ARTICLE OF FOOTWEAR INCLUDING A SOLE STRUCTURE

- Nike, Inc.

An article of footwear with an upper; and a sole structure. The sole structure has a midsole, wherein the midsole has at least one partially enclosed cavity; a first cushioning element disposed within the at least one partially enclosed cavity, wherein the cushioning element comprises a first barrier film and a second barrier film enclosing an internal volume, the first barrier film and the second barrier adjoining to form a peripheral seam; a second cushioning element disposed within the at least one partially enclosed cavity, wherein the second cushioning element includes a third barrier film and a fourth barrier film enclosing an internal volume; and an outsole, wherein the outsole has a ground-engaging surface.

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Description
CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority under 35 U.S.C. § 119(e) to Provisional U.S. Patent Application No. 63/598,364, filed Nov. 13, 2023, the disclosure of which is hereby incorporated by reference in its entirety.

FIELD

The present disclosure relates generally to sole structures for articles of footwear and more particularly to sole structures incorporating a fluid-filled bladder.

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 rubber or other materials that impart durability and wear-resistance, as well as enhance 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 may be 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 additionally or alternatively incorporate a fluid-filled bladder to increase the durability of the sole structure, as well as to provide cushioning to the foot by compressing resiliently under an applied load to attenuate ground-reaction forces. Sole structures may also include a comfort-enhancing insole or a sockliner located within a void proximate to the bottom portion of the upper and a strobel attached to the upper and disposed between the midsole and the insole or sockliner.

Midsoles employing fluid-filled bladders typically include a bladder formed from two barrier layers of polymer material that are sealed or bonded together. The fluid-filled bladders are pressurized with a fluid such as air, and may incorporate tensile members within the bladder to retain the shape of the bladder when compressed resiliently under applied loads, such as during athletic movements. Generally, bladders are designed with an emphasis on balancing support for the foot and cushioning characteristics that relate to responsiveness as the bladder resiliently compresses under an applied load.

BRIEF DESCRIPTION OF DRAWINGS

The drawings described herein are for illustrative purposes only of selected configurations and are not intended to limit the scope of the present disclosure.

FIG. 1 is a perspective view of an article of footwear;

FIG. 2 is an exploded perspective view of a sole structure of the article of footwear of FIG. 1;

FIG. 3 is a perspective view of the sole structure of the article of footwear of FIG. 1;

FIG. 4 is a perspective plan view of the sole structure of the article of footwear of FIG. 1;

FIG. 5A is a perspective view of a cushioning element of the sole structure of FIG. 4;

FIG. 5B is a top view of a cushioning element of the sole structure of FIG. 4;

FIG. 5C is a cross-section view of a cushioning element of the sole structure of FIG. 4;

FIG. 6A is a top view of a cushioning element of the sole structure of FIG. 4;

FIG. 6B is a perspective view of a cushioning element of the sole structure of FIG. 4;

FIG. 6C is a side view of a cushioning element of the sole structure of FIG. 4;

FIG. 6D is a cross-section view of a cushioning element of the sole structure of FIG. 4;

FIG. 7A is a perspective view of an outsole of the sole structure of FIG. 4;

FIG. 7B is a side view of an outsole of the sole structure of FIG. 4;

FIG. 8A is a perspective view of a filler of the sole structure of FIG. 4;

FIG. 8B is a side view of a filler of the sole structure of FIG. 4;

FIG. 9 is a bottom view of the article of footwear of FIG. 1; and

FIG. 10 is a side view of the sole structure of the article of footwear of FIG. 1.

Corresponding reference numerals indicate corresponding parts throughout the drawings.

DETAILED DESCRIPTION

Example configurations will now be described more fully with reference to the accompanying drawings. Example configurations are provided so that this disclosure will be thorough, and will fully convey the scope of the disclosure to those of ordinary skill in the art. Specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of configurations of the present disclosure. It will be apparent to those of ordinary skill in the art that specific details need not be employed, that example configurations may be embodied in many different forms, and that the specific details and the example configurations should not be construed to limit the scope of the disclosure.

The terminology used herein is for the purpose of describing particular exemplary configurations only and is not intended to be limiting. As used herein, the singular articles “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, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, 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. Additional or alternative steps may be employed.

When an element or layer is referred to as being “on,” “engaged to,” “connected to,” “attached to,” or “coupled to” another element or layer, it may be directly on, engaged, connected, attached, 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,” “directly attached 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.

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 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 configurations. 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.

When an element or layer includes a directional and/or spatial term (e.g., top, bottom, medial, lateral, etc.), the directional and/or spatial term is used relative to a user's foot anatomy when the article of footwear is being worn by a user. The user is considered to be standing on a flat, level surface.

The subject matter of embodiments of the present disclosure is described with specificity herein to meet statutory requirements. But the description itself is not intended to necessarily limit the scope of claims. Rather, the claimed subject matter might be embodied in other ways to include different steps or combinations of steps similar to the ones described in this document, in conjunction with other present or future technologies. Terms should not be interpreted as implying any particular order among or between various steps herein disclosed unless and except when the order of individual steps is explicitly stated.

Articles of footwear include different types of shoes, sandals, boots, heels, or the like. For the sake of clarity, articles of footwear will be discussed herein as shoes; however, embodiments are not limited solely to shoes. The technology disclosed herein may equally be used to create footwear other than shoes. To alleviate confusion and to provide a more readable disclosure, embodiments simply reference shoes. To that end and to provide a robust disclosure, different component portions of shoes are discussed herein, including uppers, midsoles, and outsoles. One skilled in the art will understand that shoes may include an upper and a sole structure, with the latter comprising an outsole, a midsole, and perhaps an insole.

Referring to FIG. 1, an article of footwear 10 may include an upper 100 and a sole structure 102. 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, and a posterior end 20 associated with a rearward-most point of the heel region 16. A longitudinal axis A10 of the footwear 10 may extend along a length of the footwear 10 from the anterior end 18 to the posterior end 20, and may generally divide the footwear 10 into a lateral side 22 and a medial side 24. Accordingly, the lateral side 22 and the medial side 24 respectively correspond with opposite sides of the footwear 10 and extend through the regions 12, 14, 16.

The upper 100 may include interior surfaces that define an interior void configured to, for example, receive and secure a foot for support on sole structure 102. 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 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.

In some examples, the upper 100 may include a strobel having a bottom surface opposing the sole structure 102 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. An ankle opening 104 in the heel region 16 may provide access to the interior void. For example, the ankle opening 104 may receive a foot to secure the foot within the void and facilitate entry and removal of the foot from and to the interior void.

In some examples, one or more fasteners 106 may 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 fasteners 106 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.

With reference to FIG. 2, the sole structure 102 may include a midsole 202 configured to provide cushioning characteristics to the sole structure 102, a first cushioning element 204 configured to provide cushioning characteristics to the sole structure 102, an outsole 206 configured to provide a portion of a ground-engaging surface of the article of footwear 10, a second cushioning element 208 configured to provide cushioning characteristics to the sole structure 102, and a filler 210 configured to provide a portion of a ground-engaging surface of the article of footwear 10 as well as to provide cushioning characteristics to the sole structure 102. The first cushioning element 204 and the second cushioning element 208 may be disposed within the midsole 202, as will be described in further detail below.

Referring to FIG. 3, the midsole 202 extends continuously from the anterior end 18 to the posterior end 20. The midsole 202 spans the width of the article of footwear 10 from the lateral side 24 to the medial side 22. The midsole 202 may include a foam material (e.g. ethylene-vinyl acetate (EVA), polyurethane, or the like.) The midsole 202 includes a top surface 246, a lateral face 245, a bottom surface (not shown), a first interior cavity 224a, a second interior cavity 224b, a third interior cavity 224c, a heel portion 226, a forefoot portion 228, one or more sidewalls 230, a first foam 223, and a second foam 225. Midsole 202 includes a medial face (not shown) opposite the lateral face 245. The first foam 223 may be an upper inner foam of the midsole 202 while the article of footwear 10 is at rest with the outsole 206 facing a ground surface. The second foam 225 may be a lower inner foam of the midsole 202 while the article of footwear 10 is at rest with the outsole 206 facing a ground surface.

The top surface 246 may be a substantially smooth surface. Top surface 246 may extend continuously from the heel portion 226 to the forefoot portion 228. As top surface 246 extends from the heel portion 226 to the forefoot portion 228, top surface 246 may slope downwards in the mid-foot region 14 when viewed from an exterior of the midsole 202. On medial side 24 and lateral side 22, one or more sidewalls 230 may extend upward from the top surface 246.

The lateral face 245 of the midsole 202 includes one or more windows (232a, 232b, and 232c). The midsole 202 may further include a posterior window 232d (shown in FIG. 10). The one or more windows 232a, 232b, 232c, and 232d may be defined by an absence of material and/or comprise a material having a transparent region. The entirety of the one or more windows 232a, 232b, 232c, and 232d may include the material comprising the transparent region. It is contemplated that the one or more windows 232a, 232b, 232c, and 232d may include a material comprising a translucent region. The entirety of the one or more windows 232a, 232b, 232c, and 232d may include the material comprising the translucent region. It is contemplated that the one or more windows 232a, 232b, 232c, and 232d may include a material comprising an opaque region. The entirety of the one or more windows 232a, 232b, 232c, and 232d may include the material comprising the opaque region.

The windows 232a and 232d may be disposed in and/or adjacent to the heel region 16. The windows 232b and 232c may be disposed in and/or adjacent to the forefoot region 12, and, in particular, window 232b may be disposed in a portion of the mid-foot region 14. The window 232a may have a height measured perpendicular to axis A10 ranging from about 8 mm to about 40 mm. Further, the window 232a may have a height ranging from about 16 mm to about 32 mm. In an exemplary embodiment, the height of the window 232a is about 30 mm. The window 232b may have a height ranging from about 8 mm to about 40 mm. Further, the window 232b may have a height ranging from about 14 mm to about 28 mm. In an exemplary embodiment, the height of the window 232a is about 20 mm. The window 232c may have a height ranging from about 8 mm to about 40 mm. Further, the window 232c may have a height ranging from about 14 mm to about 28 mm. In an exemplary embodiment, the height of the window 232c is about 20 mm. The window 232d may have a height ranging from about 8 mm to about 40 mm. Further, the window 232d may have a height ranging from about 16 mm to about 32 mm. In an exemplary embodiment, the height of the window 232d is about 30 mm.

In an exemplary embodiment, windows 232a and 232d are substantially ovular with a maximum height at its tallest region ranging from about 10 mm to about 35 mm. In an exemplary embodiment, the windows 232a and 232d each have a maximum height of 18 mm. In an exemplary embodiment, the windows 232a and 232d each have a maximum height of 19 mm. In an exemplary embodiment, the windows 232a and 232d each have a maximum height of 20 mm. In an exemplary embodiment, the windows 232a and 232d each have a maximum height of 23 mm. In other examples, the windows 232a and 232d may be rounded rectangles or any other shape which allows a user to view interior portions of the midsole 202.

In an exemplary embodiment, window 232d extends further than a furthest most posterior end of the midsole 202. In other words, a furthest most posterior point of the window 232d extends past a furthest most posterior point of the midsole 202.

As described above, a material disposed within the window 232a may be transparent, such that the window 232a may allow for a person viewing from the exterior of the sole structure 102 to see through the material of the window 232a to the interior of the sole structure 102. More particularly, when viewing through window 232, a person viewing from the exterior will see first (upper inner) foam 223 and the second (lower inner) foam 225. Accordingly, the window 232a is configured such that a user may be able to see through the cushioning element 204 and out through the opposing window 232a.

Still referring to FIG. 3, the one or more sidewalls 230 may extend from the heel portion 226 to the forefoot portion 228. The one or more sidewalls 230 may have a first region 233 along the heel region 16. The first region 233 may rise towards a first apex 234 in the heel region 16. The one or more sidewalls 230 may extend from the first apex 234 towards a second region 235. The one or more sidewalls 230 may be sized, shaped, and/or otherwise configured to slop upward from the second region 235 to a second apex 236. The one or more sidewalls 230 may be sized, shaped, and/or otherwise configured to slope downwards in the mid-foot region 14 from the second apex 236 toward a third region 237, when viewed from an exterior of the midsole 202. The one or more sidewalls 230 may be sized, shaped, and/or otherwise configured to slope upwards in the mid-foot region 14 from the third region 237 to a third apex 238, when viewed from an exterior of the midsole 202. The one or more sidewalls 230 may be sized, shaped, and/or otherwise configured to slope downwards in the mid-foot region 14 from the third apex 238 toward a fourth region 239, when viewed from an exterior of the midsole 202. The one or more sidewalls 230 may be further sized, shaped, and/or otherwise configured to extend from the fourth region 239 to the forefoot portion 228.

The interior cavities 224a, 224b, and 224c may be present within an interior of the midsole 202. Interior cavities 224a, 224b, and 224c may be defined by the first (upper inner) foam 223 and the second (lower inner) foam 225. Upper inner foam 223 and lower inner foam 225 may comprise one or more interior portions of midsole 202. Upper inner foam 223 may comprise an upper interior portion of midsole 202. Lower inner foam 225 may comprise a lower interior portion of midsole 202. Interior cavity 224a may further be defined by the window 232a. Interior cavity 224b may further be defined by the window 232b. Interior cavity 224c may further be defined by the window 232c. Interior cavity 224a may be configured to enclose the first cushioning element 204, as will be described in further detail below. Interior cavities 224b and 224c may be configured to enclose the second cushioning element 208, as will be described in further detail below.

The forefoot portion 228 may be disposed in the forefoot region 12. An anterior most end 229 of the forefoot portion 228 may be curved radially inward towards the center of midsole 202. Alternatively, it is contemplated that the anterior most end 229 may curve radially outward away from the center of midsole 202. The heel portion 226 may be disposed at a rearmost portion of the midsole 202 corresponding to the heel region 16 and the posterior end 20.

With reference to FIG. 4, the first cushioning element 204 and the second cushioning element 208 are disposed within the midsole 202 such that portions of the first cushioning element 204 are visible through window 232a and portions of the second cushioning element 208 are visible through both of windows 232b and 232c, as will be described in greater detail below.

Referring to FIG. 5A, the first cushioning element 204 may include an opposing pair of barrier films 242 and 244 (shown in FIG. 5C), which can be joined to each other at discrete locations to define a chamber 247 (shown in FIG. 5C), a web area 248, and a peripheral seam 249. The first cushioning element 204 may be an airbag or a bladder. The peripheral seam 249 extends continuously around an entirety of an outer periphery of the first cushioning element 204.

The first cushioning element 204 includes a first (medial) pod 256, a second (lateral) pod 258, a third (posterior) pod 260, a fourth (central) pod 262, and a fifth (anterior) pod 264. The first cushioning element 204 further includes a valve, which may be divided into one or more sections 266a, 266b, and 266c, aligned along an axis A204. The axis A204 is perpendicular to a medial-lateral axis AML of the first cushioning element 204. The peripheral seam 249 is disposed centrally along each of the first pod 256, the second pod 258, the third pod 260, and the fifth pod 264.

In an example, the first pod 256 is disposed on a medial side 204a of the first cushioning element 204. The first pod 256 may have a longitudinal length that extends from a first end 256a to a second end 256b. The first end 256a is disposed at an anterior end 204c of the first cushioning element 204. The first end 256a is disposed adjacent to the fifth pod 264. The second end 256b is disposed at a posterior end 204d of the first cushioning element 204. The second end 256b is disposed near the third pod 260. In the example, the first pod 256 has an oblong shape. It is contemplated that the first pod 256 may have any shape such as ovular, circular, rectangular, or the like suitable for providing a desired form of cushioning and support to the first cushioning element 204. The longitudinal length of the first pod 256 may extend perpendicular to the axis AML and parallel to the axis A204.

Still referring to FIG. 5A, in an example, the second pod 258 is disposed on a lateral side 204b of the first cushioning element 204. The second pod 258 may have a longitudinal length that extends from a first end 258a to a second end 258b. The first end 258a is disposed at the anterior end 204c of the first cushioning element 204. The first end 258a is disposed adjacent the fifth pod 264. The second end 258b is disposed at the posterior end 204d of the first cushioning element 204. The second end 258b is disposed near the third pod 260. In the example, the second pod 258 has an oblong shape. It is contemplated that the first pod 258 may have any shape such as ovular, circular, rectangular, or the like suitable for providing a desired form of cushioning and support to the article of footwear 10.

The second pod 258 may be substantially similar to the first pod 256. The second pod 258 may be symmetrical with the first pod 256 about the axis A204. In some examples, the first pod 256 and the second pod 258 may be asymmetrical. In other examples, the first pod 256 may have a different shape from the second pod 258. The first pod 258 extends perpendicular to the axis AML and parallel to the axis A204.

In an example, the third pod 260 is disposed at the posterior end 204d of the first cushioning element 204. The third pod 260 includes a first end 260a, a second end 260b, a medial projection 260c, a lateral projection 260d, and a main body 260e. The first end 260a is disposed adjacent valve section 266c. The second end 260b is disposed at the posterior end 204d. The medial projection 260c is disposed on the medial side 204a of the cushioning element 204. The lateral projection 260d is disposed on the lateral side 204b of the cushioning element 204. The main body 260e is defined by the first end 260a, the second end 260b, the medial projection 260c, and the lateral projection 260d.

The medial projection 260c and the lateral projection 260d of the third pod 260 are symmetrical about the axis A204. In some examples, the medial projection 260c and the lateral projection 260d of the third pod 260 may be asymmetrical. In the example, the third pod 260 has a substantially mushroom shape. The third pod 260 may include any shape suitable for providing a desired form of cushioning and support to the first cushioning element 204.

The fourth pod 262 is disposed between the first pod 256, the second pod 258, the third pod 260, and the fifth pod 264. The fourth pod 262 includes a first end 262a and a second end 262b. The first end 262a is disposed adjacent to the valve section 266b. The second end 262b is disposed adjacent to the valve section 266c. In the example, the fourth pod 262 is substantially square. The fourth pod 262 may include any shape suitable for providing a desired form of cushioning and support to the first cushioning element 204.

Still referring to FIG. 5A, the fifth pod 264 is disposed at the anterior end 204c. The fifth pod 264 extends from a first end 264a to a second end 264b. The first end 264a is disposed adjacent to the first end 256a of the first pod 256. The second end 264b is disposed adjacent to the first end 258a of the second pod 258. In the example, the fifth pod 264 is substantially tubular in shape. The fifth pod 264 may include any shape suitable for providing a desired form of cushioning and support to the first cushioning element 204. The fifth pod 264 extends parallel to the axis AML and perpendicular to the axis A204. The fifth pod 264 is bisected by the axis A204.

The valve sections 266a, 266b, and 266c are separated by the fifth pod 264 and the fourth pod 262. For example, the fifth pod 264 extends such that the valve sections 266a and 266b are respectively disposed on an anterior side 264d and a posterior side 264c (shown in FIG. 5C) of the fifth pod 264. The valve section 266a extends from the anterior side 264d of the fifth pod 264. The valve section 266b extends between the first end 262a of the fourth pod 262 and the posterior side 264c of the fifth pod 264. The valve section 266c extends between the second end 262b of the fourth pod 262 and the first end 260a of the third pod 260. The fourth pod 262 separates the valve section 266b from the valve section 266c.

In some examples, each of the valve sections 266a and 266b are in fluid communication with the fifth pod 264. In other examples, each of the valve sections 266a and 266b are not in fluid communication with the fifth pod 264. In other examples, one of the valve sections 266a and 266b is in fluid communication with the fifth pod 264 while the other of the valve sections 266a and 266b is not in fluid communication with the fifth pod 264. In some examples, each of the valve sections 266b and 266c are in fluid communication with the fourth pod 262. In other examples, each of the valve sections 266b and 266c are not in fluid communication with the fourth pod 262. In other examples, one of the valve sections 266b and 266c is in fluid communication with the fourth pod 262 while the other of the valve sections 266b and 266c is not in fluid communication with the fourth pod 262. In some examples, the valve section 266c is in fluid communication with the third pod 260. In other examples, the valve section 266c is not in fluid communication with the third pod 260.

Referring to FIG. 5B, the web area 248 separates each of the first pod 256 and the second pod 258 from the third pod 260 and the fourth pod 262. The web area 248 separates the third pod 260 from the fourth pod 262. The web area 248 separates the fourth pod 262 from the fifth pod 264.

In an example, each of pods 256, 258, 260, 262, and 264 and valve sections 266a, 266b, and 266c include a width (e.g., a medial-lateral diameter). The width of each of pods 256, 258, 260, 262, and 264 and valve sections 266a, 266b, and 266c extend parallel to the medial-lateral axis AML. The width of a given pod or a given valve section is measured from approximately a medial center point to a lateral center point of [a given pod or a given valve section]. Between the medial center point and the lateral center point exists a centerline extending along the medial-lateral axis AML. The width of a given pod is measured using the centerline. In addition to or in place of using the centerline, the width can be measured using any line extending between the medial center point and the lateral center point, and parallel to the medial-lateral axis AML. The lines extending between the medial center point and the lateral center point, and parallel to the medial-lateral axis AML of a given pod, include a value that can be represented as an average width. The average width is the average of the values attained via the lines taken between the medial center point and the lateral center point, and parallel to the medial-lateral axis AML.

In the example, first pod 256 has a width 256w, second pod 258 has a width 258w, and third pod 260 has a first width 260w1 and a second width 260w2. The first width 260w1 of the third pod 260 is less than the second width 260w2 of the third pod 260. Fourth pod 262 has a width 262w, and fifth pod 264 has a width 264w. The widths 256w, 258w, 260w1, 260w2, 262w, and 264w may range from about 0.75 mm to about 20 mm. The widths 256w, 258w, 260w1, 260w2, 262w, and 264w may range from about 2 mm to about 17 mm. The widths 256w, 258w, 260w1, 260w2, 262w, and 264w may range from about 5 mm to about 13 mm. The widths 256w, 258w, 260w1, 260w2, 262w, and 264w may range from about 7 mm to about 11 mm. In an example, width 256w may be about 9 mm. In another example, width 258w may be about 9 mm. In an exemplary embodiment, width 260w1 is about 10 mm. In a further example, width 260w2 may be about 13 mm. In an example, width 262w may be about 11 mm and width 264w may be about 12 mm.

Valve section 266a has a width 266aw. Valve section 266b has a width 266bw. Valve section 266c has a width 266cw. The widths 266aw, 266bw, and 266cw may range from about 0.01 mm to about 4 mm. The widths 266aw, 266bw, and 266cw may range from about 0.1 mm to about 2 mm. The widths 266aw, 266bw, and 266cw may range from about 0.25 mm to about 1 mm. In the example, the width 266aw may be about 0.75 mm, the width 266bw may be about 0.75 mm, and the width 266cw may be about 0.75 mm.

In one example, each of the widths 256w, 258w, 260w1, 260w2, 262w, and 264w may vary from one another. In one example, some of the widths 256w, 258w, 260w1, 260w2, 262w, and 264w may be the same while others may be different to one another. For example, width 256w and width 258w may be the same while each of the widths 260w1, 260w2, 262w, and 264w may be different from one another and each of the widths 256w and 258w.

Each of the pods 256, 258, 260, 262, and 264 and valve sections 266a, 266b, and 266c extend in a longitudinal direction corresponding to a length of the pods 256, 258, 260, 262, and 264 and valve sections 266a, 266b, and 266c, respectively. The length of each of pods 256, 258, 260, 262, and 264 and valve sections 266a, 266b, and 266c extends along or parallel to the axis A204. The length is measured using a line extending from a first end inclusive of a first center point to a second end inclusive of a second center point in the longitudinal direction. Any line taken between the first end and the second end that is parallel to the axis A204 may correspond to a length of the respective pod or valve section.

In the example, first pod 256 has a length 256L. Second pod 258 has a length 258L. Third pod 260 has a length 260L. Fourth pod 262 has a length 262L. Fifth pod 264 has a length 264L. The lengths 256L, 258L, 260L, 262L, and 264L may range between 2 mm and 50 mm. In an example, length 256L may be about 35 mm. In an example, length 258L may be about 35 mm. In an exemplary embodiment, length 260L may be about 20 mm. In an example, length 262L may be about 15 mm. In an example, length 264L may be about 5 mm.

In one example, the lengths 256L, 258L, 260L, 262L, and 264L may vary from one another. In one example, some of the lengths 256L, 258L, 260L, 262L, and 264L may be the same while others of the lengths 256L, 258L, 260L, 262L, and 264L may be different from one another. For example, length 256L and length 258L may be the same while each of the lengths 260L, 262L, and 264L may be different from one another and each of lengths 256L and 258L.

In the example, valve section 266a has a length 266aL. Valve section 266b has a length 266bL. Valve section 266c has a length 266cL. The lengths 266aL, 266bL, and 266cL may range from about 0.01 mm to about 4 mm. The lengths 266aL, 266bL, and 266cL may range from about 0.1 mm to about 2 mm. The widths 266aL, 266bL, and 266cL may range from about 0.25 mm to about 1 mm. The width 266aw may be about 0.5 mm. The width 266bw may be about 0.6 mm. The width 266cw may be about 0.1 mm.

Referring to FIG. 5C, the barrier films 242 and 244 may include a first, upper barrier film 242 and a second, lower barrier film 244. Alternatively, the chamber 247 can be produced from any suitable combination of one or more barrier films. Web area 248 (see FIG. 5B) may be an area where opposing barrier films 242 and 244 are bonded directly to one another without an intervening gap between the films.

Referring back to FIGS. 5A-5B, the pods 256, 258, 260, 262, and 264 are shown in a fluid-filled state. The pods 256, 258, 260, 262, and 264 may be configured to be filled with any suitable fluid, such as a gas or liquid. In an aspect, the gas may include air, nitrogen gas (N2), inert gasses, or any other suitable gas. In other examples, the pods 256, 258, 260, 262, and 264 may be configured to 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 pods 256, 258, 260, 262, and 264 may cause the pods 256, 258, 260, 262, and 264 to be at least partially pressurized. The pods 256, 258, 260, 262, and 264 may be pressurized to a value ranging between about 3 pounds per square inch (PSI) to about 40 PSI (about 20 kilopascals (kPA) to about 276 kPA). In the example, the first pod 256 may be pressurized to about 25 PSI. The second pod 258 may be pressurized to about 25 PSI. The third pod 260 may be pressurized to about 5 PSI. The fourth pod 262 may be pressurized to about 5 PSI. The fifth pod 264 may be pressurized to about 5 PSI. Alternatively, the fluid provided to the pods 256, 258, 260, 262, and 264 may be at atmospheric pressure such that the pods 256, 258, 260, 262, and 264 are not pressurized but, rather, each contains a volume of fluid at atmospheric pressure.

As detailed above, the pods 256, 258, 260, 262, and 264 may be configured to retain a fluid, particularly a gas such as air, oxygen or nitrogen. The pods 256, 258, 260, 262, and 264 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 one embodiment, the pods 256, 258, 260, 262, and 264 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. In further aspects, the transmission rate may be about 10 cm3/m2·atm·day or less, about 5 cm3/m2·atm·day or less, or about 1 cm3/m2·atm·day or less.

Referring to FIG. 6A, the second cushioning element 208 may include a plurality of tubes, including a first tube 600, a second tube 602, a third tube 604, a fourth tube 606, a fifth tube 608, and a sixth tube 610. The second cushioning element 208 may include a plurality of pods, including a first pod 612, a second pod 614, a third pod 616, and a fourth pod 618. Further, the second cushioning element 208 may include one or more web areas, such as a web area (divided into portions 620a, 620b, 620c, 620d, 620e, and 620f). The first cushioning element 204 may further include one or more holes 622 and a valve (divided into portions 624a, 624b, 624c, 624d, 624e, and 624f) aligned along an axis A208. The axis A208 is perpendicular to a medial-lateral axis AML of the second cushioning element 208.

The first pod 612 is disposed on a medial side 208a of the second cushioning element 208. The first pod 612 extends from a first end 612a to a second end 612b. The first end 612a is disposed at a posterior end 208d of the second cushioning element 208. The second end 612b is disposed adjacent to the web area portion 620d. In the example, the first pod 612 has an oblong shape. It is contemplated that the first pod 612 may have any shape such as ovular, circular, rectangular, or the like suitable for providing a desired form of cushioning and support to the article of footwear 10. The first pod 612 extends perpendicular to the axis AML and substantially parallel to the axis A208.

The second pod 614 is disposed on the medial side 208a. The second pod 614 extends from a first end 614a to a second end 614b. The first end 614a is disposed at an anterior end 208c of the second cushioning element 208. The second end 614b is disposed adjacent the web area portion 620d. In the example, the second pod 614 has an oblong shape. It is contemplated that the second pod 614 may have any shape such as ovular, circular, rectangular, or the like suitable for providing a desired form of cushioning and support to the second cushioning element 208. The second pod 614 extends perpendicular to the axis AML and substantially parallel to the axis A208. The second pod 614 may be substantially similar in size, shape, length, or any other dimension to the first pod 612. In other examples, the first pod 612 may have a different dimension from the second pod 614.

Still referring to FIG. 6A, the third pod 616 is disposed on a lateral side 208b. The third pod 616 extends from a first end 616a to a second end 616b. The first end 616a is disposed at the anterior end 208c of the second cushioning element 208. The second end 616b is disposed adjacent the web area portion 620d. In the example, the third pod 616 has an oblong shape. It is contemplated that the third pod 616 may have any shape such as ovular, circular, rectangular, or the like suitable for providing a desired form of cushioning and support to the second cushioning element 208. The third pod 616 extends perpendicular to the axis AML and substantially parallel to the axis A208. The third pod 616 may be substantially similar in size, shape, length, or any other dimension to the first pod 612 and the second pod 614. In other examples, the third pod 616 may have a different dimension from the first pod 612 and the second pod 614.

The fourth pod 618 is disposed on the lateral side 208b. The fourth pod 618 extends from a first end 618a to a second end 618b. The first end 618a is disposed at the posterior end 208d of the second cushioning element 208. The second end 618b is disposed adjacent the web area portion 620d. In the example, the fourth pod 618 has an oblong shape. It is contemplated that the fourth pod 618 may have any shape such as ovular, circular, rectangular, or the like suitable for providing a desired form of cushioning and support to the second cushioning element 208. The fourth pod 618 extends perpendicular to the axis AML and substantially parallel to the axis A208. The fourth pod 618 may be substantially similar in size, shape, length, or any other dimension to the first pod 612, the second pod 614, and the third pod 616. In other examples, the fourth pod 618 may have a different dimension from the first pod 612, the second pod 614, and the third pod 616.

The first tube 600 is disposed at the posterior end 208d. The first tube 600 extends from a first end 600a to a second end 600b. The first end 600a is disposed adjacent the first pod 612. The second end 600b is disposed adjacent the fourth pod 618. In the example, the first tube 600 is substantially tubular in shape. The first tube 600 may include any shape suitable for providing a desired form of cushioning and support to the second cushioning element 208. The first tube 600 extends parallel to the axis AML and perpendicular to the axis A208. The first tube 600 may have a longitudinal length that is bisected by the axis A208.

Still referring to FIG. 6A, the second tube 602 is disposed nearer the posterior end 208d relative to the third tube 604. The second tube 602 extends from a first end 602a to a second end 602b. The first end 602a is disposed adjacent the first pod 612. The second end 602b is disposed adjacent the fourth pod 618. The second tube 602 is substantially tubular in shape. The second tube 602 may include any shape suitable for providing a desired form of cushioning and support to the second cushioning element 208. The second tube 602 extends parallel to the axis AML and perpendicular to the axis A208. The second tube 602 may have a longitudinal length that is bisected by the axis A208.

The third tube 604 is disposed adjacent the web area portion 620d relative to the first tube 600 and the second tube 602. The third tube 604 extends from a first end 604a to a second end 604b. The first end 604a is disposed adjacent the first pod 612. The second end 604b is disposed adjacent the fourth pod 618. The third tube 604 is substantially tubular in shape. The third tube 604 may include any shape suitable for providing a desired form of cushioning and support to the second cushioning element 208. The third tube 604 extends parallel to the axis AML and perpendicular to the axis A208. The third tube 604 may have a longitudinal length that is bisected by the axis A208.

The fourth tube 606 is disposed adjacent the web area portion 620d relative to the fifth tube 608 and the sixth tube 610. The fourth tube 606 extends from a first end 606a to a second end 606b. The first end 606a is disposed adjacent the second pod 614. The second end 606b is disposed adjacent the third pod 616. The fourth tube 606 is substantially tubular in shape. The fourth tube 606 may include any shape suitable for providing a desired form of cushioning and support to the second cushioning element 208. The fourth tube 606 extends parallel to the axis AML and perpendicular to the axis A208. The fourth tube 606 may have a longitudinal length that is bisected by the axis A208.

Still referring to FIG. 6A, the fifth tube 608 is disposed near the anterior end 208c relative to the fourth tube 606. The fifth tube 608 extends from a first end 608a to a second end 608b. The first end 608a is disposed adjacent the second pod 614. The second end 608b is disposed adjacent the third pod 616. The fifth tube 608 is substantially tubular in shape. The fifth tube 608 may include any shape suitable for providing a desired form of cushioning and support to the second cushioning element 208. The fifth tube 608 extends parallel to the axis AML and perpendicular to the axis A208. The fifth tube 608 may have a longitudinal length that is bisected by the axis A208.

The sixth tube 610 is disposed at the anterior end 208c. The sixth tube 610 extends from a first end 610a to a second end 610b. The first end 610a is disposed adjacent the second pod 614. The second end 610b is disposed adjacent the third pod 616. The sixth tube 610 is substantially tubular in shape. The sixth tube 610 may include any shape suitable for providing a desired form of cushioning and support to the second cushioning element 208. The sixth tube 610 extends parallel to the axis AML and perpendicular to the axis A208. The sixth tube 610 may have a longitudinal length that is bisected by the axis A208.

Still referring to FIG. 6A, the valve portion 624a is disposed posterior to the first tube 600. The valve portions 624b, 624c, 624d, 624e, and 624f are disposed between adjacent tubes of the plurality of tubes 600, 602, 604, 606, 608, and 610. For example, the valve portion 624b extends between the first tube 600 and the second tube 602. The valve portion 624c extends between the second tube 602 and the third tube 604. The valve portion 624d extends between the third tube 604 and the fourth tube 606. The valve portion 624e extends between the fourth tube 606 and the fifth tube 608. The valve portion 624f extends between the fifth tube 608 and the sixth tube 610.

In some examples, each of the valve portions 624b, 624c, 624d, 624e, and 624f are in fluid communication with one or more of the respective tubes 600, 602, 604, 606, 608, and 610. In other examples, each of the valve portions 624b, 624c, 624d, 624e, and 624f are not in fluid communication with the tubes 600, 602, 604, 606, 608, and 610. In other examples, one or some of the valve portions 624b, 624c, 624d, 624e, and 624f may be in fluid communication with one or more of the respective tubes 600, 602, 604, 606, 608, and 610, while others of the valve portions 624b, 624c, 624d, 624e, and 624f may not be in fluid communication with the tubes 600, 602, 604, 606, 608, and 610.

The web area portion 620a is disposed adjacent the first tube 600. The web area portion 620b is disposed between and separates the first tube 600 from the second tube 602. The web area portion 620c is disposed between and separates the second tube 602 from the third tube 604. The web area portion 620d is disposed between and separates the third tube 604 from the fourth tube 606. The holes 622 are disposed within and extend through the web area portion 620d. The web area portion 620e is disposed between and separates the fourth tube 606 from the fifth tube 608. The web area portion 620f is disposed between and separates the fifth tube 608 from the sixth tube 610.

Still referring to FIG. 6A, the plurality of tubes 600, 602, 604, 606, 608, and 610, and the plurality of pods 612, 614, 616, and 618 are shown in a fluid-filled state. The tubes 600, 602, 604, 606, 608, and 610, and pods 612, 614, 616, and 618 may be filled to include any suitable fluid, such as a gas or liquid. In an aspect, the gas may include air, nitrogen gas (N2), inert gasses, or any other suitable gas. In other examples, the tubes 600, 602, 604, 606, 608, and 610, and pods 612, 614, 616, and 618 may 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 tubes 600, 602, 604, 606, 608, and 610, and pods 612, 614, 616, and 618 may cause the tubes 600, 602, 604, 606, 608, and 610, and pods 612, 614, 616, and 618 to be at least partially pressurized. The tubes 600, 602, 604, 606, 608, and 610, and pods 612, 614, 616, and 618 may be pressurized to a value ranging between about 3 pounds per square inch (PSI) to about 40 PSI (about 20 kilopascals (kPA) to about 276 kPA). The first tube 600 may be pressurized to about 5 PSI. The second tube 602 may be pressurized to about 5 PSI. The third tube 604 may be pressurized to about 5 PSI. The fourth tube 606 may be pressurized to about 5 PSI. The fifth tube 608 may be pressurized to about 5 PSI. The sixth tube 610 may be pressurized to about 5 PSI. The first pod 612 may be pressurized to about 25 PSI. The second pod 614 may be pressurized to about 25 PSI. The third pod 616 may be pressurized to about 25 PSI. The fourth pod 618 may be pressurized to about 25 PSI. Alternatively, the fluid provided to the tubes 600, 602, 604, 606, 608, and 610, and pods 612, 614, 616, and 618 may be at atmospheric pressure such that the tubes 600, 602, 604, 606, 608, and 610, and pods 612, 614, 616, and 618 are not pressurized. In this instance, each of the pods and the tubes may contain a volume of fluid at atmospheric pressure.

The tubes 600, 602, 604, 606, 608, and 610, and pods 612, 614, 616, and 618 may be configured to retain a fluid, particularly a gas such as air, oxygen or nitrogen. The tubes 600, 602, 604, 606, 608, and 610, and pods 612, 614, 616, and 618 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 one embodiment, the tubes 600, 602, 604, 606, 608, and 610, and pods 612, 614, 616, and 618 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. In further aspects, the transmission rate may be about 10 cm3/m2·atm·day or less, about 5 cm3/m2·atm·day or less, or about 1 cm3/m2·atm·day or less.

Referring to FIGS. 6B and 6C, the second cushioning element 208 may include a peripheral seam 626 extending about an outer perimeter of the second cushioning element 208. The second cushioning element 208 may include an opposing pair of films 642, 644 (as shown in FIG. 6D). One or both of the opposing pair of films 642, 644 may comprise a barrier material. For example, one or both of the opposing pair of films 642, 644 comprises a multi-layer film. The films 642 and 644 are joined to each other at discrete locations to define the plurality of tubes 600, 602, 604, 606, 608, and 610, the plurality of pods 612, 614, 616, and 618, the plurality of web area portions 620a, 620b, 620c, 620d, 620e, and 620f, and the peripheral seam 626. The peripheral seam 626 is disposed centrally between film 642 and 644, with the film 642 defining an upper film and the film 644 defining a lower film, such that the peripheral seam 626 is disposed in the center of the second cushioning element 208. The peripheral seam 626 being a center seam allows for equal portions of the upper film 642 and the lower film 644 to stretch. Additionally, the peripheral seam 626 being a center seam provides for the use of larger windows 232b and 232c, as will be described in greater detail below.

In some examples, the upper film 642 and the lower film 644 cooperate to define a geometry and/or configuration (e.g., thicknesses, width, and lengths) of the tubes 600, 602, 604, 606, 608, and 610, and pods 612, 614, 616, and 618, respectively. For example, the web area portions 620a, 620b, 620c, 620d, 620e, and 620f, and the peripheral seam 626 may be collectively configured to bound and extend around the tubes 600, 602, 604, 606, 608, and 610, and pods 612, 614, 616, and 618 to seal the fluid (e.g., air) within an interior void (chamber) 646 (shown in FIG. 6D) of tubes 600, 602, 604, 606, 608, and 610, and pods 612, 614, 616, and 618. Thus, the tubes 600, 602, 604, 606, 608, and 610, and pods 612, 614, 616, and 618 may be positioned and/or disposed within an area of the second cushioning element 208 where interior surfaces of the upper and lower films 642, 644 are not joined together and, thus, are separated from one another.

Referring to FIG. 7A, the outsole 206 extends from a first end 206a to a second end 206b, and includes a medial side 206c and a lateral side 206d. The first end 206a is disposed at the anterior end 18 of the article of footwear 10. The second end 206b is disposed at the posterior end 20 of the article of footwear 10. The outsole 206 includes a first surface 700 and a second surface 702 (shown in FIG. 9) that is opposite of the first surface 700. The outsole 206 further includes a receptacle 704 and a ridge 706. The receptacle 704 may have a longitudinal length that extends from a first end positioned near the second end 206b to a second end positioned near a middle portion of the outsole 206. In some examples, the receptacle 704 may have a longitudinal length that extends along a substantial entirety of the outsole 206. In an example, the receptacle 704 defines a hole within the outsole 206 extending through the first surface 700 and second surface 702 such that other portions of the article of footwear 10 may be received therein. In the example, the receptacle 704 is substantially oblong in shape. The receptacle 704 may have any shape suitable for receiving other portions of the article of footwear 10.

The ridge 706 includes a medial ridge portion 706a and a lateral ridge portion 706b. The medial ridge portion 706a is disposed on the medial side 206c. The lateral ridge portion 706b is disposed on the lateral side 206d. The medial ridge portion 706a bounds a medial side of the receptacle 704. The lateral ridge portion 706b bounds a lateral side of the receptacle 704. The ridge 706 is disposed at a substantially central portion of the outsole 206. As shown in FIG. 7B, the ridge 706 may be sized, shaped, and/or otherwise configured to form a raised portion of the outsole 206. A portion of the first surface 700 positioned along the ridge 706 rests in a plane that is disposed relatively closer to the upper 100 than that of a plane of a remaining portion of the first surface 700.

Referring to FIGS. 8A and 8B, the filler 210 may have a longitudinal length that extends from a first end 210a to a second end 210b. The filler 210 includes a first surface 800 and a second surface 802 (shown in FIG. 9) opposite the first surface 800. The first surface 800 includes one or more pockets 804. The one or more pockets 804 extend outwardly from the second surface 802. The one or more pockets 804 may be substantially square, rectangular, triangular, or circular in shape. The filler 210 further includes a raised portion 806. The raised portion 806 is disposed near the first end 210a. A portion of the first surface 800 positioned along the raised portion 806 rests in a plane that is disposed relatively closer to the upper 100 than that of a plane of a remaining portion of the first surface 800.

Referring to FIG. 9, the filler 210 is disposed within the receptacle 704 of the outsole 206. In some embodiments, the filler 210 rests flush within the receptacle 704 and/or with the second surface 702. Although not shown, the article of footwear 10 may include one or more traction elements.

Referring to FIG. 10, the first cushioning element 204 may be configured to cooperate with the internal cavity 224a of the midsole 202. In other words, the first cushioning element 204 is sized and shaped to fit within the confines of the internal cavity 224a. The midsole 202 contacts portions of the first cushioning element 204. The first cushioning element 204 may be disposed within the midsole 202 such that the midsole 202 surrounds an outer periphery of the first cushioning element 204. Specifically, first pod 256 and second pod 258 of the first cushioning element 204 may be surrounded by the midsole 202 such that a user would be able to see through the transparency of window 232a as well as barrier films 242 and 244 of the first cushioning element 204. Interior portions of the pod 260 may be visible by the window 232d.

The second cushioning element 208 may be configured to cooperate with the internal cavities 224b and 224c of the midsole 202. In other words, the second cushioning element 208 is sized and shaped to fit within the confines of the internal cavities 224b and 224c. The upper inner foam 223 and the lower inner foam 225 is in contact with portions of the second cushioning element 208. The second cushioning element 208 may be disposed between the upper inner foam 223 and lower inner foam 225. The upper and lower inner foams 223 and 225 may be in communication with the web area portions 620a, 620b, 620c, 620d, 620e, and 620f of the second cushioning element 208 thereby allowing the upper and lower inner foams 223 and 225 to surround the second cushioning element 208. Specifically, each of the tubes 600, 602, 604, 606, 608, and 610 and the pods 612, 614, 616, and 618 of the second cushioning element 208 may be surrounded by the upper and lower inner foams 223 and 225 such that a user would be able to see through the transparency of windows 232b and 232c as well as barrier films 642 and 644 of the second cushioning element 208. The inclusion of the peripheral seam 626 of the second cushioning element 208 allows for the use of larger windows 232b and 232c. The windows 232b and 232c may include a height that ranges between about 5 mm and about 40 mm. In an exemplary embodiment, the windows 232b and 232c may include a height of about 12 mm.

The outsole 206 may be formed of various suitable materials, such as one or more resilient materials configured to impart properties of abrasion resistance and traction to the sole structure 102. The outsole 206 may form the ground-engaging surface of the article of footwear 10.

The material of the outsole 206 can be a resilient material as described below. In one aspect, the resilient material is an elastomeric material comprising or consisting essentially of one or more elastomers. Examples of elastomers include butyl rubber, isoprene rubber, nitrile rubber, styrenic block copolymer rubber such as styrene-butadiene rubber, polyolefin rubber such as ethylene propylene rubber, silicone rubber, and combinations thereof. In some aspects, the one or more elastomers comprise thermoset elastomers. In other aspects, the one or more elastomers comprise thermoplastic elastomers. Examples of thermoplastic elastomers include thermoplastic styrenic block copolymer rubber, thermoplastic vulcanizate rubber, thermoplastic polyolefin rubber, thermoplastic polyurethane rubber, and combinations thereof. In addition to the one or more elastomers, the elastomeric material optionally can comprise one or more non-polymeric compounds, including fillers, processing aids, colorants, and combinations thereof.

As used herein, the term “barrier film” or “barrier membrane” (e.g., barrier films 242 and 244, and barrier films 642 and 644) encompasses both monolayer and multilayer films. In some embodiments, one or both of barrier films 242 and 244, and barrier films 642 and 644 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 films 242 and 244, and barrier films 642 and 644 may each be produced (e.g., thermoformed or blow molded) from a multilayer film (multiple sublayers).

The multi-layered film may comprise a plurality of layers. The plurality of layers may comprise one or more barrier layers. The one or more barrier layers may comprise a barrier material. The barrier material may comprise or consist essentially of one or more gas barrier compounds. The multi-layered film may comprise at least 5 layers or at least 10 layers. In other embodiments, the multi-layered film may comprise from about 5 layers to about 400 layers. In one aspect of a multi-layered film, the plurality of layers may include a series of alternating layers, in which the alternating layers include two or more barrier layers. Each of the two or more barrier layers may individually comprise a barrier material, the barrier material comprising or consisting essentially of one or more gas barrier compounds. In the series of alternating layers, adjacent layers may be individually formed of materials which differ from each other at least in their chemical compositions based on the individual components present (e.g., the materials of adjacent layers may differ based on whether or not a gas barrier compound is present, or differ based on class or type of gas barrier compound present), the concentration of the individual components present (e.g., the materials of adjacent layers may differ based on the concentration of a specific type of gas barrier compound present), or may differ based on both the components present and their concentrations.

The barrier film may be a multi-layered film comprising a plurality of layers, the plurality of layers including one or more layers comprising, consisting essentially of, or consisting of one or more barrier materials, the one or more barrier materials comprising, consisting essentially of, or consisting of one or more gas barrier compounds. The one or more gas barrier compounds may comprise, consist essentially of, or consist of one or more gas barrier polymers. The multi-layered film may comprise a total of at least 5 layers or at least 10 layers. The multi-layered film may comprise at least 5 barrier layers or at least 10 barrier layers. The multi-layered film may comprise a total of from about 5 to about 200 layers, from about 10 to about 100 layers, from about 20 to about 80 layers, from about 20 to about 50 layers, or from about 40 to about 90 layers. The multi-layered film may comprise from about 5 to about 200 barrier layers, from about 10 to about 100 barrier layers, from about 20 to about 80 barrier layers, from about 20 to about 50 barrier layers, or from about 40 to about 90 barrier layers.

The plurality of layers of the multi-layered film may include a series of alternating layers, wherein the alternating layers include two or more barrier layers, each of the two or more barrier layers individually comprising a barrier material, the barrier material comprising, consisting essentially of, or consisting of one or more gas barrier compounds. Optionally, the one or more gas barrier compounds may comprise, consist essentially of, or consist of one or more gas barrier polymers, one or more non-polymeric gas barrier compounds, or a mixture of one or more gas barrier polymers and one or more non-polymeric gas barrier compounds. In the series of alternating layers, adjacent layers are individually formed of materials which differ from each other at least in their chemical compositions based on the individual components present in the materials forming the adjacent layers. For example, the materials of adjacent layers may differ based on whether or not a gas barrier compound is present, or may differ based on a class or type of gas barrier compound present (e.g., may differ based on whether or not a gas barrier polymer is present, or whether or not a non-polymeric gas barrier compound is present), or may differ based on a concentration of an individual compound present (e.g., may differ based on the concentration of a gas barrier compound present), or any combination thereof. In one example, the series of alternating layers of a multi-layer barrier film may include barrier layers comprising, consisting essentially of, or consisting of a polymeric barrier compound, and layers which are substantially free of the polymeric barrier compound. In another example, the series of alternating layer of a multi-layer barrier film may include barrier layers consisting essentially of a polymeric barrier compound, and layers of a polymeric material comprising a mixture of one or more non-barrier polymers and less than about 20 weight percent of the polymeric barrier compound based on the total weight of the polymeric material. The multi-layered film may have a gas transmittance rate as described herein.

The plurality of layers of the multi-layered film may include first barrier layers comprising a first barrier material and second barrier layers comprising a second barrier material, wherein the first and second barrier materials comprise first and second gas barrier compounds which differ from each other either based on their chemical structures or based on their concentration in the barrier material or based on both their chemical structures and their concentrations in the barrier material. The first barrier material may comprise, consist essentially of, or consist of a first gas barrier component, the first gas barrier component consisting of all the gas barrier compounds present in the first barrier material. Similarly, the second barrier material may comprise, consist essentially of, or consist of a second gas barrier component, the second barrier material component consisting of all the gas barrier compounds present in the second barrier material. In a first example, the first barrier component may consist of one or more one gas barrier polymers, and the second barrier component may consist of one or more inorganic gas barrier compounds. In a second example, the first barrier component may consist of a first gas barrier polymer, and the second component may consist of a second gas barrier polymer, wherein the first gas barrier polymer differs from the second gas barrier polymer based on its chemical structure, for example, based on the chemical structures of the monomers or oligomers used to make the polymers, or based on molecular weight of the polymers, or based on both. In a third example, the first barrier component and the second barrier component may both include one or more of the same gas barrier compounds, but the concentration of the gas barrier compounds in the first barrier material and the second barrier material may differ, optionally the concentrations may differ by at least 5 weight percent based on the weight of the barrier material. In the multi-layered film, the first barrier layers and the second barrier layers may alternate with each other, or may alternate with additional barrier layers (e.g., third barrier layers comprising a third barrier material, fourth barrier layers comprising a fourth barrier material, etc., wherein each of the first, second, third and fourth, etc., barrier materials differ from each other as described above). The multi-layer film may have a gas transmittance rate as described herein.

In addition to the one or more barrier layers (e.g., one or more first barrier layers, one or more second barrier layers, etc.), the multi-layered film may further comprise one or more second layers, the one or more second layers comprising a second material. The one or more second layers may comprise or consist of non-barrier layers, i.e., layers which do not include a barrier material, and which may have a relatively high gas permeation rate. The second layers, including the non-barrier layers, may comprise a polymeric material, such as a thermoplastic material, an elastomeric material, or a thermoplastic elastomeric material. The second material of the second layers may comprises one or more polymers. In one such configuration of the multi-layered film, the one or more barrier layers comprise or consist of a plurality of barrier layers alternating with a plurality of second layers. Each of the one or more barrier layers may be positioned between two second layers (e.g., with one second layer positioned on a first side of the barrier layer, and another second layer on a second side of the barrier layer, the second side opposing the first side). Optionally the concentrations may differ by at least 5 weight percent based on the weight of the barrier material. In these multi-layered films, the first barrier layers and the second barrier layers may alternate with each other, or may alternate with additional barrier layers (e.g., third barrier layers comprising a third barrier material, fourth barrier layers comprising a fourth barrier material, etc., wherein each of the first, second, third and fourth, etc., barrier materials differ from each other as described above).

In either example, each layer can have a film thickness ranging from about 0.2 micrometers to about 1 millimeter. In further examples, the film thickness for each layer can range from about 0.5 micrometers to about 500 micrometers. In yet further examples, the film thickness for each layer can range from about 1 micrometer to about 100 micrometers.

The lower barrier films 244 and 644 may have a greater thickness than the upper barrier films 242 and 642, or vice versa. When thicker than the upper barrier films 242 and 642, the lower barrier films 244 and 644 may be configured to provide a portion of the ground-contacting surface of the article of footwear 10. Alternatively, the lower barrier films 244 and 644 and upper barrier films 242 and 642 may have equal thicknesses.

One or both of barrier films 242 and 244, and barrier films 642 and 644, may independently be transparent, translucent, and/or opaque. For example, the upper barrier films 242 and 642 may be transparent, while the lower barrier films 244 and 644 may be opaque. It is contemplated that upper barrier films 242 and 642 may be transparent or translucent, while lower barrier films 244 and 644 are opaque, or upper barrier films 242 and 642 may be opaque, while lower barrier films 244 and 644 are transparent or translucent, etc. As used herein, the term “transparent” for a barrier film and/or a fluid-filled chamber means that light passes through the barrier film in substantially straight lines and a viewer can see through the barrier film. In comparison, for an opaque barrier film, light does not pass through the barrier film and one cannot see clearly through the barrier film at all. A translucent barrier film falls between a transparent barrier film and an opaque barrier film, in that light passes through a translucent film but some of the light is scattered so that a viewer cannot see clearly through the film.

The chambers 247 and 646 may be produced from films 242 and 244, and films 642 and 644, respectively, 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 aspect, films 242 and 244, and films 642 and 644 may be produced by co-extrusion followed by vacuum thermoforming to produce an inflatable chamber 247 and an inflatable chamber 646, respectively, which may optionally include one or more valves (e.g., one way valves) that allows the chambers 247 and 646 to be filled with a fluid (e.g., gas).

In some implementations, the upper and lower films 242, 642 and 244, 644 may be formed by respective mold portions. The respective mold portions may each define various surfaces for forming depressions and pinched surfaces corresponding to locations where the web areas 248 and 620a, 620b, 620c, 620d, 620e, and 620f and/or the peripheral seams 249 and 626 are formed when the upper barrier film 242 and the lower barrier film 244 are joined and bonded together. In some implementations, adhesive bonding may join the upper barrier films 242, 642 and the lower barrier films 244, 644 to form the web areas 248 and 620a, 620b, 620c, 620d, 620e, and 620f and the peripheral seam 626, respectively. In other implementations, the respective upper and lower barrier films may be joined to form the respective web areas 248 and 620a, 620b, 620c, 620d, 620e, and 620f and the respective peripheral seams 249 and 626 by thermal bonding. In some examples, one or both of the barrier films may be heated to a temperature that facilitates shaping and melding. In some examples, the barrier films may be heated prior to being located between their respective molds. In other examples, the mold may be heated to raise the temperature of the barrier films. In some implementations, a molding process used to form the fluid-filled chambers 247 and 646 may incorporate vacuum ports within mold portions to remove air such that the upper and lower barrier films are drawn into contact with respective mold portions. In other implementations, fluids such as air may be injected into areas between the upper and lower barrier films such that pressure increases cause the barrier films to engage with surfaces of their respective mold portions.

Barrier films 242, 642 and 244, 644 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 example, 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.

As used herein, “polyurethane” refers to a copolymer (including oligomers) that contains a urethane group (—N(C═O)O—). These polyurethanes can 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 can 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 examples, the polyurethane polymer chains are produced from diisocynates including HMDI, TDI, MDI, H12 aliphatics, and combinations thereof. In an aspect, the thermoplastic TPU can include polyester-based TPU, polyether-based TPU, polycaprolactone-based TPU, polycarbonate-based TPU, polysiloxane-based TPU, or combinations thereof.

In another example, the polymeric layer can 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.

The films 242, 642 and 244, 644 may be multi-layer films including two or more layers. Films 242, 642 and 244, 644 may each independently include alternating layers of one or more TPU copolymer materials and one or more EVOH copolymer materials, where the total number of layers in each of barrier films 242, 642 and 244, 644 includes at least four (4) layers, at least ten (10) layers, at least twenty (20) layers, at least forty (40) layers, and/or at least sixty (60) layers.

The cushioning elements described herein are resilient structures configured to retain a fluid, particularly a gas. Typically, the fluid needs to be retained over an intended lifetime of the cushioning element, including when the cushioning element is exposed to repeated cycles of applying and releasing force or pressure, as would be encountered when the cushioning element is used in an article of footwear. As many of the polymeric materials conventionally used to manufacture consumer goods are relatively impermeable to water and aqueous solutions but are permeable to small gas molecules such as air, oxygen (O2) gas and nitrogen (N2) gas and inert gasses, barrier materials, i.e., materials which have relatively low rates of fluid transmittance, and so provide relatively high levels of liquid and gas retention to the cushioning element, may be used alone or in combination with conventional polymeric materials. Thus, the cushioning elements described herein, including the various structures forming the cushioning elements, may comprise, consist essentially of, or consist of a barrier material. The inclusion of the barrier material in the cushioning element may allow the cushioning element to retain a fluid, such as small gas molecules, over the lifetime of the cushioning element. The inclusion of the barrier material in the cushioning element may allow the cushioning element to remain adequately pressurized over its lifetime. The cushioning element may retain a minimum pressure of about 2 PSI (14 kPA) to about 40 PSI (276 kPA) over a minimum duration of about 5 years to about 30 years.

As used herein, a barrier material refers to a material comprising, consisting essentially of, or consisting of one or more gas barrier compounds. The gas barrier compound may be a polymeric gas barrier compound (i.e., a gas barrier polymer), or may be a non-polymeric gas barrier compound, such as an inorganic gas barrier compound. The barrier material may be a polymeric barrier material comprising, consisting essentially of, or consisting of one or more gas barrier polymers. The barrier material may be a polymeric barrier material comprising, consisting essentially of, or consisting of a mixture of one or more non-gas barrier polymers and one or more gas barrier polymers, or a barrier material comprising, consisting essentially of, or consisting of a mixture of one or more non-gas barrier polymers and one or more non-polymeric gas barrier compounds. The barrier material may comprise, consist essentially of, or consist of a non-polymeric barrier material, i.e., a material comprising, consisting essentially of, or consisting of a non-polymeric gas barrier compound. The barrier material may be present in a structure which includes regions of polymeric materials and non-polymeric barrier materials, such as a polymeric film coated with one or more layers of a non-polymeric barrier material. The gas transmission rate of the portion of the cushioning element comprising the barrier material may be less than 4 or less than 3 or less than 2 cubic centimeters per square meter per atmosphere per day per day. The portion of the cushioning element comprising the barrier material may be a portion of a tube, an entire tube, a portion of a web area, an entire web area, or any combination thereof. The cushioning element may comprise a barrier film comprising the barrier material. The portion of the cushioning element comprising the barrier film may be a portion of a tube, an entire tube, a portion of a web area, an entire web area, or any combination thereof. The gas transmission rate of the barrier film may be less than 4 or less than 3 or less than 2 cubic centimeters per square meter per atmosphere per day per day for a barrier film having a thickness of from about 72 micrometers to about 320 micrometers, as measured at 23 degrees Celsius and 0 percent relative humidity. The gas transmission rate of the barrier film may be from about 0.1 to about 3, or from about 0.5 to about 3, or from about 0.5 to about 3 cubic centimeters per square meter per atmosphere per day per day, including from about 0.1 to about 3, or from about 0.5 to about 3, or from about 0.5 to about 3 cubic centimeters per square meter per atmosphere per day per day for a film having a thickness of from about 72 micrometers to about 320 micrometers, as measured at 23 degrees Celsius and 0 percent relative humidity. The gas transmission rate, such as the oxygen gas or nitrogen gas transmission rate, may be measured using ASTM D1434.

The barrier material may comprise, consist essentially of, or consist of one or more non-polymeric gas barrier compounds, including one or more inorganic gas barrier compounds. The one or more inorganic gas barrier compounds may be chosen from a form of carbon, silica, silicate, clay, a metal, an any combination thereof. The metal may include a metal oxide or a metal alloy. The one or more inorganic gas barrier compounds may take the form of fibers, particulates, platelets, or combinations thereof. The fibers, particulates, or platelets may be nanoscale structures, including nanoscale fibers, nanoscale particulates, nanoscale platelets, and combinations thereof. Examples of inorganic barrier compounds include carbon fibers, glass fibers, glass flakes, silica particles, silica platelets, silica flakes, silicate particles, silicate platelets, silicate flakes, calcium carbonate particles, clay particles, clay platelets, mica platelets, talc particles, carbon black particles, graphite particles, graphite platelets, graphite flakes, metallic particles, metallic platelets, metallic flakes, and the like. The barrier material may comprise an inorganic gas barrier component consisting of all the inorganic gas barrier compounds present in the barrier material. The inorganic gas barrier component may consist of one or more clays. Suitable clays include bentonite, montmorillonite, kaolinite, and mixtures thereof. Optionally, in addition to the one or more non-polymeric gas barrier compounds, the barrier material may further comprise one or more additional ingredients, such as a polymer, processing aid, colorant, or any combination thereof. When one or more inorganic gas barrier compounds are included in the barrier material, the total concentration of the inorganic gas barrier component present in the barrier material may be less than 60 weight percent, or less than 40 weight percent, or less than 20 weight percent of the barrier material.

The one or more gas barrier compounds of the barrier material may comprise, consist essentially of one, or consist of one or more gas barrier polymers. The barrier material may be a thermoplastic material, meaning that the polymeric component of the barrier material consists of one or more thermoplastic polymers, optionally including thermoplastic polymers which are not gas barrier polymers. The barrier material may comprise, consist essentially of, or consist of one or more thermoplastic gas barrier polymers. The barrier material comprises a gas barrier polymer component consisting of all gas barrier polymers present in the barrier material. The gas barrier polymer component of the barrier material may consist of one or more gas barrier polymer of a single class of polymers such as, for example, one or more polyolefins. The gas barrier polymer component may consist of gas barrier polymers having similar or the same chemical structures, such as one or more ethylene-vinyl alcohol copolymers. Optionally, the barrier material may further comprise one or more non-polymeric additives, such as one or more fillers, processing aids, colorants, or any combination thereof; or one or more non-polymeric barrier compounds, such as one or more inorganic barrier compounds. Many gas barrier polymers are known in the art. Examples of gas barrier polymers include vinyl polymers such as vinylidene chloride polymers, acrylic polymers such as acrylonitrile polymers, polyamides, epoxy polymers, amine polymers, polyolefins such as polyethylenes and polypropylenes, copolymers thereof, such as ethylene-vinyl alcohol copolymers, and mixtures thereof. When the barrier material comprises, consists essentially of, or consists of one or more gas barrier polymers, the one or more gas barrier polymers may be chosen from a vinyl polymer, an acrylic polymer, an amide polymer, an imide polymer, an epoxy polymer, an olefin polymer, any homopolymer thereof, any copolymer thereof, and any mixture thereof. The one or more gas barrier polymer may comprise, consist essentially of, or consist of one or more thermoplastic gas barrier polymers. Examples of thermoplastic gas barrier polymers include thermoplastic vinyl homopolymers and copolymers, thermoplastic acrylic homopolymers and copolymers, thermoplastic amine homopolymers and copolymers, thermoplastic polyolefin homopolymers and copolymers, and mixtures thereof. The one or more gas barrier polymers may comprise, consist essentially of, or consist of one or more thermoplastic polyethylene copolymers. The one or more gas barrier polymers may comprise, consist essentially of, or consist of one or more thermoplastic ethylene-vinyl alcohol copolymers. The thermoplastic ethylene-vinyl alcohol copolymer may be an ethylene-vinyl alcohol copolymer having from about 28 mole percent to about 44 mole percent ethylene content, or from about 32 mole percent to about 44 mole percent ethylene content. The one or more gas barrier polymers may comprise, consist essentially of, or consist of one or more one or more polyethyleneimine, polyacrylic acid, polyethyleneoxide, polyacrylamide, polyamidoamine, or any combination thereof.

The barrier material (including a first barrier material, a second barrier material, etc.) may have a low gas transmittance rate. For example, when formed into a single-layer film consisting essentially of the barrier material, the single-layer film may have a low gas transmittance rate of less than 4 cubic centimeters per square meter per atmosphere per day per day for a film having a thickness of from about 72 micrometers to about 320 micrometers, as measured at 23 degrees Celsius and 0 percent relative humidity, and may be measured using ASTM D1434. The barrier material may comprise, consists essentially of, or consist of one or more gas barrier compounds. The one or more gas barrier compounds may comprise, consist essentially of, or consist of one or more gas barrier polymers, or may comprise one or more non-polymeric gas barrier compounds, including one or more inorganic gas barrier compounds. The barrier material may comprise, consist essentially of, or consist of a combination of at least one gas barrier polymer and at least one inorganic gas barrier compound. The combination of at least one gas barrier polymer and at least one inorganic gas barrier compound may comprise a blend or mixture, or may comprise a composite in which fibers, particles, or platelets of the inorganic gas barrier compound are surrounded by the gas barrier polymer.

The cushioning elements disclosed herein may comprise or consist of a barrier film comprising one or more barrier materials. The barrier film may be a thermoformed, welded or molded barrier film. The barrier film may be thermoformed, welded or molded into the shape of a portion of a tube or into an entire tube, or into the shape of a portion of a web or into an entire web, or both into the shape of a portion of a tube or an entire tube and into the shape of a portion of a web or an entire web of a cushioning element. The barrier film comprises a barrier material as described herein. The barrier material of the barrier film may comprise, consist essentially of, or consist of a polymeric gas barrier compound (i.e., a gas barrier polymer); or the barrier material of the barrier film may comprise, consist essentially of, or consist of a non-polymeric gas barrier compound; or the barrier material of the barrier film may comprise, consist essentially of, or consist of or a mixture of a polymeric gas barrier compound and a non-polymeric gas barrier compound. The barrier film may have a gas transmission rate as described above. When used alone or in combination with other materials in a cushioning element, the barrier film resiliently retains the fluid. Depending upon the structure and use of the cushioning element, the barrier film may retain the fluid at a pressure which is above, at, or below atmospheric pressure. The fluid may be a liquid or a gas, such as air, oxygen gas, or nitrogen gas. The barrier film may comprise a polymeric barrier material which is a nitrogen gas barrier material having a nitrogen gas transmission rate as described above.

Depending upon the gas barrier compounds used and the intended use of the multi-layered film, the second material may have a higher gas transmittance rate than the barrier material, meaning that the second material is a poorer gas barrier than the barrier material. The one or more second layers may act as substrates for the one or more barrier layers, and may serve to increase the strength, elasticity, and/or durability of the multi-layered film. The one or more second layers may serve to decrease the amount of gas barrier material(s) needed, thereby reducing the overall material cost. Even when the second material has a relatively high gas transmittance rate, the presence of the one or more second layers, particularly when the one or more second layers are positioned between one or more barrier layers, may help maintain the overall barrier properties of the film by increasing the distance between cracks in the barrier layers, thereby increasing the distance gas molecules must travel between cracks in the barrier layers in order to pass through the multi-layered film. While small fractures or cracks in the barrier layers of a multi-layered film may not significantly impact the overall barrier properties of the film, using a larger number of thinner barrier layers may avoid or reduce visible cracking, crazing, or hazing of the multi-layered film. The one or more second layers may include, but are not limited to, a tie layer located between and promoting adhesion between two different layers of the multi-layered film, a structural layer providing mechanical support to the multi-layered film, a bonding layer including a bonding material such as a hot melt adhesive material, on an exterior surface of the multi-layered film, a cap layer providing protection to an exterior surface of the multi-layered film, and any combination thereof.

The second material may be an elastomeric material comprising, consisting essentially of, or consist of one or more elastomers. The one or more elastomers may consist of one or more thermoplastic elastomers. Many gas barrier compounds (including gas barrier polymers) are brittle and/or relatively inflexible, and so the one or more barrier layers may be susceptible to cracking when subjected to repeated, excessive stress loads, such as those potentially generated during when a multi-layered film is exposed to repeated flexing and releasing cycles. A multi-layered film which includes one or more barrier layers alternating with second layers, wherein the second layers consist of one or more elastomeric materials, may produce a multi-layered film which is better able to withstand repeated flexing and releasing cycles while maintaining its gas barrier properties, as compared to a film comprising the same materials except without the elastomeric second layers.

The second material may comprise, consist essentially of, or consist of one or more polymers. As used herein, the one or more polymers present in the second material are referred to as “second polymers” or a “second polymer”, as these polymers are present in the second material. References to “second polymer(s)” are not intended to indicate that a “first polymer” necessarily is present, either in the second material, or in the multi-layered film as a whole, although multiple polymers may be present. The second material may comprise, consist essentially of, or consist of one or more thermoplastic polymers. The second material may comprise, consist essentially of, or consist of one or more elastomeric polymers. The second material may comprise, consist essentially of, or consist of one or more thermoplastic elastomers. The second material may include a polymeric component consisting of all polymers present in the second material. The polymeric component of the second material may comprise, consist essentially of, or consist of one or more elastomers, such as one or more thermoplastic elastomers. Alternatively, the polymeric component may comprise, consist essentially of, or consist of one or more thermoset elastomers, or thermosetting elastomers which react to become thermoset in the finished cushioning element. Examples of thermoset and thermosetting elastomers include natural and synthetic rubbers such as a butadiene rubber, an isoprene rubber, a silicone rubber, and the like. Optionally, the second material may further comprise one or more non-polymeric additives, such as fillers, processing aids, and/or colorants. Many polymers which are suitable for use in the second material are known in the art. Exemplary polymers which may be included in the second material (e.g., second polymers) include a polymer chosen from a polyolefin, a polyamide, a polyimide, a polycarbonate, a polyester, a polyether, a polyacrylate, a polystyrene, a polyvinyl, a polyurea, a polyurethane, a polysilane, a polysiloxane, any copolymer thereof, and any mixture thereof. The one or more second polymers of the second material may comprise, consist essentially of, or consist of a polymer chosen from a polyolefin, a polyamide, a polyester, a polystyrene, and a polyurethane.

The second material may comprise one or more polyolefin. The polymeric component of the second material may comprise, consist essentially of, or consist of one or more polyolefin, including a thermoplastic polyolefin, for example a thermoplastic polyolefin elastomer. Polyolefins are a class of polymers which include monomeric units derived from simple alkenes, such as ethylene, propylene, and butene. The one or more polyolefin may be a polyolefin homopolymer, a polyolefin copolymer, or any mixture thereof. Examples of polyolefins include ethylene homopolymers, propylene homopolymers, propylene copolymers (including polyethylene-polypropylene copolymers), polybutene, ethylene-octene copolymers, olefin block copolymers, propylene-butane copolymers, and combinations thereof, including blends of ethylene homopolymers and propylene homopolymers. Ethylene-vinyl acetate (EVA) is an example of an ethylene copolymer. Examples of polyolefin elastomers include polyisobutylene elastomers, poly (alpha-olefin) elastomers, ethylene propylene elastomers, ethylene propylene diene monomer elastomers, and combinations thereof.

The second material may comprise one or more polyamide. The polymeric component of the second material may comprise, consist essentially of, or consist of one or more polyamide, including a thermoplastic polyamide, for example a thermoplastic polyamide elastomer. Polyamides are a class of polymers which include monomeric units linked by amide bonds. Naturally-occurring polyamides include proteins such as wool and silk, while synthetic amides include polymers such as nylons and aramids. The one or more second polymers may include thermoplastic polyamides such as nylon 6, nylon 6-6, and/or nylon-11, as well as thermoplastic amide copolymers and thermoplastic amide copolymer elastomers, such as a polyether block amide (PEBA) copolymer.

The second material may comprise one or more polyester. The polymeric component of the second material may comprise, consist essentially of, or consist of one or more polyester, including a thermoplastic polyester, for example a thermoplastic polyester elastomer. Polyesters are a class of polymers which include monomeric units derived from an ester functional group, and are commonly made by condensing dibasic acids such as, for example, terephthalic acid, with one or more polyols. The one or more polyesters may include polyesters such as polyethylene terephthalate (PET), polybutylene terephthalate (PBT), and poly-1,4-cyclohexylene-dimethylene terephthalate, as well as copolymers such as polyester-ether copolymers and polyester-polyurethane copolymers.

The second material may comprise one or more polystyrene. The polymeric component of the second material may comprise, consist essentially of, or consist of one or more polystyrene, including a thermoplastic polystyrene, for example a thermoplastic polystyrene elastomer. Polystyrenes are a class of polymers which include monomeric units derived from styrene. The one or more polymers may include a polystyrene homopolymer, a styrenic random copolymer, a styrenic block copolymer, such as an acrylonitrile-butadiene-styrene (ABS) block copolymer, a styrene acrylonitrile block copolymer, a styrene-ethylene-butylene-styrene (SEBS) block copolymer, a styrene-butadiene-styrene (SBS) block copolymer, a styrene-ethylene-propylene-styrene (SEPS) block copolymer, or a mixture thereof.

The second material may comprise one or more polyurethane. The polymeric component of the second material may comprise, consist essentially of, or consist of one or more polyurethane, including a thermoplastic polyurethane (often referred to as a thermoplastic polyurethane (TPU), for example a thermoplastic polyurethane elastomer. Polyurethanes are a class of polymers which include monomeric units joined by carbamate linkages. Polyurethanes are commonly formed by reacting a polyisocyanate (e.g., a diisocyanate or a triisocyanate) with a polyol (e.g., a diol or triol), optionally in the presence of a chain extender. The monomeric units derived from the polyisocyanate are often referred to as the hard segments of the polyurethane, while the monomeric units derived from the polyols are often referred to as the soft segments of the polyurethane. The hard segments may be derived from aliphatic polyisocyanates, or from organic isocyanates, or from a mixture of both. The soft segments may be derived from saturated polyols, or from unsaturated polyols such as polydiene polyols, or from a mixture of both. When the second material is to be bonded to natural or synthetic rubber, the presence of soft segments derived from one or more polydiene polyols may facilitate bonding between the rubber and the second material when the rubber and the second material are crosslinked in contact with each other, such as in a vulcanization process. Examples of suitable polyisocyanates from which the hard segments of the polyurethane may be derived include hexamethylene diisocyanate (HDI), isophorone diisocyanate (IPDI), butylenediisocyanate (BDI), bisisocyanatocyclohexylmethane (HMDI), 2,2,4-trimethylhexamethylene diisocyanate (TMDI), bisisocyanatomethylcyclohexane, bisisochanatomethyltricyclodecane, norbornane diisocyanate (NDI), cyclohexane diisocyanate (CHDI), 4,4′-dicyclohexhylmethane diisocyanate (H12MDI), diisocyanatododecane, lysine diisocyanate, toluene diisocyanate (TDI), TDI adducts with trimethylolpropane (TMP), methylene diphenyl diisocyanate (MDI), xylylene diisocyanate (XDI), tetramethylxylylene diisocyanate (TMXDI), hydrogenated xylylene 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 any combination thereof. In one aspect, the polyurethane comprises or consists essentially of hard segments derived from toluene diisocyanate (TDI), or from methylene diphenyl diisocyanate (MDI), or from both. The soft segments of the polyurethane may be derived from a wide variety of polyols, including polyester polyols, polyether polyols, polyester-ether polyols, polycarbonate polyols, polycaprolactone polyethers, and combinations thereof. The polyurethane may comprise, consist essentially of, or consist of monomeric units derived from C4-C12 polyols, or C6-C10 polyols, or C8 or lower polyols, meaning polyols with 4 to 12 carbon molecules, or with 6 to 10 carbon molecules, or with 8 or fewer carbon molecules in their chemical structures. The polyurethane may comprise, consist essentially of, or consist of monomeric units derived from polyester polyols, polyester-ether polyols, polyether polyols, or any combination thereof. In yet another aspect, the polyurethane comprises or consists essentially of soft segments derived from polyols or diols having polyester functional units. The soft segments derived from polyols or diols having polyester functional units may comprise about 10 to about 50, or about 20 to about 40, or about 30 weight percent of the soft segments present in the polyurethane. The one or more polymers may include a urethane copolymer. Examples of urethane copolymers include polyester-polyurethane copolymers, including polyester-polyurthane elastomers.

The multi-layered film may be produced by various means such as co-extrusion, lamination, layer-by-layer deposition, or the like. When co-extruding one or more barrier layers alone or with one or more second layers, selecting materials (e.g., a first barrier material and a second barrier material, or a single barrier material and a second material) having similar processing characteristics such as melt temperature and melt flow index, may reduce interlayer shear during the extrusion process, and may allow the alternating barrier layers and second layers to be co-extruded while retaining their structural integrities and desired layer thicknesses. In one example, the one or more barrier materials and, optionally, the second material when used, may be extruded into separate individual films, which may then be laminated together to form the multi-layered film.

The multi-layered film may be produced using a layer-by-layer deposition process. A substrate, which optionally may comprise a second material or a barrier material, may be built into a multi-layered film by depositing a plurality of layers onto the substrate. The layers may include one or more barrier layers (e,g., first barrier layers, second barrier layers, etc.). Optionally, the layers may include one or more second layers. The one or more barrier layers and/or second layers may be deposited by any means known in the art such as, for example, dipping, spraying, coating, or another method. The one or more barrier layers may be applied using charged solutions or suspensions, e.g., cationic solutions or suspensions or anionic solutions or suspensions, including a charged polymer solution or suspension. The one or more barrier layers may be applied using a series of two or more solutions having opposite charges, e.g., by applying a cationic solution, followed by an anionic solution, followed by a cationic solution, followed by an anionic solution, etc.

The barrier films, including the multi-layered film, may have an overall thickness of from about 40 micrometers to about 500 micrometers, or about 50 micrometers to about 400 micrometers, or about 60 micrometers to about 350 micrometers. Each individual layer of the plurality of layers of the multi-layered film may have a thickness of from about 0.001 micrometers to about 10 micrometers. The thickness of an individual barrier layer may range from about 0.001micrometers to about 3 micrometers thick, or from about 0.5 micrometers to about 2 micrometers thick, or from about 0.5 micrometers to about 1 micrometer thick. The thickness of an individual second layer may range from about 2 micrometers to about 8 micrometers thick, or from about 2 micrometers to about 4 micrometers thick. The thickness of the film and/or their individual layers may be measured by any method known in the art such as, for example, ASTM E252, ASTM D6988, ASTM D8136, or using light microscopy or electron microscopy.

The barrier material, including the multi-layered film comprising the barrier material, may have a Shore hardness of from about 35 A to about 95 A, optionally from about 55 A to about 90 A. In these aspects, hardness may be measured using ASTM D2240 using the Shore A scale.

When a co-extrusion process is used to form the barrier film from a plurality of alternating barrier layers and second layers, the barrier material may have a melt flow index of from about 5 to about 7 grams per 10 minutes at 190 degrees Celsius when using a weight of 2.16 kilograms, while the second material may have a melt flow index of from about 20 to about 30 grams per 10 minutes at 190 degrees Celsius when using a weight of 2.16 kilograms. The melt flow index of the barrier material may be from about 80 percent to about 120 percent of the melt flow index of the second material per 10 minutes when measured at 190 degrees Celsius when using a weight of 2.16 kilograms. The melt flow index may be measured using ASTM D1238. The barrier material or the second material or both may have a melting temperature of from about 165 degrees Celsius to about 183 degrees Celsius, or from about 155 degrees Celsius to about 165 degrees Celsius. The barrier material may have a melting temperature of from about 165 degrees Celsius to about 183 degrees Celsius, while the second material may have a melting temperature of from about 155 degrees Celsius to about 165 degrees Celsius. The melting temperature may be measured using ASTM D3418.

In an alternative example, instead of being a fluid-filled bladder, any of the cushioning element 204 comprises a material, such as a foam or an unfoamed solid, to impart properties of cushioning, responsiveness, and energy distribution to the foot of the wearer. For example, the sole structure 102 may include any of the cushioning elements 204 or 206. Any of the cushioning elements 204 and 206 may comprise a foam. The foam may comprise a material. Example materials for the alternate cushioning element 204 and 206 may include those based on foaming or molding material, e.g. a resilient material, comprising 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 addition to one or more barrier materials, the sole structures described herein may comprise one or more additional polymeric materials. A polymeric material is understood to comprise, consist essentially of, or consist of one or more polymers. In addition to a cushioning element, the sole structures may include additional elements such as support elements, and the support elements may be made using one or more additional materials. Also, in addition to a barrier material, a cushioning element may be made using one or more additional materials, such as a second material as described above.

The additional material may be an elastomeric material comprising, consisting essentially of, or consist of one or more elastomers. The one or more elastomers may consist of one or more thermoplastic elastomers. The additional material may comprise, consist essentially of, or consist of one or more thermoplastic polymers. The additional material may comprise, consist essentially of, or consist of one or more elastomeric polymers. The additional material may comprise, consist essentially of, or consist of one or more thermoplastic elastomers. The additional material may include a polymeric component consisting of all polymers present in the additional material. The polymeric component of the additional material may comprise, consist essentially of, or consist of one or more elastomers, such as one or more thermoplastic elastomers. Alternatively, the polymeric component may comprise, consist essentially of, or consist of one or more thermoset elastomers, or thermosetting elastomers which react to become a thermoset in the finished sole structure. Examples of thermoset and thermosetting elastomers include natural and synthetic rubbers such as a butadiene rubber, an isoprene rubber, a silicone rubber, and the like. Optionally, the additional material may further comprise one or more non-polymeric additives, such as fillers, processing aids, and/or colorants. The additional material may comprise, consist essentially of, or consist of one or more polymers chosen from a polyolefin, a polyamide, a polyimide, a polycarbonate, a polyester, a polyether, a polyacrylate, a polystyrene, a polyvinyl, a polyurea, a polyurethane, a polysilane, a polysiloxane, any copolymer thereof, and any mixture thereof. The one or more polymers of the additional material may comprise, consist essentially of, or consist of a polymer chosen from a polyolefin, a polyamide, a polyester, a polystyrene, and a polyurethane. The additional material may comprise one or more polyolefins. The polymeric component of the additional material may comprise, consist essentially of, or consist of one or more polyolefin, including a thermoplastic polyolefin, for example a thermoplastic polyolefin elastomer. The polyolefin may be an olefin homopolymer or copolymer as described above with respect to second materials. The one or more polyolefin may comprise, consist essentially of, or consist of an EVA copolymer, including a crosslinked EVA copolymer. The additional material may comprise one or more polyamide. The polymeric component of the additional material may comprise, consist essentially of, or consist of one or more polyamide, including a thermoplastic polyamide, for example a thermoplastic polyamide elastomer. The polyamide may be an amide homopolymer or copolymer as described above with respect to second materials. The one or more polyamide may comprise, consist essentially of, or consist of a PEBA copolymer. The additional material may comprise one or more polyester. The polymeric component of the additional material may comprise, consist essentially of, or consist of one or more polyester, including a thermoplastic polyester, for example a thermoplastic polyester elastomer. The polyester may be a polyester homopolymer or copolymer as described above with respect to second materials. The additional material may comprise one or more polystyrene. The polymeric component of the additional material may comprise, consist essentially of, or consist of one or more polystyrene, including a thermoplastic polystyrene, for example a thermoplastic polystyrene elastomer. The one or more polystyrene may be a polystyrene homopolymer or copolymer as described above with respect to second polymers. The one or more polystyrene may comprise, consist essentially of, or consist of a SEBS copolymer. The additional material may comprise one or more polyurethane. The polymeric component of the additional material may comprise, consist essentially of, or consist of one or more polyurethane, including a TPU, such as a TPU elastomer. One example of a polyurethane copolymer is a polyester-polyurethane copolymer, including a polyester-polyurethane elastomer. The one or more polyurethane may be a polyurethane as described above with respect to second polymers.

Optionally, when the resilient material is a foam, the foam 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. Examples of foamed polymeric materials commonly used in footwear include a foamed polymeric material comprising a polyurethane (PU) or a foamed polymeric material comprising an ethylene-vinyl acetate copolymer (EVA). A solid polymeric support material is also contemplated. Examples of solid polymeric materials commonly used in footwear include solid elastomeric materials, including a solid elastomeric material comprising a polyurethane elastomer or comprising a polyamide elastomer.

The compression molding process desirably starts by forming one or more foam preforms, such as by injection molding and foaming a material, e.g. a resilient 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 foam preforms in a compression mold, and applying sufficient pressure to the one or more preforms to compress the one or more foam preforms in a closed mold. Once the mold is closed, sufficient heat and/or pressure is applied to the one or more foam preforms in the closed mold for a sufficient duration of time to alter the foam preform(s), to form a skin on the outer surface of the compression molded foam, or to fuse individual foam particles to each other, to permanently or semi-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.

In another example, the resilient material is an unfoamed solid. The material may be shaped using a molding process, including an injection molding process. In one example, when the material is an elastomeric material, the elastomeric material (e.g., uncured rubber) may be mixed in a Banbury mixer with an optional filler and a curing package such as, for example, a UV curing package or a thermal curing package including a sulfur-based or peroxide-based curing package, calendared, formed into shape, placed in a mold, and cured (e.g., using a UV curing process or a thermal curing process such as a vulcanization process).

The outsole 206 may be formed of resilient materials configured to impart properties of abrasion resistance and traction to the sole structure 102.

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

Clause 1. An article of footwear comprising: an upper; and a sole structure, wherein the sole structure comprises: a midsole, wherein the midsole comprises at least one partially enclosed cavity; a first cushioning element disposed within the at least one partially enclosed cavity, wherein the cushioning element comprises a first barrier film and a second barrier film enclosing an internal volume, the first barrier film and the second barrier adjoining to form a peripheral seam; a second cushioning element disposed within the at least one partially enclosed cavity, wherein the second cushioning element includes a third barrier film and a fourth barrier film enclosing an internal volume; and an outsole, wherein the outsole comprises a ground-engaging surface.

Clause 2. The article of footwear of Clause 1, wherein the midsole further comprises a first window extending along a medial side of the sole structure, a second window extending along the medial side of the sole structure, a third window extending along a lateral side of the sole structure, and a fourth window extending along the lateral side of the sole structure; wherein the medial side of the sole structure is positioned opposite of the lateral side of the sole structure.

Clause 3. The article of footwear of Clause 2, wherein the midsole further comprises a first foam component and a second foam component, wherein the at least one cavity is defined by the first foam component, the second foam component, the first window, the second window, the third window, and the fourth window.

Clause 4. The article of footwear of Clause 3, wherein the first foam contacts a first portion of an outer surface of the cushioning element, and the second foam contacts a second portion of the outer surface of the cushioning element than the first foam.

Clause 5. The article of footwear of Clause 2, wherein the first cushioning element includes: a first pod extending from a first anterior medial end of the first pod to a second posterior medial end of the first pod, the first pod is disposed adjacent to the first window; a second pod extending from a first anterior medial end of the second pod to a second posterior medial end of the second pod, the second pod is disposed adjacent to the second window; a third pod extending from a first anterior lateral end of the third pod to a second posterior lateral end of the third pod, the third pod is disposed adjacent to the third window; a fourth pod extending from a first anterior lateral end of the fourth pod to a second posterior lateral end of the fourth pod, the fourth pod is disposed adjacent to the fourth window; one or more central tubes disposed between each of the first pod, the second pod, the third pod, and the fourth pod, and the one or more central tubes extend in a medial direction and a lateral direction; and a web area disposed between each of the first pod, the second pod, the third pod, the fourth pod, and the one or more central tubes.

Clause 6. The article of footwear of Clause 5, wherein each of the first cushioning element and the second cushioning element is configured to receive a fluid.

Clause 7. The article of footwear of Clause 5, wherein each of the first pod, the second pod, the third pod, the fourth pod, and the one or more central tubes are in fluid communication with one another.

Clause 8. The article of footwear of Clause 5, wherein the first barrier film and the second barrier film are coupled to one another at the peripheral seam disposed around an entirety of the cushioning element.

Clause 9. The article of footwear of Clause 8, wherein the peripheral seam is positioned such that the peripheral seam is visible from the exterior of the article of footwear through a lateral window of the article of footwear or a medial window of the article of footwear.

Clause 10. The article of footwear of Clause 8, wherein the first barrier film and the second barrier film are coupled to one another at the web area disposed between each of the first pod, the second pod, the third pod, the fourth pod, and the one or more central tubes, wherein the web area is positioned in a first plane that coincides with a second plane in which the peripheral seam is positioned.

Clause 11. The article of footwear of Clause 5, wherein the web area is configured such that only co-planar portions of the web area are visible from an exterior of the article of footwear through at least one of the first window, the second window, the third window, or the fourth window.

Clause 12. The article of footwear of Clause 2, wherein each of the first window, the second window, the third window, and the fourth window include a transparent material.

Clause 13. The article of footwear of Clause 5, wherein the one or more central tubes comprises six central tubes.

Clause 14. The article of footwear of Clause 5, wherein a hollow interior of each of the one or more central tubes is visible from an exterior of the article of footwear through each of the first window, the second window, the third window, and the fourth window.

Clause 15. An article of footwear comprising: a forefoot region, a mid-foot region, a heel region opposite of the forefoot region, a medial side, and a lateral side opposite the medial side; a posterior end and an anterior end opposite the posterior end; an upper extending from the posterior end to the anterior end; and a sole structure extending from the posterior end to the anterior end, wherein the sole structure comprises: a midsole, wherein the midsole comprises a first partially enclosed cavity and a second partially enclosed cavity; a first thermoformed cushioning element disposed within the first partially enclosed cavity, wherein the first cushioning element comprises a first barrier film and a second barrier film enclosing an internal volume, and wherein the first barrier film and the second barrier film are coupled to one another at a center peripheral seam that extends along an outer surface of the cushioning element; a second cushioning element disposed within the second partially enclosed cavity, wherein the second cushioning element includes a third barrier film and a fourth barrier film enclosing an internal volume, wherein the third barrier film and the fourth barrier film are coupled to one another at a peripheral seam that extends along an outer surface of the cushioning element; one or more windows extending along an outer surface of the midsole; and an outsole, wherein the outsole forms a ground-engaging surface of the article of footwear.

Clause 16. The article of footwear of Clause 15, wherein the one or more windows comprise a first window, a second window, a third window, a fourth window, a fifth window, a sixth window, and a seventh window.

Clause 17. The article of footwear of Clause 16, wherein the first window is disposed substantially in the forefoot region on the medial side, the second window is disposed substantially in the forefoot region on the lateral side, the third window is disposed substantially in the mid-foot region on the medial side, the fourth window is disposed substantially in the mid-foot region on the lateral side, the fifth window is disposed substantially in the heel region on the medial side, the sixth window is disposed substantially in the heel region on the lateral side, and the seventh window is disposed at the posterior end of the article of footwear in the heel region.

Clause 18. The article of footwear of Clause 17, wherein the peripheral seam of the first cushioning element is positioned centrally within the fifth window, the sixth window, and the seventh window.

Clause 19. The article of footwear of Clause 17, wherein the fifth window, the sixth window, and the seventh window have a height of 20 mm.

Clause 20. The article of footwear of Clause 15, wherein the first barrier film and the second barrier film each includes a multi-layer film.

Clause 21. The article of footwear of Clause 15, wherein the first cushioning element and the second cushioning element include bladders that are configured to receive a fluid.

Clause 22. The article of footwear of Clause 15, wherein the first cushioning element is thermoformed.

Clause 23. A cushioning element for an article of footwear, the cushioning element comprising: a first barrier film and a second barrier film enclosing an internal volume of the cushioning element; a first pod extending from a first end of the first pod to a second end of the first pod; a second pod extending from a first end of the second pod to a second end of the second pod; a third pod extending from a first end of the third pod to a second end of the third pod, the third pod including one or more projections; a fourth pod extending from a first end of the fourth pod to a second end of the fourth pod; a fifth pod extending from a first end of the fifth pod to a second end of the fifth pod; and a web area, wherein the first barrier film and the second barrier film are coupled to one another to form the web area, and the web area is disposed between each of the first pod, the second pod, the third pod, the fourth pod, and the fifth pod.

Clause 24. The cushioning element of Clause 23, wherein each of the first pod and the second pod include an oblong-shape, the third pod includes a substantially mushroom-shape, the fourth pod includes a square shape, and the fifth pod includes a tubular shape.

Clause 25. The cushioning element of Clause 23, wherein the fifth pod is in fluid communication with the first pod and the second pod.

Clause 26. The cushioning element of Clause 23, wherein a valve is disposed between and interconnects each of the third pod, the fourth pod, and the fifth pod.

Clause 27. The cushioning element of Clause 23, wherein the cushioning element is disposed within a midsole of the article of footwear.

Clause 28. The cushioning element of Clause 23, wherein the first barrier film and the second barrier film form a peripheral seam disposed centrally along an outer periphery of the cushioning element.

Clause 29. The cushioning element of Clause 23, wherein the cushioning element is thermoformed.

Claims

1. An article of footwear comprising:

an upper; and
a sole structure, wherein the sole structure comprises: a midsole, wherein the midsole comprises at least one partially enclosed cavity; a first cushioning element disposed within the at least one partially enclosed cavity, wherein the cushioning element comprises a first barrier film and a second barrier film enclosing an internal volume, the first barrier film and the second barrier adjoining to form a peripheral seam; a second cushioning element disposed within the at least one partially enclosed cavity, wherein the second cushioning element includes a third barrier film and a fourth barrier film enclosing an internal volume; and an outsole, wherein the outsole comprises a ground-engaging surface.

2. The article of footwear of claim 1, wherein the midsole further comprises a first window extending along a medial side of the sole structure, a second window extending along the medial side of the sole structure, a third window extending along a lateral side of the sole structure, and a fourth window extending along the lateral side of the sole structure;

wherein the medial side of the sole structure is positioned opposite of the lateral side of the sole structure.

3. The article of footwear of claim 2, wherein the midsole further comprises a first foam component and a second foam component, wherein the at least one cavity is defined by the first foam component, the second foam component, the first window, the second window, the third window, and the fourth window.

4. The article of footwear of claim 3, wherein the first foam contacts a first portion of an outer surface of the cushioning element, and the second foam contacts a second portion of the outer surface of the cushioning element than the first foam.

5. The article of footwear of claim 2, wherein the first cushioning element includes:

a first pod extending from a first anterior medial end of the first pod to a second posterior medial end of the first pod, the first pod is disposed adjacent to the first window;
a second pod extending from a first anterior medial end of the second pod to a second posterior medial end of the second pod, the second pod is disposed adjacent to the second window;
a third pod extending from a first anterior lateral end of the third pod to a second posterior lateral end of the third pod, the third pod is disposed adjacent to the third window;
a fourth pod extending from a first anterior lateral end of the fourth pod to a second posterior lateral end of the fourth pod, the fourth pod is disposed adjacent to the fourth window;
one or more central tubes disposed between each of the first pod, the second pod, the third pod, and the fourth pod, and the one or more central tubes extend in a medial direction and a lateral direction; and
a web area disposed between each of the first pod, the second pod, the third pod, the fourth pod, and the one or more central tubes.

6. The article of footwear of claim 5, wherein each of the first cushioning element and the second cushioning element is configured to receive a fluid.

7. The article of footwear of claim 5, wherein each of the first pod, the second pod, the third pod, the fourth pod, and the one or more central tubes are in fluid communication with one another.

8. The article of footwear of claim 5, wherein the first barrier film and the second barrier film are coupled to one another at the peripheral seam disposed around an entirety of the cushioning element.

9. The article of footwear of claim 8, wherein the peripheral seam is positioned such that the peripheral seam is visible from the exterior of the article of footwear through a lateral window of the article of footwear or a medial window of the article of footwear.

10. The article of footwear of claim 8, wherein the first barrier film and the second barrier film are coupled to one another at the web area disposed between each of the first pod, the second pod, the third pod, the fourth pod, and the one or more central tubes, wherein the web area is positioned in a first plane that coincides with a second plane in which the peripheral seam is positioned.

11. The article of footwear of claim 5, wherein the web area is configured such that only co-planar portions of the web area are visible from an exterior of the article of footwear through at least one of the first window, the second window, the third window, or the fourth window.

12. The article of footwear of claim 2, wherein each of the first window, the second window, the third window, and the fourth window include a transparent material.

13. The article of footwear of claim 5, wherein the one or more central tubes comprises six central tubes.

14. The article of footwear of claim 5, wherein a hollow interior of each of the one or more central tubes is visible from an exterior of the article of footwear through each of the first window, the second window, the third window, and the fourth window.

15. An article of footwear comprising:

a forefoot region, a mid-foot region, a heel region opposite of the forefoot region, a medial side, and a lateral side opposite the medial side;
a posterior end and an anterior end opposite the posterior end;
an upper extending from the posterior end to the anterior end; and
a sole structure extending from the posterior end to the anterior end, wherein the sole structure comprises: a midsole, wherein the midsole comprises a first partially enclosed cavity and a second partially enclosed cavity; a first thermoformed cushioning element disposed within the first partially enclosed cavity, wherein the first cushioning element comprises a first barrier film and a second barrier film enclosing an internal volume, and wherein the first barrier film and the second barrier film are coupled to one another at a center peripheral seam that extends along an outer surface of the cushioning element; a second cushioning element disposed within the second partially enclosed cavity, wherein the second cushioning element includes a third barrier film and a fourth barrier film enclosing an internal volume, wherein the third barrier film and the fourth barrier film are coupled to one another at a peripheral seam that extends along an outer surface of the cushioning element; one or more windows extending along an outer surface of the midsole; and an outsole, wherein the outsole forms a ground-engaging surface of the article of footwear.

16. The article of footwear of claim 15, wherein the one or more windows comprise a first window, a second window, a third window, a fourth window, a fifth window, a sixth window, and a seventh window.

17. The article of footwear of claim 16, wherein the first window is disposed substantially in the forefoot region on the medial side, the second window is disposed substantially in the forefoot region on the lateral side, the third window is disposed substantially in the mid-foot region on the medial side, the fourth window is disposed substantially in the mid-foot region on the lateral side, the fifth window is disposed substantially in the heel region on the medial side, the sixth window is disposed substantially in the heel region on the lateral side, and the seventh window is disposed at the posterior end of the article of footwear in the heel region.

18. The article of footwear of claim 17, wherein the peripheral seam of the first cushioning element is positioned centrally within the fifth window, the sixth window, and the seventh window.

19. The article of footwear of claim 17, wherein the fifth window, the sixth window, and the seventh window have a height of 20 mm.

20. The article of footwear of claim 15, wherein the first barrier film and the second barrier film each includes a multi-layer film.

Patent History
Publication number: 20250151844
Type: Application
Filed: Nov 8, 2024
Publication Date: May 15, 2025
Applicant: Nike, Inc. (Beaverton, OR)
Inventors: Fidencio Campos, II (Dallas, OR), Wesley K. CHAN (Portland, OR), Laura E. FLORES SANDOVAL (Hillsboro, OR), David M. FORLAND (Battle Ground, WA)
Application Number: 18/941,967
Classifications
International Classification: A43B 13/20 (20060101);