the footwear of FIG. 15; and

FIG. 17 illustrates a bottom view of the sole structure of FIG. 15.

Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.

DETAILED DESCRIPTION

Example embodiments will now be described more fully with reference to the accompanying drawings. Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope of those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well known technologies are not described in detail.

The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.

When an element or layer is referred to as being “on,” “engaged to,” “connected to,” or “coupled to” another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.

Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.

Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” may encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

In the discussion that follows, terms “about,” “approximately,” “substantially,” and the like, when used in describing a numerical value, denote a variation of +/−10% of that value, unless specified otherwise.

Examples of the present disclosure relate to, among other things, articles of footwear having a sole structure. In one example, the articles of footwear may improve performance of a user. Each of the examples disclosed herein may include one or more of the features described in connection with any of the other disclosed examples. Examples of the present disclosure may incorporate cushioning elements into a sole structure while maintaining an overall height of an article of footwear relatively low/short.

Article of Footwear

Referring to FIG. 1, an article of footwear 10 includes an upper 100 and sole structure 101 (shown in FIG. 2). The article of footwear 10 may be divided into one or more regions. The regions may include a forefoot region 12, a mid-foot region 14, and a heel region 16. The forefoot region 12 may be subdivided into a toe portion 12T corresponding with phalanges, and a ball portion 12B associated with metatarsal bones of a foot. The mid-foot region 14 may correspond with an arch area of the foot, and the heel region 16 may correspond with rear portions of the foot, including a calcaneus bone. The footwear 10 may further include an anterior end 18 associated with a forward-most point of the forefoot region 12 and a posterior end 20 associated with a rearward-most point of the heel region 16. A longitudinal axis of the footwear 10 extends along a length of the footwear 10 from the anterior end 18 to the posterior end 20, and generally divides the footwear 10 into a medial side 22 (shown in FIG. 3B) and a lateral side 24 (also shown in FIG. 3B). Accordingly, the medial side 22 and the lateral side 24 respectively correspond with opposite sides of the footwear 10 and extend through the regions 12, 14, 16.

Upper

Referring to FIG. 1, the upper 100 includes interior surfaces that define an interior void configured to receive and secure a foot for support on the sole structure 101. The upper 100 may be formed from one or more materials that are stitched or adhesively bonded together to form the interior void. Suitable materials of the upper 100 may include, but are not limited to, mesh, textiles, foam, leather, and synthetic leather. The materials may be selected and located to impart properties of durability, air-permeability, wear-resistance, flexibility, and comfort. An ankle opening 110 in the heel region 16 may provide access to the interior void. For example, the ankle opening 110 may receive a foot to secure the foot within the void and to facilitate entry and removal of the foot to and from the interior void.

In some examples, the upper 100 includes a strobel having a bottom surface opposing the sole structure 101 and an opposing top surface defining a footbed of the interior void. Stitching or adhesives may secure the strobel to the upper 100. The footbed may be contoured to conform to a profile of the bottom surface (e.g., plantar) of the foot. Optionally, the upper 100 may also incorporate additional layers such as an insole or sockliner that may be disposed upon the strobel and reside within the interior void of the upper 100 to receive a plantar surface of the foot to enhance the comfort of the article of footwear 10. The sockliner may include resilient materials thereby imparting a desired level of support and stiffness.

In some examples, one or more fasteners 111 extend along the upper 100 to adjust a fit of the interior void around the foot and to accommodate entry and removal of the foot therefrom. The upper 100 may include apertures such as eyelets and/or other engagement features such as fabric or mesh loops that receive the fasteners 111. The fasteners 111 may include laces, straps, cords, hook-and-loop, or any other suitable type of fastener. The upper 100 may include a tongue portion that extends between the interior void and the fasteners 111. Additionally or alternatively, the upper 100 may be formed with a tensioning system including a series of cables routed through cable locking devices attached to the article of footwear.

Sole Structure

With reference to FIGS. 1 and 2, the sole structure 101 includes a chassis plate (chassis) 102 extending between the medial side 22 and the lateral side 24 from the anterior end 18 to the posterior end 20. The sole structure 101 further includes a forefoot cushion 103 disposed on an outsole plate (stud plate) 104. The outsole plate 104 and forefoot cushion 103 may be coupled to the chassis plate 102. The bottom surface of outsole plate 104 may define a ground-engaging surface of the article of footwear 10.

Chassis

Referring to FIG. 2, the chassis plate 102 may extend continuously from the anterior end 18 of the sole structure 101 to the posterior end 20, and may span a width of the sole structure 101 from the medial side 22 to the lateral side 24. The chassis plate 102 may further comprise a top (upper) surface 202 facing the bottom of the upper 100, and a bottom (lower) surface 204 formed on an opposite side of the chassis plate 102 from the top surface 202, facing in the direction of a ground surface. A distance from the top surface 202 to the bottom surface may define a thickness of the chassis plate 102. In the present embodiment, the top surface 202 of the chassis plate 102 may be positioned against the strobel of the upper 100 (shown in FIG. 1) from the anterior end 18 to the posterior end 20. In some examples, the entire top surface 202 may be attached (e.g., directly attached) to the strobel of the upper 100, such that the upper surface 202 of the chassis plate 102 may define a profile of the footbed.

The chassis plate 102 may be formed of a material providing relatively high strength and stiffness, such as polymeric material and/or composite materials. In some examples, the chassis plate 102 may be a composite material manufactured using fiber sheets or textiles, including pre-impregnated (i.e., “prepreg”) fiber sheets or textiles. Alternatively or additionally, the chassis plate 102 may be manufactured by strands formed from multiple filaments of one or more types of fiber (e.g., fiber tows) by affixing the fiber tows to a substrate or to each other to produce a plate having the strands of fibers arranged predominately at predetermined angles or in predetermined positions. When using strands of fibers, the types of fibers included in the strand may include synthetic polymer fibers which may be melted and re-solidified to consolidate the other fibers present in the strand and, optionally, other components such as stitching thread or a substrate or both. Alternatively or additionally, the fibers of the strand and, optionally the other components such as stitching thread or a substrate or both, may be consolidated by applying a resin after affixing the strands of fibers to the substrate and/or to each other.

In some configurations, chassis plate 102 may be formed from one or more layers of tows of fibers and/or layers of fibers including at least one of carbon fibers, boron fibers, glass fibers, and polymeric fibers. In a particular configuration, the fibers include carbon fibers, or glass fibers, or a combination of both carbon fibers and glass fibers. The tows of fibers may be affixed to a substrate. The tows of fibers may be affixed by stitching or using an adhesive. Additionally or alternatively, the tows of fibers and/or layers of fibers may be consolidated with a thermoset polymer and/or a thermoplastic polymer. Accordingly, the chassis plate 102 may have a tensile strength or flexural strength in a transverse direction substantially perpendicular to the longitudinal axis of the article of footwear (i.e., the axis extending from the anterior end 18 to the posterior end 20). The stiffness of the chassis plate 102 may be selected for a particular wearer based on the wearer's tendon flexibility, calf muscle strength, and/or metatarsophalangeal (MTP) joint flexibility. Moreover, the stiffness of the chassis plate 102 may also be tailored based upon a running motion of the athlete. In other configurations, the chassis plate 102 may be formed from one or more layers/plies of unidirectional tape. In some examples, each layer in the stack includes a different orientation than the layer disposed underneath. The plate may be formed from unidirectional tape including at least one of carbon fibers, boron fibers, glass fibers, and polymeric fibers. In some examples, the one or more materials forming the chassis plate 102 may result in the chassis plate 102 having a Young's modulus of at least 70 gigapascals (GPa).

In some embodiments, the chassis plate 102 may have a substantially uniform thickness. In some examples, the thickness of the chassis plate 102 may range from about 0.6 millimeters (mm) to about 3.0 mm. In an exemplary embodiment, the thickness of the chassis plate 102 is equal to one 1.0 mm. In other implementations, the thickness of the chassis plate 102 may be non-uniform such that the chassis plate 102 may have a greater thickness in one of regions 12, 14, and 16 of the sole structure 101 than the thicknesses in the other regions 12, 14, and 16. In other words, chassis plate 102 may have a variable thickness in each of regions 12, 14, and 16. In some embodiments, chassis plate 102 may be replaced by a sockliner.

In an alternative embodiment, described in further detail in the Alternative Embodiments section below, a chassis board 1402 may be disposed solely within the forefoot region 12. Further, the chassis board 1402 may be located within the toe portion 12T of the forefoot region 12. It is contemplated that in other alternative embodiments, the chassis board 1402 may be disposed in the forefoot region 12 and a portion of the mid-foot region 14. It is further contemplated that in other alternative embodiments, the chassis board 1402 may be disposed within any of the forefoot region 12, the mid-foot portion 14, and the heel portion 16 so as to provide a desired level of support, stability, and comfortability to the article of footwear 10.

Outsole Plate

With reference to FIGS. 3A and 3B, the outsole plate 104 may extend continuously from the anterior end 18 of the article of footwear 10 to the posterior end 20 of the article of footwear. The outsole plate 104 may further include an upper surface 302 facing the upper 100 and a lower surface 304 formed on an opposite side of the outsole plate 104 from the upper surface 302. A sidewall 306 (shown in FIG. 2) may extend vertically upward from the upper surface 302. Sidewall 306 may further define an outer periphery of the outsole plate 104. The upper surface 302 of the outsole plate 104 may be attached to the bottom surface of the chassis 102.

The upper surface 302 may further include a recess 308. Recess 308 may be present in the forefoot of the outsole plate 104. Recess 308 may form a depression in the outsole plate 104. Recess 308 may extend outwardly from a center of the recess toward an anterior segment 310, a posterior segment 312, a lateral segment 314, and a medial segment 316. A portion extending from the center toward the anterior segment 310 may extend in a direction toward the anterior end 18. A portion extending from the center toward the posterior segment 312 may extend in a direction toward the posterior end 20. A portion extending from the center toward the lateral segment 314 may extend in a direction toward the lateral side 24. A portion extending from the center toward the medial segment 316 may extend in a direction toward the medial side 22. Following a path along the exterior of recess 308, each of segments 310-316 may be interconnected by the upper surface 302. A portion 317 of the path running in between segments 310-316 may be incurved. In other words, the recess 308 may be bounded at its exterior by the upper surface 302, and the exterior of the recess 308 bounded by the upper surface 302 may follow a path between the segments 310-316 that is concave when viewed from a radially exterior position. Each of the incurved portions 317 of the path may be convex when viewed from a center of recess 308, although other configurations are contemplated.

Further, the outsole plate 104 may be divided into an anterior region and a posterior region by an axis A114 that may be perpendicular to a central longitudinal axis A104. Axis A114 may intersect the central longitudinal axis 104 at a point that is a longitudinal center between the anterior most and posterior most portions of the outsole plate 104. Additionally, axis A114 may divide the outsole plate 104 into an anterior region 322 and a posterior region 324. Anterior region 322 and posterior region 324 may or may not have equal two-dimensional areas or area projections (when viewed from directly above). The anterior region 322 may include the recess 308 disposed within. The area of recess 308 may be less than about 80%, less than about 70%, less than about 60%, or less than about 50% of the total two-dimensional area of the anterior region 322.

Recess 308 may be substantially symmetrical about the axis A104, although non-symmetrical configurations are contemplated. Lateral segment 314 and medial segment 316 may be mirrors of one another. Anterior segment 310 and posterior segment 312 may be mirrors of one another. In an exemplary embodiment, each of segments 310-316 may be substantial mirrors of one another. In other words, recess 308 may form a substantially plus-sign or cross shape. It is contemplated that recess 308 may be of a shape that is substantially ovular, diamond, or irregular in shape.

The lower surface 304 of the outsole plate 104 may form the ground-engaging surface of the article of footwear 10, and may include a plurality of traction elements 318. Lower surface 304 may also include a corresponding opposite face 320 of the recess 308. The plurality of traction elements 318 may be integrally molded with the bottom surface 304 of the outsole plate 104. Additionally, some of the plurality of traction elements 318 may be integrally molded with the opposite face 320 of the recess 308. In FIG. 3B, two traction elements 318 are shown extending directly from opposite face 320, but it is contemplated that fewer (e.g., zero or one), or more traction elements 318 may extend directly from opposite face 320. The remainder of the plurality of traction elements 318 in the forefoot region 12 may surround opposite face 320 in various patterns in order to provide a desired form of traction. In the embodiment shown, there are six additional traction elements 318 in forefoot region 312, but other numbers and patterns other than those shown in FIG. 3B are contemplated. The plurality of traction elements 318 may all have the same size, or they may have different sizes to provide the desired traction, stability, and/or other properties. It is contemplated that the traction elements 318 may alternatively be attached to the outsole plate 104 by a snap fit, screw structure, or the like. The opposite face 320 may have fewer traction elements 318 than the remainder of the bottom surface 304 of the outsole plate 104. The traction elements 318 may be disposed in the forefoot region 12 and the heel region 16. The traction elements 318 may extend from the heel region 16 toward the mid-foot region 14 and from the forefoot region 12 to the mid-foot region 14. Portions of the traction elements 318 may partially extend into the mid-foot region 14. In some embodiments, the mid-foot region 14 may be substantially free of traction elements 318.

Forefoot Cushioning Element

With reference to FIGS. 4 and 4A-4D, the recess 308 of the outsole plate 104 may have disposed within it, a forefoot cushioning element 103. The forefoot cushioning element 103 may be a fluid-filled bladder, for example, that may be inflated to provide a desired form of cushioning and support. Forefoot cushioning element 103 may be formed from a pair of barrier layers, which when joined together may define an enclosed inner volume (or hollow interior) for receiving, for example, a pressurized fluid (e.g. a gas as set forth in further detail below). The barrier layers may be joined to each other at discrete locations to define an overall shape of the forefoot cushioning element 103. In an exemplary embodiment, the forefoot cushioning element 103 may include a first, upper barrier layer 402 and a second, lower barrier layer 404. The upper barrier layer 402 may be attached to the lower barrier layer 404 by applying heat and pressure at a perimeter of the upper barrier layer 402 and the lower barrier layer 404 to define a peripheral seam 406. The peripheral seam 406 may seal the forefoot cushioning element 103 and may define the peripheral profile of the forefoot cushioning element 103.

As used herein, the term “barrier layer” (e.g., barrier layers 402, 404) may encompass both monolayer and multilayer films. In some embodiments, one or both of barrier layers 402, 404 may each be produced (e.g., thermoformed or blow molded) from a monolayer film (a single layer). In other embodiments, one or both of barrier layers 402, 404 may each be produced (e.g., thermoformed or blow molded) from a multilayer film (multiple sublayers). In either embodiment, each layer or sublayer can have a film thickness ranging from about 0.2 micrometers to about be about 1 millimeter. In further embodiments, the film thickness for each layer or sublayer can range from about 0.5 micrometers to about 500 micrometers. In yet further embodiments, the film thickness for each layer or sublayer can range from about 1 micrometer to about 100 micrometers. It is contemplated that the forefoot cushioning element 103 may have a thickness ranging from 6 mm to 10 mm, although other suitable values are contemplated. In an exemplary embodiment, forefoot cushioning element 103 may have a thickness of 8 mm.

One or both of barrier layers 402, 404 may independently be transparent, translucent, and/or opaque. As used herein, the term “transparent” for a barrier layer and/or a fluid-filled chamber means that light passes through the barrier layer in substantially straight lines and a viewer can see through the barrier layer. In comparison, for an opaque barrier layer, light does not pass through the barrier layer and one cannot see clearly through the barrier layer at all. A translucent barrier layer falls between a transparent barrier layer and an opaque barrier layer, in that light passes through a translucent layer but some of the light is scattered so that a viewer cannot see clearly through the layer.

The barrier layers 402, 404 may each be produced from an elastomeric material that includes one or more thermoplastic polymers and/or one or more cross-linkable polymers. In an embodiment, the elastomeric material can include one or more thermoplastic elastomeric materials, such as one or more thermoplastic polyurethane (TPU) copolymers, one or more ethylene-vinyl alcohol (EVOH) copolymers, and the like.

The forefoot cushioning 103 may be produced from the barrier layers 402, 404 using any suitable technique, such as thermoforming (e.g. vacuum thermoforming), blow molding, extrusion, injection molding, vacuum molding, rotary molding, transfer molding, pressure forming, heat sealing, casting, low-pressure casting, spin casting, reaction injection molding, radio frequency (RF) welding, and the like. In an embodiment, the barrier layers 402, 404 can be produced by co-extrusion followed by vacuum thermoforming to produce forefoot cushioning element 103, which can optionally include one or more valves (e.g., one way valves) that allows forefoot cushioning element 103 to be filled with a fluid (e.g., gas).

The forefoot cushioning element 103 may be provided in a fluid-filled or in an unfilled state. The forefoot cushioning element 103 may be filled to include any suitable fluid, such as a gas or liquid. In an embodiment, the gas may include air, nitrogen (N₂), or any other suitable gas. In other embodiments, the forefoot cushioning element 103 may alternatively include other media, such as pellets, beads, ground recycled material, and the like (e.g., foamed beads and/or rubber beads). The fluid provided to the forefoot cushioning element 103 can result in the forefoot cushioning element 103 being pressurized. In some examples, the forefoot cushioning element 103 may have a pressure ranging from 15 psi (pounds per square inch) to 25 psi. In other examples, the forefoot cushioning element 103 may have a pressure ranging from 20 psi to 25 psi. In some examples, the forefoot cushioning element 103 may have a pressure of 20 psi. In other examples, the forefoot cushioning element 103 may have a pressure of 25 psi. Alternatively, the fluid provided to the forefoot cushioning element 103 may be at atmospheric pressure such that the forefoot cushioning element 103 is not pressurized but, rather, simply contains a volume of fluid at atmospheric pressure.

The forefoot cushioning element 103 desirably has a low gas transmission rate to preserve its retained gas pressure. In some embodiments, forefoot cushioning element 103 may have a gas transmission rate for nitrogen gas that is at least about ten (10) times lower than a nitrogen gas transmission rate for a butyl rubber layer of substantially the same dimensions. In an embodiment, forefoot cushioning element 103 may have a nitrogen gas transmission rate of 15 cubic-centimeter/square-meter·atmosphere·day (cm³/m²·atm·day) or less for an average film thickness of 500 micrometers (based on thicknesses of barrier layers 402, 404). In further embodiments, the transmission rate may be 10 cm³/m²·atm·day or less, 5 cm³/m²·atm·day or less, or 1 cm³/m²·atm·day or less.

The forefoot cushioning element 103 may receive a tensile element 408 therein (or one or more tensile elements 408). Each tensile element 408 may include a series of tensile strands extending between an upper tensile sheet (not shown) and a lower tensile sheet (not shown). The upper tensile sheet may be attached to the upper barrier layer 402 while the lower tensile sheet may be attached to the lower barrier layer 404. In this manner, when the forefoot cushioning element 103 receives the pressurized fluid, the tensile strands of the tensile element are placed in tension. Because the upper tensile sheet is attached to the upper barrier layer 402 and the lower tensile sheet is attached to the lower barrier layer 404, the tensile strands retain a desired shape of the forefoot cushioning element 103 when the pressurized fluid is injected into the chamber.

In an alternative embodiment, forefoot cushioning element 103 may include a polymer foam and/or particulate matter in one or more, or all, regions of the forefoot cushioning element 103 corresponding to the enclosed inner volume of the forefoot cushioning element 103. For example, the forefoot cushioning element 103 may include a plurality of fluid-filled chambers arranged in the forefoot region, as described in greater detail below. Additionally or alternatively, the forefoot cushioning element 103 may be replaced or supplemented with other cushioning elements. For example, the cushion may include a foam block that replaces or supplements the pressurized fluid. The foam block(s) may be received within the inner void 408 defined by the upper barrier layer 402 and the lower barrier layer 404. Positioning the foam block(s) within the inner void 408 defined by the upper barrier layer 402 and the lower barrier layer 404 may allow the barrier layers to restrict expansion of the foam blocks beyond a predetermined amount when subjected to a predetermined load. Accordingly, the overall shape and, thus, the performance of the foam blocks may be controlled by allowing the foam blocks to interact with the barrier layers 402 and 404 during loading. While the foam blocks are described as being received within the inner void 408 of the barrier layers 402 and 404, the foam blocks may alternatively be positioned between the chassis plate 102 and the outsole plate 104 absent the barrier layers 402 and 404. In such a configuration, the foam blocks may be directly attached to the bottom surface of the chassis plate 102 and to outsole plate 104, respectively.

Forefoot cushioning element 103 may extend outwardly from its center toward an anterior segment 410, a posterior segment 412, a lateral segment 414, and a medial segment 416. A portion extending from the center toward the anterior segment 410 may extend in a direction toward the anterior end 18. A portion extending from the center toward the posterior segment 412 may extend in a direction toward the posterior end 20. A portion extending from the center toward the lateral segment 414 may extend in a direction toward the lateral side 24. A portion extending from the center toward the medial segment 416 may extend in a direction toward the medial side 22. When viewing the exterior of forefoot cushioning element 103 from above, there may be a path defining the outer bounds of forefoot cushioning element 103. The exterior path may run between each of segments 410-416, and may also include each of segments 410-416. A portion 417 of the path running between the ends of the segments may be concave when viewed from a radially exterior position. Each of the incurved portions 417 of the path may be convex when viewed from a center of forefoot cushioning element 103, although other configurations are contemplated.

Forefoot cushioning element 103 may be substantially symmetrical about the axis A104, although non-symmetrical configurations are contemplated. Lateral segment 414 and medial segment 416 may be mirrors of one another. Anterior segment 410 and posterior segment 412 may be mirrors of one another. In an exemplary embodiment, each of segments 410-416 may be substantial mirrors of one another. In other words, recess 308 may form a substantially plus-sign or cross shape. It is contemplated that recess 308 may be of a shape that is substantially ovular, diamond, or irregular in shape.

Referring to FIG. 5, the recess 308 (shown in FIG. 3A) may receive the forefoot cushioning element 103. Recess 308 and forefoot cushioning element 103 may have substantially corresponding geometries. Referring to FIGS. 4B-4D, recess 308 may receive all or a portion of forefoot cushioning element 103. In an exemplary configuration, 100% of the forefoot cushioning element 103 may be disposed within the recess 308. When all of the forefoot cushioning element is disposed within recess 308, a top surface of the forefoot cushioning element 103 and a top surface of the outsole plate 104 may be substantially flush with each other, or the top surface of forefoot cushioning element 103 may be below the top surface of outsole plate 104. In other configurations, less than an entirety of the forefoot cushioning element (e.g., about 90% or less, about 75% or less, about 50% or less) may be disposed within the recess 308 so that a top surface of the forefoot cushioning element 103 rests slightly above a top surface of the outsole plate 104. The percentage of forefoot cushioning element 103 contained by recess 308 may be varied to impart desired cushioning characteristics.

Assembled Configuration

Referring to FIGS. 4A-4D, when assembled, a top surface of the forefoot cushioning element 103 may protrude slightly above the upper surface 302 of the outsole plate 104. In other embodiments, the top surface of the forefoot cushioning element 103 may rest substantially flush with the upper surface 302 of the outsole plate 104 when the forefoot cushioning element 103 is disposed within the recess 308.

Referring to FIG. 6, the fully assembled sole structure 101 may include the chassis plate 102, the forefoot cushioning element 103, and the outsole plate 104. Forefoot cushioning element 103 may be disposed within recess 308. Chassis plate 102 may be disposed along a substantial portion of the outsole plate 104. Chassis plate 102 may be disposed on the forefoot cushioning element 103. In other words, chassis plate 102 may span a majority (or substantial entirety) of the length of the outsole plate 104 and may cover the forefoot cushioning element 103 in the forefoot. The sole structure 101 may be adhered by stock fit, cementing, or any other suitable method for adhering elements of a sole structure made of varying materials.

When the top surface of the forefoot cushioning element 103 protrudes slightly above the upper surface 302, there may be substantially no gap between the chassis plate 102 and the forefoot cushioning element 103. In an exemplary embodiment, the forefoot cushioning element 103 is not subject to compressive forces from the chassis plate 102 during a state of rest of the article of footwear 10, or is otherwise subject to substantially minimal compressive forces from the chassis plate 102 during a state of rest. The state of rest may correspond to the article of footwear 10 not being engaged by a foot of a user. Alternatively, the chassis plate 102 may apply a compressive force to the forefoot cushioning element 103. In the alternative, the compressive force of the chassis plate 102 applies preloading to the forefoot cushioning element 103.

Alternative Embodiments

Referring to FIGS. 7-13, an alternative embodiment of the sole structure 101 may include chassis plate 102, forefoot cushioning element 703, outsole plate 704, a moderator plate 105, and a gasket 106.

With reference to FIG. 7, chassis plate 102 may be substantially similar as depicted and described with respect to FIGS. 1-6. When assembled, chassis plate 102 may be attached (e.g. directly attached) to forefoot cushioning element 703. There may be substantially no gap between the chassis plate 102 and the forefoot cushioning element 703.

Referring to FIG. 8, forefoot cushioning element 703 may be similar to forefoot cushioning element 103. For example, forefoot cushioning element 703 may extend outwardly from its center toward an anterior segment 710, a posterior segment 712, a lateral segment 714, and a medial segment 716. A portion 717 of the path extending between the ends of segments may be concave when viewed from a radially exterior position. Each of the portions of the path may be convex when viewed from a center of forefoot cushioning element 703, although other configurations are contemplated. In other words, the exterior path may bound the forefoot cushioning element 103 and may follow an inwardly curved path between the ends of segments of the forefoot cushioning element.

Segment 710 may have an area that is larger than that of segment 712. Segments 714 may be similar to segment 716, but the anterior most part of segment 714 may be anterior to the most anterior part of segment 716. In other words, segments 714 and 716 may generally be similar to one another, but the anterior most portions of the segments 714 and 716 may be offset from one another. Additionally, each of segments 710, 714, and 716 may have similar outer extending dimensions (i.e. width and length) that may be greater than the outer extending dimensions of segment 712. Thus, forefoot cushioning element 103 may be irregular in shape.

Referring to FIGS. 9 and 10, moderator plate 105 may have a similar cross or plus-sign shape as forefoot cushioning element 703, and extend outwardly from its center toward the anterior end 18, posterior end 20, the medial side 22, and the lateral side 24. Moderator plate 105 may have a top surface 726 and a bottom surface 728. The portions extending outwardly from the center of the moderator plate 105 may define an outer boundary of moderator plate 105. Moderator plate 105 may have disposed on its bottom surface a plurality of traction elements 724. Further, element 105 may be flexible so as to impart a desired support characteristic to the article of footwear 10.

Referring to FIG. 11, gasket 106 may include a lower periphery 718, an upper periphery 720, a sidewall 719, and an opening 722. Sidewall 719 may extend vertically upward from the lower periphery 718 to the upper periphery 720. When viewed from above, upper periphery 720 may follow an undulating path corresponding to the undulating path of the lower periphery 718. Upper periphery 720 and lower periphery 718 may form respective flanges of the gasket 106. Thus, lower periphery 718 may receive and contact the moderator plate 105. The lower periphery 718 of the gasket 106 may enclose opening 722. Opening 722 may be bound by the path of the top surface 718. The upward facing surface of sidewall 719 may receive forefoot cushioning assembly 703.

Outsole plate 704 may extend continuously from the anterior end 18 of the article of footwear 10 to the posterior end 20 of the article of footwear. Outsole plate 704 may include a narrowed portion 705 at the midfoot region. The outsole plate 704 may further include an upper surface 702 facing the upper 100 and a lower surface formed on an opposite side of the outsole plate 704 from the upper surface 702. Outsole plate 104 may have the plurality of traction elements 318 disposed on its lower surface 705. A sidewall 706 may extend vertically upward from the upper surface 702. Sidewall 706 may further define an outer periphery of the outsole plate 704. The upper surface 702 of the outsole plate 704 may be attached to the bottom surface of the chassis 102.

The outsole plate 704 may further include an opening 708. Opening 708 may be bounded by an undulating path that is generally complementary in shape to forefoot cushioning element 703, moderator plate 105, and gasket 106. The opening 708 may be configured to receive the gasket 106, moderator plate 105, and/or cushioning element 703.

The moderator plate 105 may attach to a ground-facing surface of the forefoot cushioning element 703. The moderator plate 105 and the forefoot cushioning element 703 may have corresponding geometries, and the moderator plate 105 may rest within the inner bounds of the segments of the forefoot cushioning element 703. The forefoot cushioning element 703 may be disposed on the top surface 718 of the gasket 106. The moderator plate 105 may rest flush within the inner bounds of the gasket 106. In other words, each of the forefoot cushioning element 703, the moderator plate 105, and the gasket 106 have corresponding geometries to communicate and rest flush with another. The combination of the gasket 106 and the moderator plate 105 may form a portion of a ground-engaging surface. The outsole plate 704 may form another portion of the ground-engaging surface. In other words, the outsole plate 704, along with the moderator plate 105, and the gasket 106 resting within the opening 708, may form the entirety of the ground-engaging surface of the article of footwear.

Referring to FIG. 14, an alternative embodiment of the sole structure 101 may include the chassis board 1402, a forefoot cushioning element 1403, an external plate 1404, a moderator plate 1405, and a gasket 1406.

Chassis board 1402 may extend continuously from the ball portion 12B of the forefoot region 12 through the toe portion 12T of the forefoot region 12 to the anterior end 18, and may span a width of the sole structure 101 from the medial side 22 to the lateral side 24. In other words, the chassis board 1402 may be disposed solely within the forefoot region 12. The chassis board 1402 may further comprise a top (upper) surface facing the bottom of the upper 100, and a bottom (lower) surface formed on an opposite side of the chassis board 1402 from the top surface, facing in the direction of a ground surface. A distance from the top surface to the bottom surface may define a thickness of the chassis board 1402. In the present embodiment, the top surface of the chassis board 1402 may be positioned against the strobel of the upper 100 (shown in FIG. 1) from the anterior end 18 to the end of the ball portion 12B closest to the midfoot region 14. In some examples, the entire top surface of the chassis board 1402 may be attached (e.g., directly attached) to the strobel of the upper 100, such that the upper surface of the chassis board 1402 may define a profile of the footbed in the forefoot region 12. It is contemplated that, in other examples, chassis board 1402 may be attached (e.g. directly attached) to a sockliner 1401 of the upper 100. The sockliner 1401 may include resilient materials to provide a desired form of support and stability when coupled with the chassis board 1402.

Chassis board 1402 may be formed of an injection molded material. While shown as a separate component, chassis board 1402 may be integrally formed in the upper 100. It is contemplated that the chassis board 1402 may be used in lieu of chassis 102. In alternative embodiments, the chassis board 1402 may be used in conjunction with chassis 102 to provide a desired form of cushioning, support, and stability.

It is contemplated that in other alternative embodiments, the chassis board 1402 may be disposed in the forefoot region 12 and a portion of the mid-foot region 14. It is further contemplated that in other alternative embodiments, the chassis board 1402 may be disposed within any of the forefoot region 12, the mid-foot portion 14, and the heel portion 16 so as to provide a desired level of support, stability, and comfortability to the article of footwear 10.

Forefoot cushioning element 1403 may be substantially similar as depicted and described with respect to FIGS. 1-6.

Moderator plate 1405 may be substantially similar to moderator plate 106 as depicted and described with respect to FIGS. 7, 9, 10, and 13. Moderator plate 1405 may have a substantially cross or plus-sign shape corresponding to forefoot cushioning element 1403.

Gasket 1406 may be substantially similar to gasket 106 as depicted and described with respect to FIGS. 7, 11, and 13. Gasket 1406 may have a corresponding geometry to that of moderator plate 1405 and forefoot cushioning element 1403.

External plate 1404 may be substantially similar to outsole plate 104 as depicted and described with respect to FIGS. 7, 12, and 13. External plate 1404 may provide a desired level of stiffness, structure, and flexibility.

The moderator plate 1405, the forefoot cushioning element 1403, and the gasket 1406 may be attached in a similar manner as depicted and described in FIGS. 7-13.

Referring to FIG. 15, an alternative embodiment of the sole structure 101 may include the chassis board 1502, a forefoot cushioning element 1503, and an external plate 1504.

Chassis board 1502 may be substantially similar to chassis board 1402 as depicted and described with respect to FIG. 14.

Forefoot cushioning element 1503 may be substantially similar to forefoot cushioning element 703 as depicted and described with respect to FIGS. 7-13. In other embodiments, the forefoot cushioning element 1503 may have a shape that is larger or smaller than the forefoot cushioning element 703. For example, respective segments of the forefoot cushioning element 1503 may be narrower than any one or more of the segments 710, 712, 714, and 716. As another example, respective segments of the forefoot cushioning element 1503 may be wider than any one or more of segments 710, 712, 714, and 716.

A receptacle 1506 may be disposed within the external plate 1504 and may be substantially similar to receptacle 308 as depicted and described with respect to FIG. 2. Receptacle 1506 may have a corresponding geometry to that of forefoot cushioning element 1503.

External plate 1504 may be substantially similar to outsole plate 1404 as depicted and described with respect to FIG. 14. External plate 1504 may provide a desired level of stiffness, structure, and flexibility.

The chassis board 1502, the forefoot cushioning element 1503, and the external plate 1504 may be attached in a similar manner as depicted and described in FIGS. 1-6.

A cross-sectional view of the alternative embodiment of the sole structure 101 is shown in FIG. 16. The cross-sectional view may be taken perpendicular to a plane extending from the anterior end 18 to the posterior end 20. The forefoot cushioning element 1503 is disposed within the receptacle 1506 of the outsole plate 1504. The chassis board 1502 is disposed on a side of the forefoot cushioning element 1503 opposite the receptacle 1506.

FIG. 17 shows a bottom view of the outsole plate 1504 and the receptacle 1506 including a set of major cleats 1518 and minor cleats 1522a and 1522b. The major cleats 1518 and minor cleats 1522a and 1522 are disposed on a ground-facing surface 1520 of the receptacle 1506. The major cleats 1518 include a substantially crescent shape. Major cleats 1518 may be any other shape, such as ovular, circular, rectangular, or the like. The minor cleats 1522a and 1522b include a substantially triangular shape. Minor cleats 1522a and 1522b may be any other shape such as ovular, circular, rectangular, or the like. The minor cleats 1522a and 1522b are disposed at opposing ends of the ground-facing surface 1520. The major cleats 1518 are disposed between the opposing minor cleats 1522a and 1522b. One or more of the major cleats 1518 may be disposed near the minor cleat 1522a and another one of the one or more major cleats 1518 may be disposed near the minor cleat 1522b. Opposing ones of the major cleats 1518 may include opposing inner surfaces. For example, one major cleat 1518 may have a concave inner surface while an opposing major cleat 1518 may have a convex inner surface. In another example, one major cleat 1518 may have a concave inner surface while an opposing major cleat 1518 may have a concave inner surface. In another example, one major cleat 1518 may have a convex inner surface while an opposing major cleat 1518 may have a convex inner surface.

Materials

The barrier layers of forefoot cushioning element 103/703 may each be produced from an elastomeric material that includes one or more thermoplastic polymers and/or one or more cross-linkable polymers. In an aspect, the elastomeric material may include one or more thermoplastic elastomeric materials, such as one or more thermoplastic polyurethane (TPU) copolymers, one or more ethylene-vinyl alcohol (EVOH) copolymers, and the like.

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

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

In particular aspects, the polyurethane polymer chains are produced from diisocynates including HMDI, TDI, MDI, H12 aliphatics, and combinations thereof. In an aspect, the thermoplastic TPU may include polyester-based TPU, polyether-based TPU, polycaprolactone[1] based TPU, polycarbonate-based TPU, polysiloxane-based TPU, or combinations thereof.

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

One or more of the elements 102 and 103 may be formed of a resilient polymeric material, such as foam or rubber, to impart properties of cushioning, responsiveness, and energy distribution to the foot of the wearer. The elements 102 and 103 may be affixed within the sole structure using a fusing process, using an adhesive, or by suspending the elements in a different resilient polymeric material. As discussed above, the elements 102, 103, and 104 may be formed with cooperating geometries (e.g., steps, protrusions) for restricting relative motion between the elements 102, 103, and 104 of the sole structure.

Example resilient polymeric materials for the elements 102 and 103 may include those based on foaming or molding one or more polymers, such as one or more elastomers (e.g., thermoplastic elastomers (TPE)). The one or more polymers may include aliphatic polymers, aromatic polymers, or mixtures of both; and may include homopolymers, copolymers (including terpolymers), or mixtures of both.

In some aspects, the one or more polymers may include olefinic homopolymers, olefinic copolymers, or blends thereof. Examples of olefinic polymers include polyethylene, polypropylene, and combinations thereof. In other aspects, the one or more polymers may include one or more ethylene copolymers, such as, ethylene-vinyl acetate (EVA) copolymers, EVOH copolymers, ethylene-ethyl acrylate copolymers, ethylene-unsaturated mono-fatty acid copolymers, and combinations thereof.

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

In yet further aspects, the one or more polymers may include one or more ionomeric polymers. In these aspects, the ionomeric polymers may include polymers with carboxylic acid functional groups, sulfonic acid functional groups, salts thereof (e.g., sodium, magnesium, potassium, etc.), and/or anhydrides thereof. For instance, the ionomeric polymer(s) may include one or more fatty acid-modified ionomeric polymers, polystyrene sulfonate, ethylene-methacrylic acid copolymers, and combinations thereof.

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

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

When the resilient polymeric material is a foamed polymeric material, the foamed material may be foamed using a physical blowing agent which phase transitions to a gas based on a change in temperature and/or pressure, or a chemical blowing agent which forms a gas when heated above its activation temperature. For example, the chemical blowing agent may be an azo compound such as adodicarbonamide, sodium bicarbonate, and/or an isocyanate.

In some embodiments, the foamed polymeric material may be a cross-linked foamed material. In these embodiments, a peroxide-based crosslinking agent such as dicumyl peroxide may be used. Furthermore, the foamed polymeric material may include one or more fillers such as pigments, modified or natural clays, modified or unmodified synthetic clays, talc glass fiber, powdered glass, modified or natural silica, calcium carbonate, mica, paper, wood chips, and the like.

The resilient polymeric material may be formed using a molding process. In one example, when the resilient polymeric material is a molded elastomer, the uncured elastomer (e.g., rubber) may be mixed in a Banbury mixer with an optional filler and a curing package such as a sulfur-based or peroxide-based curing package, calendared, formed into shape, placed in a mold, and vulcanized.

In another example, when the resilient polymeric material is a foamed material, the material may be foamed during a molding process, such as an injection molding process. A thermoplastic polymeric material may be melted in the barrel of an injection molding system and combined with a physical or chemical blowing agent and optionally a crosslinking agent, and then injected into a mold under conditions which activate the blowing agent, forming a molded foam.

Optionally, when the resilient polymeric material is a foamed material, the foamed material may be a compression molded foam. Compression molding may be used to alter the physical properties (e.g., density, stiffness and/or durometer) of a foam, or to alter the physical appearance of the foam (e.g., to fuse two or more pieces of foam, to shape the foam, etc.), or both.

The compression molding process desirably starts by forming one or more foam preforms, such as by injection molding and foaming a polymeric material, by forming foamed particles or beads, by cutting foamed sheet stock, and the like. The compression molded foam may then be made by placing the one or more preforms formed of foamed polymeric material(s) in a compression mold, and applying sufficient pressure to the one or more preforms to compress the one or more preforms in a closed mold. Once the mold is closed, sufficient heat and/or pressure is applied to the one or more preforms in the closed mold for a sufficient duration of time to alter the preform(s) by forming a skin on the outer surface of the compression molded foam, fuse individual foam particles to each other, permanently increase the density of the foam(s), or any combination thereof. Following the heating and/or application of pressure, the mold is opened and the molded foam article is removed from the mold.

The barrier layers 402 and 404 may include two or more sublayers (multilayer film) such as shown in Mitchell et al., U.S. Pat. No. 5,713,141 and Mitchell et al., U.S. Pat. No. 5,952,065, the disclosures of which are incorporated by reference in their entirety. In embodiments where the barrier layers 402 and 404 include two or more sublayers, examples of suitable multilayer films include microlayer films, such as those disclosed in Bonk et al., U.S. Pat. No. 6,582,786, which is incorporated by reference in its entirety. In further embodiments, the barrier layers 402 and 404 may each independently include alternating sublayers of one or more TPU copolymer materials and one or more EVOH copolymer materials, where the total number of sublayers in each of the barrier layers 402 and 404 includes at least four (4) sublayers, at least ten (10) sublayers, at least twenty (20) sublayers, at least forty (40) sublayers, and/or at least sixty (60) sublayers.

The forefoot cushioning element 103 may be provided in a fluid-filled (shown in FIG. 4A) or in an unfilled state. The forefoot cushioning element 103 may be filled to include any suitable fluid, such as a gas or liquid. In an aspect, the gas may include air, nitrogen (N₂), or any other suitable gas. In other aspects, the forefoot cushioning element 103 may alternatively include other media, such as pellets, beads, ground recycled material, and the like (e.g., foamed beads and/or rubber beads).

The following clauses provide an exemplary configuration for an article of footwear and sole structure described above.

Clause 1. A sole structure for an article of footwear, the sole structure including a forefoot region and a heel region; a chassis plate; an outsole plate extending from the forefoot region to the heel region, the outsole plate including a recess disposed in a top surface, wherein the outsole plate is disposed below the chassis plate; and a cushioning element disposed within the recess.

Clause 2. The sole structure of clause 1, wherein the cushioning element includes a fluid-filled bladder.

Clause 3. The sole structure of clause 1, wherein a top surface of the cushioning element is flush with the top surface of the outsole plate when the cushioning element is disposed within the recess.

Clause 4. The sole structure of clause 1, wherein the outsole plate includes; a bottom surface; and a plurality of traction elements disposed on the bottom surface of the outsole plate.

Clause 5. The sole structure of clause 4, wherein the plurality of traction elements are integrally molded into the bottom surface of the outsole plate.

Clause 6. The sole structure of clause 1, wherein a bottom surface of the outsole plate forms a ground-contacting surface of the sole structure.

Clause 7. The sole structure of clause 1, wherein the outsole plate has a longitudinal length, and a midpoint along the longitudinal length, wherein the outsole plate includes an anterior area that is anterior to the midpoint, and wherein an area of the cushioning element is less than about 70% of the anterior area.

Clause 8. The sole structure of clause 1, wherein the chassis plate and outsole plate have substantially the same length.

Clause 9. An article of footwear comprising the sole structure of clause 1.

Clause 10. A sole structure for an article of footwear, the sole structure including a forefoot region and a heel region; a chassis plate; an outsole plate extending from the forefoot region to the heel region, the outsole plate including an opening in the forefoot region, wherein the outsole plate is disposed below the chassis plate; and a cushioning element disposed in the opening.

Clause 11. The sole structure of clause 10, further including a moderator plate disposed in the opening and in contact with the cushioning element.

Clause 12. The sole structure of clause 11, wherein a bottom surface of the outsole plate and a bottom surface of the moderator plate form a portion of a ground-contacting surface of the sole structure.

Clause 13. The sole structure of clause 12, further including a gasket disposed within the opening, wherein the gasket radially surrounds the moderator plate and the cushioning element.

Clause 14. The sole structure of clause 11, wherein a bottom surface of the moderator plate includes one or more traction elements.

Clause 15. The sole structure of clause 10, wherein a bottom surface of the outsole plate includes one or more traction elements.

Clause 16. The sole structure of clause 10, wherein the cushioning element includes a fluid-filled bladder.

Clause 17. An article of footwear comprising the sole structure of clause 10.

Clause 18. A sole structure for an article of footwear, the sole structure including a forefoot region and a heel region; an outsole plate extending from the forefoot region to the heel region, the outsole plate including an opening in the forefoot region; a moderator plate disposed within the opening; and a gasket surrounding the moderator plate.

Clause 19. The sole structure of clause 18, wherein the outsole plate, the moderator plate, and the gasket, form a ground-contacting surface of the sole structure.

Clause 20. An article of footwear comprising the sole structure of clause 18.

Claims

1-20. (canceled)

21. A sole structure for an article of footwear, the sole structure comprising:

a forefoot region and a heel region;

a rigid chassis plate;

a rigid outsole plate extending from the forefoot region to the heel region, wherein the outsole plate is disposed below the chassis plate; and

a cushioning element disposed between the chassis plate and the outsole plate.

22. The sole structure of claim 21, wherein the cushioning element includes a fluid-filled bladder.

23. The sole structure of claim 21, wherein a top surface of the cushioning element is flush with the top surface of the outsole plate when the cushioning element is disposed within the recess.

24. The sole structure of claim 21, wherein the outsole plate includes;

a bottom surface; and

a plurality of traction elements disposed on the bottom surface of the outsole plate.

25. The sole structure of claim 24, wherein the plurality of traction elements are integrally molded into the bottom surface of the outsole plate.

26. The sole structure of claim 21, wherein a bottom surface of the outsole plate forms a ground-contacting surface of the sole structure.

27. The sole structure of claim 21, wherein the outsole plate has a longitudinal length, and a midpoint along the longitudinal length, wherein the outsole plate includes an anterior area that is anterior to the midpoint, and wherein an area of the cushioning element is less than about 70% of the anterior area.

28. The sole structure of claim 21, wherein the chassis plate and outsole plate have substantially the same length.

29. The sole structure of claim 21, wherein the chassis plate has an oblong shape.

30. The sole structure of claim 21, wherein the chassis plate is disposed in the forefoot region.

31. The sole structure of claim 21, wherein the outsole plate includes a recess, and wherein the cushioning element is disposed within the recess of the outsole plate.

32. An article of footwear comprising the sole structure of claim 21.

33. A sole structure for an article of footwear, the sole structure comprising:

a forefoot region and a heel region;

a chassis plate disposed in the forefoot region, the chassis plate having an oblong shape;

a cleated outsole plate extending from the forefoot region to the heel region, wherein the outsole plate is disposed below the chassis plate; and

a fluid-filled bladder disposed within the recess between the chassis plate and the outsole plate.

34. The sole structure of claim 33, wherein a bottom surface of the outsole plate includes one or more traction elements.

35. The sole structure of claim 33, wherein the cushioning element includes a fluid-filled bladder.

36. An article of footwear comprising the sole structure of claim 33.

37. The sole structure of claim 33, wherein the chassis plate is disposed solely in the forefoot region.

38. The sole structure of claim 33, wherein the chassis plate is disposed solely in the forefoot region and a midfoot region.

39. The sole structure of claim 33, wherein the chassis plate is not disposed in the heel region.

40. The sole structure of claim 33, wherein the chassis plate is formed of a rigid material, and wherein the cleated outsole plate is formed of a rigid material.