SOLE STRUCTURE FOR ARTICLE OF FOOTWEAR

A sole structure for an article of footwear includes a midsole, a first columnar fluid-filled chamber extending between a first end proximate to the midsole and a second end proximate to a ground-engaging surface of the sole structure, a second columnar fluid-filled chamber spaced apart from the first columnar fluid-filled chamber and extending between a first end proximate to the midsole and a second end proximate to the ground-engaging surface of the sole structure, and a third columnar fluid-filled chamber disposed between the first columnar fluid-filled chamber and the second columnar fluid-filled chamber and extending between a first end proximate to the midsole and a second end proximate to a ground-engaging surface of the sole structure, the third columnar fluid-filled chamber including a different size than at least one of the first columnar fluid-filled chamber and the second columnar fluid-filled chamber.

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Description
CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority under 35 U.S.C. § 119(e) to U.S. Provisional Application No. 63/725,475, filed on Nov. 26, 2024. The disclosure of this prior application is considered part of the disclosure of this application and is hereby incorporated by reference in its entirety.

FIELD

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

BACKGROUND

This section provides background information related to the present disclosure and 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. For example, a sole structure may include a midsole and an outsole. The midsole is generally disposed between the outsole and the upper and provides cushioning for the foot. The midsole may include a pressurized fluid-filled chamber that compresses resiliently under an applied load to cushion the foot by attenuating ground-reaction forces. The outsole provides abrasion-resistance and traction with the ground surface and may be formed from rubber or other materials that impart durability and wear-resistance, as well as enhance traction with the ground surface.

While known sole structures adequately provide cushioning and support during wear, such sole structures generally provide a uniform level of cushioning and support over wide areas of the sole structure. Accordingly, conventional sole structures are not able to be tuned such that specific regions of the sole structure provide targeted cushioning and responsiveness.

DRAWINGS

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

FIG. 1 is a perspective view of an article of footwear incorporating a sole structure in accordance with the principles of the present disclosure, the sole structure incorporating fluid-filled chambers located between opposing portions of an outsole;

FIG. 2 is a medial side view of the article of footwear of FIG. 1;

FIG. 3 is a lateral side view the article of footwear of FIG. 1;

FIG. 4 is a top exploded view of the sole structure of FIG. 1;

FIG. 5 is a bottom exploded view of the sole structure of FIG. 1;

FIG. 6 is a perspective view of a cushion for use in the sole structure of FIG. 1;

FIG. 7 is a perspective view of a cushion for use in the sole structure of FIG. 1;

FIG. 8 is a bottom view of the sole structure of FIG. 1 with an outsole removed to show elements of a midsole and a cushion assembly;

FIG. 9 is a perspective view of an article of footwear incorporating a sole structure in accordance with the principles of the present disclosure, the sole structure incorporating fluid-filled chambers located between an outsole and a rigid portion of a midsole;

FIG. 10 is a medial side view of the article of footwear of FIG. 9;

FIG. 11 is a lateral side view the article of footwear of FIG. 9;

FIG. 12 is a top exploded view of the sole structure of FIG. 9;

FIG. 13 is a bottom exploded view of the sole structure of FIG. 9;

FIG. 14 is a bottom view of the sole structure of FIG. 9 with an outsole removed to show elements of a midsole and a cushion assembly;

FIG. 15 is an alternate bottom view of the sole structure of FIG. 9 with an outsole removed to show elements of a midsole and a cushion assembly;

FIG. 16 is a perspective view of an article of footwear incorporating a sole structure in accordance with the principles of the present disclosure, the sole structure incorporating fluid-filled chambers located between a plate and an outsole;

FIG. 17 is a medial side view of the article of footwear of FIG. 16;

FIG. 18 is a lateral side view the article of footwear of FIG. 16;

FIG. 19 is a top exploded view of the sole structure of FIG. 16;

FIG. 20 is a bottom exploded view of the sole structure of FIG. 16;

FIG. 21 is a bottom view of the sole structure of FIG. 16 with an outsole removed to show elements of a midsole and a cushion assembly;

FIG. 22 is an alternate bottom view of the sole structure of FIG. 1 with an outsole removed to show elements of a midsole and a cushion assembly;

FIG. 23 is an alternate bottom view of the sole structure of FIG. 1 with an outsole removed to show elements of a midsole and a cushion assembly;

FIG. 24 is an alternate bottom view of the sole structure of FIG. 1 with an outsole removed to show elements of a midsole and a cushion assembly;

FIG. 25 is an alternate bottom view of the sole structure of FIG. 1 with an outsole removed to show elements of a midsole and a cushion assembly;

FIG. 26 is an alternate bottom view of the sole structure of FIG. 1 with an outsole removed to show elements of a midsole and a cushion assembly;

FIG. 27 is an alternate bottom view of the sole structure of FIG. 1 with an outsole removed to show elements of a midsole and a cushion assembly;

FIG. 28 is a lateral side view of an article of footwear in accordance with the principles of the present disclosure incorporating a sole structure having a series of cushions; and

FIG. 29 is a lateral side view of an article of footwear in accordance with the principles of the present disclosure incorporating a sole structure having a series of cushions.

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 one configuration, a sole structure for an article of footwear is provided and includes a midsole, a first columnar cushion extending between a first end proximate to the midsole and a second end proximate to a ground-engaging surface of the sole structure, a second columnar cushion spaced apart from the first columnar cushion and extending between a first end proximate to the midsole and a second end proximate to the ground-engaging surface of the sole structure, and a third columnar cushion disposed between the first columnar cushion and the second columnar cushion and extending between a first end proximate to the midsole and a second end proximate to a ground-engaging surface of the sole structure, the third columnar cushion including a different size than at least one of the first columnar cushion and the second columnar cushion.

The sole structure may include one or more of the following optional features. For example, the third columnar cushion may be larger than the first columnar cushion. Additionally or alternatively, the third columnar cushion may the same size as the second columnar cushion. Further, the third columnar cushion may include a different structure than the second columnar cushion.

In one configuration, the second columnar cushion may be a fluid-filled chamber including a first barrier element joined to a second barrier element at a periphery of the second columnar cushion to define a first void, the first barrier element attached to the second barrier element proximate to a center of the second columnar cushion. Additionally or alternatively, the third columnar cushion may be a fluid-filled chamber including a third barrier element joined to a fourth barrier element at a periphery of the third columnar cushion to define a second void, the third barrier element being joined to the fourth barrier element only at the periphery of the third columnar cushion and/or the first columnar cushion may be a fluid-filled chamber including a fifth barrier element joined to a sixth barrier element at a periphery of the first columnar cushion to define a third void, the fifth barrier element being joined to the sixth barrier element only at the periphery of the first columnar cushion. The third void may be smaller than at least one of the first void and the second void.

An article of footwear may incorporate the sole structure.

In another configuration, a sole structure for an article of footwear is provided and includes a midsole, a first columnar cushion extending between a first end proximate to the midsole and a second end proximate to a ground-engaging surface of the sole structure, a second columnar cushion spaced apart from the first columnar cushion and extending between a first end proximate to the midsole and a second end proximate to the ground-engaging surface of the sole structure, and a third columnar cushion disposed between the first columnar cushion and the second columnar cushion and extending between a first end proximate to the midsole and a second end proximate to a ground-engaging surface of the sole structure, the third columnar cushion including a different structure than at least one of the first columnar cushion and the second columnar cushion.

The sole structure may include one or more of the following optional features. For example, the third columnar cushion may be larger than the first columnar cushion. Additionally or alternatively, the third columnar cushion may be the same size as the second columnar cushion.

In one configuration, the first columnar cushion, the second columnar cushion, and the third columnar cushion may be aligned along a lateral side of the sole structure. Additionally or alternatively, the first columnar cushion, the second columnar cushion, and the third columnar cushion may be disposed in a heel region of the sole structure.

The second columnar cushion may be a fluid-filled chamber including a first barrier element joined to a second barrier element at a periphery of the second columnar cushion to define a first void, the first barrier element attached to the second barrier element proximate to a center of the second columnar cushion. Additionally or alternatively, the third columnar cushion may be a fluid-filled chamber including a third barrier element joined to a fourth barrier element at a periphery of the third columnar cushion to define a second void, the third barrier element being joined to the fourth barrier element only at the periphery of the third columnar cushion and/or the first columnar cushion may be a fluid-filled chamber including a fifth barrier element joined to a sixth barrier element at a periphery of the first columnar cushion to define a third void, the fifth barrier element being joined to the sixth barrier element only at the periphery of the first columnar cushion. The third void may be smaller than at least one of the first void and the second void.

An article of footwear may incorporate the sole structure.

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

Conventional articles of footwear often include sole structures incorporating fluid-filled chambers. Such sole structures often include a single, fluid-filled chamber that is sized for the particular article of footwear and extends over a majority of a forefoot region of the sole structure and/or a heel region of the sole structure. As such, performance of the sole structure in these regions is limited to the performance characteristics of the single, large fluid-filled chamber. Manufacturing such chambers is often expensive, as only one or two chambers can be manufactured at a time and multiple molds are required to produce the chambers for various sizes of footwear.

The present disclosure relates to incorporating multiple fluid-filled chambers in a sole structure of an article of footwear to maximize performance of the sole structure as well as performance of an article of footwear in which the sole structure is installed while also reducing the costs associated with manufacturing the fluid-filled chambers.

Use of multiple fluid-filled chambers can allow a sole structure to adjust its shape and stiffness according to the terrain and the load, enhancing traction, shock absorption, and energy efficiency. For example, a sole structure incorporating multiple fluid-filled chambers that are independent from one another can flatten or curve to conform to uneven surfaces or stiffen or soften to respond to different impacts or speeds. Incorporating multiple fluid-filled chambers into a sole structure can also provide redundancy and resilience in case of damage or puncture, as the sole structure can still function with some fluid-filled chambers intact or partially deflated. Furthermore, these chambers can be used in different articles of footwear of various sizes, offering versatility in footwear design and manufacturing. Finally, many fluid-filled chambers can be manufactured in a single mold, which can streamline production and reduce costs.

As will be described below, the multiple fluid-filled chambers are used in conjunction with a plate or a plate-like moderator that supports the chambers relative to an upper. The plate or plate-like moderator may be a portion of an outsole or a midsole of the sole structure and includes a channel that bifurcates the plate or plate-like moderator into two segments each attached to at least one fluid-filled chamber. The segments can flex and move relative to one another and, as such, further enhance the ability of the sole structure to flex and move during wear. Further, because each segment is attached to at least one fluid-filled chamber, the fluid-filled chambers are permitted to flex and move relative to one another along with the segments. Use of the multiple fluid-filled chambers in conjunction with the plate or plate-like moderator segments provides the sole structure with a unique cushioning experience that may be tailored by adjusting the number, size, and/or shape of the individual fluid-filled chambers, the locations of the fluid-filled chambers on the segments, the size and/or length of the channel defining the segments, and/or the stiffness of one or more of the segments. The foregoing parameters may be tailored to a particular activity or intended use to allow the sole structure to optimally perform during wear.

With reference to FIG. 1, an article of footwear 10 includes a sole structure 12 and an upper 14. The sole structure 12 is attached to the upper 14 and includes a midsole 16, an outsole 18, and cushion assembly 20. The footwear 10 and, thus, the sole structure 12, may further include an anterior end 22 associated with a forward-most point of the footwear 10, and a posterior end 24 corresponding to a rearward-most point of the footwear 10. A longitudinal axis A10 of the footwear 10 extends along a length of the footwear 10 from the anterior end 22 to the posterior end 24 substantially parallel to a ground surface. As used herein, a longitudinal direction refers to the direction extending from the anterior end 22 to the posterior end 24, while a lateral direction refers to the direction transverse to the longitudinal direction and extending substantially perpendicular to the longitudinal direction.

The longitudinal axis A10 may extend along a center of the article of footwear 10 between the anterior end 22 and the posterior end 24. Accordingly, as shown in FIG. 2, the longitudinal axis A10 may define a medial side 26 of the article of footwear 10. The medial side 26 extends from the anterior end 22 to the posterior end 24.

With continued reference to FIG. 2, the article of footwear 10 may be divided into one or more regions. The regions may include a forefoot region 28, a mid-foot region 30, and a heel region 32. The forefoot region 28 may be subdivided into a toe portion 28T corresponding with phalanges and a ball portion 28B associated with metatarsal bones of a foot. The mid-foot region 30 may correspond with an arch area of the foot, and the heel region 32 may correspond with rear portions of the foot, including a calcaneus bone.

As shown in FIG. 3, the longitudinal axis A10 may likewise define a lateral side 34 of the article of footwear 10. As with the medial side 26, the lateral side 34 extends from the anterior end 22 to the posterior end 24.

As described above, the sole structure 12 includes the midsole 16, the outsole 18, and the cushion assembly 20 disposed between the midsole 16 and the outsole 18. The midsole 16 extends from the anterior end 22 to the posterior end 24 and between the medial side 26 and the lateral side 34. As shown in FIGS. 4 and 5, the midsole 16 includes a top surface 36 opposing the upper 14 and a bottom surface 38 disposed on an opposite side of the midsole 16 then the top surface 36. The top surface 36 includes a recess 40 defined by a flange 42 extending around a perimeter of the midsole 16. The recess 40 may cooperate with the upper 14 and an insole (not shown) received within the upper 14 to define a footbed of the article of footwear 10. The flange 42 extends substantially uninterrupted around a perimeter of the midsole 16 from the medial side 26 to the lateral side 34. While the flange 42 may extend substantially uninterrupted around a perimeter of the midsole 16, the flange 42 may include an opening 44 at the anterior end 22 to allow a portion of the outsole 18 to extend up and over a portion of the midsole 16 at the anterior end 22.

The bottom surface 38 may include a first portion 46 and a second portion 48 that are spaced apart from one another by a channel 50. The first portion 46 extends along a length of the midsole 16 from the anterior end 22 to the posterior end 24 and is disposed proximate to and extends along the medial side 26 of the midsole 16. The second portion 48 likewise extends from the anterior end 22 to the posterior end 24 but extends along the lateral side 34 of the midsole 16. The channel 50 separates the first portion 46 and the second portion 48 and extends generally along the longitudinal access A10 of the article of footwear 10 and, as such, extends from the forefoot region 28, through the mid-foot region 30, to the heel region 32. The channel 50 is elongate and has a generally arcuate shape. The channel 50 may be formed into a material of the midsole 16 such that the channel 50 terminates before reaching the top surface 36. Accordingly, the channel 50 may form a recess in the midsole 16 at the bottom surface 38. Alternatively, the channel 50 may be formed through a thickness of the midsole 16 and may extend from the top surface 36 to the bottom surface 38. Finally, the channel 50 includes a terminal end 52 located in the forefoot region 28. The terminal end 52 is located proximate to a junction of the first portion 46 and the second portion 48 located in the forefoot region 28 and proximate to the anterior end 22. The bottom surface 38 additionally includes a recess 54 located in the heel region 32 and proximate to the medial side 26 and the first portion 46. A projection 56 is located between the recess 54 and the posterior end 24 of the midsole 16 and extends in a direction away from the upper 14 to a greater extent than any other portion of the midsole 16 located in the heel region 32. The projection 56 may serve as a stabilizer adjacent to the cushion assembly 20 and may receive a portion of the outsole 18 to define a ground-engaging surface of the sole structure 12.

In one configuration, the midsole 16 is formed from a resilient polymeric material such as foam. Example resilient polymeric materials for the midsole 16 are provided below in the Materials section.

With continued reference to FIGS. 4 and 5, the outsole 18 is shown as extending from the anterior end 22 to the posterior end 24 and between the medial side 26 and the lateral side 34. The outsole 18 may include a first portion 58, a second portion 60, and a channel 62 extending between and separating the first portion 58 and the second portion 60. The first portion 58 is aligned with the first portion 46 of the midsole 16 and, as such, extends along the medial side 26. Likewise, the second portion 60 is aligned with the second portion 48 of the midsole 16 and extends along the lateral side 34. The channel 62 is aligned with the channel 50 of the midsole 16 and extends generally from the forefoot region 28 to the mid-foot region 30. As such, the channel 50 of the midsole 16 is exposed at a ground-engaging surface of the outsole 18 by the channel 62 of the outsole 18. As with the channel 50, the channel 62 is elongate and includes a substantially arcuate shape. The channel 62 includes a terminal end 64 located within the forefoot region 28 and proximate to the anterior end 22. As with the terminal end 52 of the channel 50, the terminal end 64 of the channel 62 is located proximate to a junction of the first portion 58 of the outsole 18 and the second portion 60 of the outsole 18. As with the junction of the first portion 46 of the midsole 16 and the second portion 48 of the midsole 16, the junction of the first portion 58 of the outsole 18 and the second portion 60 of the outsole 18 is located within the forefoot region 28 proximate to the anterior end 22.

The first portion 58 extends from the anterior end 22 from the junction of the first portion 58 and the second portion 60 to a distal end 66 located proximate to the mid-foot region 30. The first portion 58 includes a substantially arcuate shape from the anterior end 22 to the distal end 66. Specifically, the first portion 58 defines a substantially concave surface 68 opposing the midsole 16 and a substantially convex surface 70 disposed on an opposite side of the outsole 18 then the concave surface 68.

The second portion 60 includes a concave surface 72 opposing the midsole 16 and a convex surface 74 disposed on an opposite side of the second portion 60 then the concave surface 72. As shown in FIG. 5, the convex surface 74 extends from the forefoot region 28 proximate to the anterior end 22 to a substantially flat or planar region 76. The flat region 76 extends from the mid-foot region 30 to the heel region 32 and is located closer to the midsole 16 then the convex surface 74 of the second portion 60. The flat region 76 includes a substantially arcuate outer perimeter edge 78 that defines an overall shape of the flat region 76 within the heel region 32. The perimeter edge 78 defines a first projection 80, a second projection 82, a third projection 84, and a fourth projection 86. As shown in FIG. 5, the second projection 82 is located between the first projection 80 and the third projection 84 along the lateral side 34. The fourth projection 86 extends in a direction away from the first projection 80, the second projection 82, and the third projection 84 and in a direction from the lateral side 34 toward the medial side 26. As shown, each of the first projection 80, the second projection 82, the third projection 84, and the fourth projection 86 includes a substantially arcuate outer surface defined by the perimeter edge 78. As will be described in greater detail below, the shapes of the projections 80, 82, 84, 86 are positioned relative to and receive the cushion assembly 20 such that arcuate outer surfaces of the cushion assembly 20 are aligned with respective arcuate surfaces of the first projection 80, the second projection 82, the third projection 84, and the fourth projection 86.

The outsole 18 additionally includes a recess 88 defined by the perimeter edge 78 and located generally between the first projection 80 and the fourth projection 86 within the heel region 32. In one configuration, the midsole 16 may be visible at a ground-engaging surface of the sole structure 12 within the recess 88.

The outsole 18 may be formed from a material that provides the sole structure 12 with abrasion resistance and traction. For example, the outsole 18 may be formed from rubber. Regardless of the material forming the outsole 18, the outsole 18 includes a greater rigidity than the midsole 16. Providing the outsole 18 with a greater rigidity than the midsole 16 allows the outsole 18 to form a ground-engaging surface 90 of the sole structure 12 and, also, allows the outsole 18 to act as a moderator plate between the midsole 16 and the cushion assembly 20.

The outsole 18 forms a portion of the ground-engaging surface 90 in the forefoot region 28 and the mid-foot region 30. The outsole 18 additionally extends from the mid-foot region 30 in a direction toward the midsole 16 within the heel region 32. In so doing, the flat region 76 of the outsole 18 engages the midsole 16 within the heel region 32 and is spaced apart and separated from a ground surface during use of the article of footwear 10. Specifically, the flat region 76 is spaced apart and separated from a ground surface by the cushion assembly 20. The flat region 76 disposed between the midsole 16 and the cushion assembly 20 within the heel region 32 acts as a moderator plate between the midsole 16 and the cushion assembly 20. Because the outsole 18 includes a higher rigidity than that of the midsole 16, the flat region 76 of the outsole 18 serves to distribute point loads received from the cushion assembly 20 across the flat region 76 of the outsole 18, thereby preventing such point loads from being experienced by a wearer of the article of footwear 10.

As shown in FIGS. 4 and 5, the first portion 58, the second portion 60, and the flat region 76 are integrally formed with one another. As such, the outsole 18 extends continuously and uninterrupted from the anterior end 22 to the posterior end 24. Providing the outsole 18 with a unitary construction allows the outsole 18 to be easily attached to the midsole 16 in a single step. Attaching the outsole 18 to the midsole 16 in a single step reduces manufacturing complexity and, thus, reduces the overall cost and complexity associated with assembling the article of footwear 10.

The outsole 18 additionally includes a third portion 92 located in the heel region 32 and forming a portion of the ground-engaging surface 90. The third portion 92 is spaced apart and separated from the first portion 58 and the second portion 60 of the outsole 18 such that a gap extends between the third portion 92 and each of the first portion 58 and the second portion 60 proximate to the ground-engaging surface 90 in a direction substantially parallel to the longitudinal axis A10. As shown, the third portion 92 of the outsole 18 includes a plurality of circular depressions 96 that define respective concave surfaces 98 that oppose the cushion assembly 20 and receive respective fluid-filled chambers 100 of the cushion assembly 20.

As with the first portion 58, the second portion 60, and the flat region 76 of the outsole 18, the third portion 92 of the outsole 18 may be formed from a material that provides the sole structure 12 with abrasion resistance and traction. For example, the third portion 92 of the outsole 18 may be formed from rubber. The material forming the third portion 92 may be the same as or different from the material forming the first portion 58, the second portion 60, and the flat region 76 of the outsole 18. For example, the third portion 92 may be formed from a translucent or transparent rubber material to allow the cushion assembly 20 to be visible at the ground-engaging surface 90 through the third portion 92 of the outsole 18. Alternatively, the third portion 92 may be formed from an opaque material that does not allow the cushion assembly 20 to be visible at the ground-engaging surface 90.

With continued reference to FIGS. 4 and 5, the fluid-filled chambers 100 of the cushion assembly 20 are shown as being discreet elements such that each fluid-filled chamber 100 is spaced apart and separated from an adjacent fluid-filled chamber 100. Accordingly, each of the fluid-filled chambers 100 may be visible around an entire perimeter of the fluid-filled chamber 100 or, alternatively, at least eighty (80) percent of the perimeter of each fluid-filled chamber 100 is visible when installed in the sole structure 12. The fluid-filled chambers 100 will be described and shown hereinafter as being separate air cushions that are free to react independently when subjected to an applied load.

With reference to FIG. 6, each of the fluid-filled chambers 100 includes an opposing pair of barrier layers 102, 104. The barrier layers 102, 104 are joined together at a peripheral seam 106, whereby the peripheral seam 106 is formed by joining a material of the barrier layer 102 with a material of the barrier layer 104. In one configuration, the material of the barrier layer 102 and the material of the barrier layer 104 are melded together by applying heat and/or pressure to the material forming the barrier layers 102, 104 at a location of the peripheral seam 106. Once joined, the barrier layers 102, 104 and the peripheral seam 106 cooperate to define an interior void 108 that may be at ambient pressure or, alternatively, may receive a pressurized fluid.

With continued reference to FIG. 6, the fluid-filled chambers 100 are shown as being circular, columnar structures. Further, the fluid-filled chambers 100 include an interior void 108 that is generally open and free from bonds within the interior void 108.

With reference to FIG. 7, other fluid-filled chambers 100 of the cushion assembly 20 may include a centrally located weld 110 that bonds portions of the opposing barrier layers 102, 104 together. Specifically, as with the peripheral seam 106, a material of the barrier layers 102, 104 may be melded together by applying heat and/or pressure to one or both of the barrier layers 102, 104 to cause a material of the barrier layers 102, 104 to flow and combine with one another. Once the material of the barrier layers 102, 104 flows and combines together and is cooled, the material of the barrier layers 102, 104 is joined at the weld 110 in a similar fashion as the peripheral seam 106. Providing the fluid-filled chamber 100 with a weld 110 located substantially at a central location of the fluid-filled chamber 100 provides the fluid-filled chamber 100 with additional structure relative to a fluid-filled chamber 100 that is free from a centrally located weld 110. Accordingly, a fluid-filled chamber 100 having a centrally located weld 110 will resist sheer and/or bending forces to a greater extent than a fluid-filled chamber 100 that is free from a weld 110.

As will be described in greater detail below, providing the sole structure 12 with fluid-filled chambers 100 that are free from welds and fluid-filled chambers 100 that include welds 110 provides the sole structure 12 with customizable and variable cushioning properties at discreet locations of the sole structure 12. Further, adjusting a size of the fluid-filled chambers 100 with or without welds 110 at specific locations of the sole structure 12 further provides the ability to customize and tailor cushioning at discreet locations of the sole structure 12. As such, while the fluid-filled chambers 100 are individual elements having individual characteristics such as size and/or construction (i.e., whether the fluid-filled chamber 100 includes a weld 110) adjacent fluid-filled chambers 100 may cooperate with one another to provide the footwear 10 with a desired cushion response at the sole structure 12. Hereinafter, a fluid-filled chamber 100 having a centrally located weld 110 will be referred to as a “pinned” fluid-filled chamber while a fluid-filled chamber 100 that is free from a centrally located weld 110 will be referred to as a fluid-filled chamber.

With particular reference to FIG. 8, the cushion assembly 20 is shown as including four (4) fluid-filled chambers 100. Each of the fluid-filled chambers 100 includes an interior void 108 receiving a pressurized fluid. Accordingly, each of the fluid-filled chambers 100 is either a fluid-filled chamber or a pinned fluid-filled chamber. In the configuration shown in FIG. 8, the forward most fluid-filled chamber 100 is disposed proximate to a junction of the mid-foot region 30 and the heel region 32 and is disposed proximate to the lateral side 34 of the sole structure 12. A second fluid-filled chamber 100 is disposed adjacent to and rearward of the first fluid-filled chamber 100 and is located in the heel region 32 proximate to the lateral side 34. A third pinned fluid-filled chamber 100 is located rearward of the second fluid-filled chamber 100 and is likewise located in the heel region 32 proximate to the lateral side 34. The third pinned fluid-filled chamber 100 is located proximate to the posterior end 24 of the sole structure 12 and is disposed further from the anterior end 22 of the sole structure 12 than any other fluid-filled chamber 100 or pinned fluid-filled chamber 100. Finally, the cushion assembly 20 includes a fourth pinned fluid-filled chamber 100 located in the heel region 32 and disposed proximate to the medial side 26 of the sole structure 12.

As shown in FIG. 8, the forward most fluid-filled chamber 100 includes a smaller size than the adjacent second fluid-filled chamber 100. The rearward most third pinned fluid-filled chamber 100 located at the posterior end 24 of the sole structure 12 includes a larger size than the first fluid-filled chamber 100 but is similarly sized to the second fluid-filled chamber 100 disposed between the forward most fluid-filled chamber 100 and the rearward most pinned fluid-filled chamber 100. Finally, the fourth pinned fluid-filled chamber 100 located in the heel region 32 proximate to the medial side 26 is larger than each of the other fluid-filled chambers 100 and pinned fluid-filled chamber 100.

As described, the cushion assembly 20 includes three different sizes of fluid-filled chambers 100 and pinned fluid-filled chambers 100. In the particular configuration shown in FIG. 8, the fluid-filled chambers 100 and the pinned fluid-filled chamber 100 aligned along the lateral side 34 of the sole structure 12 are positioned such that the forward most fluid-filled chamber 100 is smaller than the rearward fluid-filled chamber 100 and the rearward pinned fluid-filled chamber 100. As such, a greater degree of cushioning is provided to a wearer at a location closer to the posterior end 24 within the heel region 32 as compared to a location within the heel region 32 that is located closer to the anterior end 22 of the sole structure 12. Finally, the fourth pinned fluid-filled chamber 100 located proximate to the medial side 26 within the heel region 32 is larger than any of the other fluid-filled chambers 100 or pinned fluid-filled chamber 100 and cooperates with the projection 56 of the midsole 16 to provide the medial side 26 of the midsole 16 with cushioning at the heel region 32.

The small, medium, and large fluid-filled chambers 100 may include the same pressure or, alternatively, may include different pressures to further tailor the cushioning response of the sole structure 12. For example, the small, forward most fluid-filled chamber 100 may include an internal pressure of five (5) pounds per square inch (psi) while the medium and large fluid-filled chambers 100 and medium and large pinned fluid-filled chambers 100 include an internal pressure of 15 psi. Use of the terms “small,” “medium,” and “large” to describe the fluid-filled chambers 100 and the pinned, fluid-filled chambers 100 are relative terms meaning that the “small” chambers 100 are smaller than the “medium” and “large” chambers 100 and the “medium” chambers 100 are larger than the “small” chambers 100 but smaller than the “large” chambers 100.

The individual fluid-filled chambers 100 are received by respective circular depressions 96 of the third portion 92 of the outsole 18 at one end and are attached to the flat region 76 of the outsole 18 at a second end. Specifically, the fluid-filled chambers 100 are received within respective circular depressions 96 of the outsole 18 such that the individual fluid-filled chambers 100 extend between separate portions of the outsole 18 (i.e., between the flat region 76 and the third portion 92). The fluid-filled chambers 100 may have a size and shape that is matingly received by the depressions 96 of the third portion 92 of the outsole 18. Specifically, the fluid-filled chambers 100 may include a bottom surface having the same curvature, size, and depth as the depressions 96 receiving the fluid-filled chambers 100. Accordingly, the fluid-filled chambers 100 provide discreet, columnar structures that extend from a first end attached to the third portion 92 of the outsole 18 to a second end attached to the flat region 76 of the second portion 60 of the outsole 18. As shown in FIG. 8, the fluid-filled chambers 100 are spaced apart and separated from one another such that a gap exists between adjacent fluid-filled chambers 100. The gaps disposed between adjacent fluid-filled chambers 100 allow the fluid-filled chambers 100 to splay and collapse under an applied load during use of the article of footwear 10 without contacting an adjacent fluid-filled chamber 100. Note that while the fluid-filled chambers 100 are described and shown as being disposed between opposing, discrete portions 76, 92 of the outsole 18, the outsole 18 is not shown in FIG. 8 in an effort to clearly show the relative positions of the fluid-filled chambers 100 and the positions of the fluid-filled chambers 100 relative to the midsole 16.

In operation, during a gait cycle, a force may initially be applied to the sole structure 12 during a heel strike. The force may initially be applied to the sole structure 12 at the projection 56 of the midsole 16 and the rearward most pinned fluid-filled chamber 100. As the heel strike transitions to a forward rolling motion, the force may then be applied to the fluid-filled chamber 100 located proximate to the lateral side 34 and to the pinned fluid-filled chamber 100 located proximate to the medial side 26 before finally being realized by the forward most fluid-filled chamber 100 as the gait cycle continues.

The channels 50, 62 allow the first portion 46 and the second portion 48 of the midsole 16 to move and flex relative to one another. In so doing, the channels 50, 62 likewise allow the first portion 58 and the second portion 60 of the outsole 18 to independently move relative to one another. Because a portion of each fluid-filled chamber 100 is attached to the outsole 18 at the flat region 76, allowing the sole structure 12 to flex and move under an applied load allows the individual fluid-filled chambers 100 to react and deform in a controlled manner, thereby improving the cushioning characteristics of the sole structure 12.

With particular reference to FIGS. 9 through 16, an article of footwear 10a is provided and includes a sole structure 12a and an upper 14 attached to the sole structure 12a. In view of the substantial similarity in structure and function of the components associated with the article of footwear 10 with respect to the article of footwear 10a, like reference numerals are used hereinafter and in the drawings to identify like components while like reference numerals containing letter extensions are used to identify those components that have been modified.

As shown in FIG. 9, the cushion assembly 20 is shown as being disposed between the midsole 16a and the outsole 18a. While the cushion assembly 20 remains unchanged relative to the cushion assembly 20 associated with the sole structure 12, the cushion assembly 20 is attached directly to the midsole 16a and to a portion of the outsole 18a, as will be described in greater detail below. The midsole 16a includes substantially the same shape and configuration as the midsole 16 but includes a first portion 112 and a second portion 114. The first portion 112 and the second portion 114 may be formed from a foamed material as described above with respect to the midsole 16. However, while the first portion 112 may include similar properties as the midsole 16, the second portion 114 of the midsole 16a is stiffer than the first portion 112 of the midsole 16a and is stiffer than the midsole 16 associated with the sole structure 12. The second portion 114 may be formed from a similar material as the first portion 112 but may include a greater density and/or an outer skin that provides the second portion 114 with a higher rigidity relative to the first portion 112 and relative to the midsole 16 associated with the sole structure 12. As will be described, providing the second portion 114 of the midsole 16a with a greater rigidity than the first portion 112 allows the second portion 114 of the midsole 16a to act as a moderator plate between the cushion assembly 20 and the midsole 16a.

The first portion 112 of the midsole 16a extends substantially along a length of the midsole 16a between the anterior end 22 and the posterior end 24. The first portion 112 likewise extends from the medial side 26 to the lateral side 34 along the length of the midsole 16a from the anterior end 22 to the posterior end 24. The second portion 114 extends from the posterior end 24 to the mid-foot region 30 and extends between the medial side 26 and the lateral side 34 in this portion of the heel region 32. As shown in FIGS. 10 and 11, the second portion 114 essentially extends along a length of the midsole 16a to allow the second portion 114 to accommodate the cushion assembly 20.

With reference to FIGS. 12 and 13, the second portion 114 defines a region 116 that receives the fluid-filled chambers 100. Because the second portion 114 is formed from a relatively stiff or rigid foam and/or includes a relatively stiff outer skin, the second portion 114 interfaces with and is attached to the fluid-filled chambers 100 in a similar fashion as the fluid-filled chambers 100 are attached to the flat region 76 of the outsole 18 of the sole structure 12 described above. In short, the relatively rigid nature of the second portion 114 allows the second portion 114 to act as a moderator in place of the flat region 76 of the outsole 18, which allows the region 116 of the second portion 114 to have a contoured shape that directly receives the individual fluid-filled chambers 100.

The outsole 18a extends along a length of the sole structure 12a from the anterior end 22 to the posterior end 24 and from the medial side 26 to the lateral side 34. As with the outsole 18 associated with the sole structure 12, the outsole 18a includes a first portion 58a and a second portion 60a. The outsole 18a additionally includes a channel 62a extending between and separating the first portion 58a of the outsole 18a and the second portion 60a of the outsole 18a. The channel 62a extends between the terminal end 64 and a second terminal end 118 located in the heel region 32. As with the outsole 18 associated with the sole structure 12, the terminal end 64 of the channel 62a is located proximate to the anterior end 22 near a junction of the first portion 58a of the outsole 18a and the second portion 60a of the outsole 18a. The second terminal end 118 of the channel 62a is located proximate to the posterior end 24 and likewise is disposed proximate to a junction of the first portion 58a of the outsole 18a and the second portion 60a of the outsole 18a within the heel region 32. The outsole 18a may be formed from a similar material as the outsole 18 associated with the sole structure 12 and may extend continuously and uninterrupted from the anterior end 22 to the posterior end 24. The outsole 18a may be formed from the same or similar materials as the outsole 18 and may be opaque, translucent, or transparent. Forming the outsole 18a from a translucent or transparent material allows the cushion assembly 20 to be viewable at the ground-engaging surface 90a of the sole structure 12a.

Once assembled, the individual, columnar fluid-filled chambers 100 of the cushion assembly 20 extend from a first end attached to the outsole 18a within the heel region 32 to a second end attached to the second portion 114 of the midsole 16a. Because the second portion 114 of the midsole 16a is formed from a relatively rigid material, the second portion 114 of the midsole 16a may act as a moderator plate between the individual fluid-filled chambers 100 of the cushion assembly 20 and the first portion 112 of the midsole 16a. Accordingly, any point loads exerted on the midsole 16a by the individual fluid-filled chambers 100 of the cushion assembly 20 will be dissipated along the second portion 114 of the midsole 16a and will not be felt as a point load by a wearer of the article of footwear 10a. Because the cushion assembly 20 is described and shown as being identical to the cushion assembly 20 associated with the sole structure 12, the cushion assembly 20 of the sole structure 12a includes a pair of fluid-filled chambers 100 and a pair of pinned fluid-filled chambers 100. The cushion assembly 20 also includes a forward most, small fluid-filled chamber 100, a medium fluid-filled chamber 100 disposed rearward of the first fluid-filled chamber 100, and a third pinned, medium, fluid-filled chamber 100 aligned along the lateral side 34 of the midsole 16a, as shown in FIG. 14. As with the sole structure 12, the cushion assembly 20 additionally includes a large, pinned fluid-filled chamber 100 disposed within the heel region 32 and proximate to the medial side 26 of the midsole 16a. As with the cushion assembly 20 associated with the sole structure 12, the terms “small” “medium” and “large” are used to denote the relative sizes amongst the various fluid-filled chambers 100 of the cushion assembly 20. Specifically, a small fluid-filled chamber 100 is smaller than both a medium fluid-filled chamber 100 and a large fluid-filled chamber 100 while a medium fluid-filled chamber 100 is larger than a small fluid-filled chamber 100 but smaller than a large fluid-filled chamber 100.

While the cushion assembly 20 associated with the sole structure 12a is described and shown in FIG. 14 as being the same as the cushion assembly 20 associated with the sole structure 12, the cushion assembly 20 could be modified relative to the cushion assembly 20. For example, one or more of the size and shape of the fluid-filled chambers 100 may be modified in the sole structure 12a relative to the sole structure 12 in an effort to change the cushioning characteristics of the sole structure 12a. For example, and with reference to FIG. 15, a cushion assembly 20a is provided in conjunction with the midsole 16a. The cushion assembly 20a is identical to the cushion assembly 20 described with respect to the sole structure 12 but includes a medium, pinned fluid-filled chamber 100 located within the heel region 32 and proximate to the medial side 26. The medium, pinned fluid-filled chamber 100 replaces the large, pinned fluid-filled chamber 100 disposed within the heel region 32 and proximate to the medial side 26 of the cushion assembly 20.

With particular reference to FIGS. 16-20, an article of footwear 10b is provided and includes a sole structure 12b and an upper 14 attached to the sole structure 12b. In view of the substantial similarity in structure and function of the components associated with the article of footwear 10b, like reference numerals are used hereinafter and in the drawings to identify like components while like reference numerals containing letter extensions are used to identify those components that have been modified.

The sole structure 12b is identical to the sole structure 12 with the exception of the outsole 18b, as shown in FIGS. 17 and 18. Specifically, the outsole 18b includes the same size and shape as the outsole 18 associated with the sole structure 12 with the exception of the flat region 76. In the sole structure 12b, the flat region 76 is formed by a plate 120. As shown in FIGS. 19 and 20, the plate 120 includes the same size and shape as the flat region 76 of the second portion 60 of the outsole 18. However, the plate 120 is formed from a different material than the outsole 18b and, as such, provides the sole structure 12b with more rigidity in an area between the cushion assembly 20 and the midsole 16. For example, the plate 120 may comprise a material providing relatively high strength and stiffness, such as a polymeric material and/or a composite material. Materials used to construct the plate 120 as well as processes for constructing the plate 120 are provided below in the Materials section.

As shown in FIGS. 19 and 20, the plate 120 may be attached to the second portion 60b at a junction 122. Specifically, the plate 120 may be attached to the second portion 60b of the outsole 18b by a suitable adhesive. Accordingly, the plate 120 may flex and move as the second portion 60b of the outsole 18b flexes and moves relative to and with the first portion 58 of the outsole 18b.

As with the sole structure 12, the sole structure 12b includes the cushion assembly 20 disposed between the midsole 16 and the third portion 92 of the outsole 18b. Specifically, the fluid-filled chambers 100 of the cushion assembly 20 extend between a first end attached to the third portion 92 of the outsole 18b and a second end attached to the plate 120. As with the sole structure 12, the second end of each fluid-filled chamber 100 may be attached to the plate 120 by a suitable adhesive. The number, size, and orientation of each fluid-filled chamber 100 is identical to the fluid-filled chambers 100 of the cushion assembly 20 associated with the sole structure 12. Accordingly, the performance of the cushion assembly 20 in the sole structure 12b is similar to the performance of the cushion assembly 20 disposed within the sole structure 12. However, because the second end of each fluid-filled chamber 100 of the cushion assembly 20 is attached to a rigid plate 120, the forces exerted on the midsole 16 by the individual fluid-filled chambers 100 will be attenuated to a greater extent as compared to the sole structure 12. Specifically, while the sole structure 12 includes a portion of the rubber outsole 18 extending between the fluid-filled chambers 100 and the midsole 16, the material of the outsole 18 will flex and move to a greater degree than the material of the plate 120. Accordingly, while the cushioning characteristics of the sole structure 12b will be similar to that of the sole structure 12, providing the sole structure 12b with a rigid plate 120 in place of the outsole 18 disposed between the midsole 16 and the third portion 92 of the outsole 18b will provide the sole structure 12b with a greater degree of stability and stiffness as compared to the sole structure 12.

With particular reference to FIGS. 21-27, various configurations of the cushion assembly 20 are shown. Specifically, cushion assemblies 20c-20i are shown in conjunction with the midsole 16 from the sole structure 12. While the various cushion assemblies 20c-20i are shown in conjunction with the midsole 16 of the sole structure 12, the cushion assemblies 20c-20i could alternatively be used in conjunction with the midsole 16a of the sole structure 12a or with the midsole 16b or the sole structure 12b. As with the description of the cushion assembly 20 associated with the sole structure 12, the cushion assemblies 20c-20i are shown in conjunction with the midsole 16 of the sole structure 12 with the outsole 18 removed to show the relative position of the cushion assemblies 20c-20i and the midsole 16. When assembled, the cushion assemblies 20c-20i would be disposed between opposing portions of the outsole 18 as described above with respect to the sole structure 12.

With reference to FIG. 21, the cushion assembly 20c is shown as including two fluid-filled chambers 100 and two pinned fluid-filled chambers 100. The cushion assembly 20c is identical to the cushion assembly 20 associated with the sole structure 12 with the exception of the sizing of the rear most pinned, fluid-filled chamber 100. Specifically, the rear most pinned fluid-filled chamber 100 is a large, pinned fluid-filled chamber 100 and includes the same size as the large, pinned fluid-filled chamber 100 disposed along the medial side 26 of the midsole 16 shown in FIG. 21. Accordingly, the cushion assembly 20c shown in FIG. 21 includes a small forward most fluid-filled chamber 100 disposed along the lateral side 34 along with a medium, fluid-filled chamber 100 disposed between the forward most fluid-filled chamber 100 and the posterior end 24 of the midsole 16. While the view shown in FIG. 21 omits the outsole 18, when constructed, the columnar fluid-filled chambers 100 of the cushion assembly 20c would extend between the flat region 76 of the outsole 18 and the third portion 92 of the outsole 18 in a similar fashion as described above with respect to the sole structure 12. The view shown in FIG. 21 omits the outsole 18 in an effort to show the relationship between the various fluid-filled chambers 100 of the cushion assembly 20c and the midsole 16.

With particular reference to FIG. 22, a midsole 16d is shown as including a cushion assembly 20d having three pinned, fluid-filled chambers 100. The pinned, fluid-filled chambers 100 are shown as being medium-sized pinned, fluid-filled chambers 100. However, the pinned, fluid-filled chambers 100 could all be small, medium, or large, pinned, fluid-filled chambers 100. As with the cushion assembly 20c, the outsole 18 of the sole structure 12 is removed for clarity in an effort to show the relationship amongst the various fluid-filled chambers 100 of the cushion assembly 20d and the midsole 16d. Further, the midsole 16d is modified relative to the midsole 16 shown in the sole structure 12, as the cushion assembly 20d no longer includes a fluid-filled chamber 100 disposed within the heel region 32 at the medial side 26. Rather, as shown in FIG. 22, the cushion assembly 20d includes three pinned, fluid-filled chambers 100 aligned with one another and disposed along the lateral side 34.

With reference to FIG. 23, a midsole 16e is shown in conjunction with a cushion assembly 20e. The cushion assembly 20e is identical to the cushion assembly 20d with the exception of the forward-most fluid-filled chamber 100 being a fluid-filled chamber 100. Specifically, the forward-most fluid-filled chamber 100 is a fluid-filled chamber 100 that is free from a centrally located weld 110. The cushion assembly 20e is otherwise identical to the cushion assembly 20d and may likewise include fluid-filled chambers 100 having any size (i.e., all small, all medium, or all large fluid-filled chambers) aligned along the lateral side 34 of the midsole 16e.

With reference to FIG. 24, a cushion assembly 20f is provided. The cushion assembly 20f includes four fluid-filled chambers 100 having a similar configuration as the cushion assembly 20 of the sole structure 12. However, each of the fluid-filled chambers 100 of the cushion assembly 120f includes a pinned, fluid-filled chamber 100. Further, each of the pinned, fluid-filled chambers 100 includes a medium size. As described above, each of the pinned, fluid-filled chambers 100 could include a small size, a medium size, or a large size. As with the cushion assembly 20 associated with the sole structure 12, the cushion assembly 20f includes three fluid-filled chambers 100 aligned along the lateral side 34 of the midsole 16 and a single fluid-filled chamber 100 disposed along the medial side 26 of the midsole 16. As shown, each of the fluid-filled chambers 100 is a pinned, medium-sized fluid-filled chamber 100.

With particular reference to FIG. 25, a cushion assembly 20g is shown in conjunction with a midsole 16 g. The cushion assembly 20g includes two fluid-filled chambers 100 disposed in the heel region 32 of the midsole 16g. The fluid-filled chambers 100 are pinned, fluid-filled chambers 100 that are aligned with one another in the heel region 32 along the lateral side 34. Each of the pinned, fluid-filled chambers 100 are a large size, pinned, fluid-filled chamber 100. While the pinned, fluid-filled chambers 100 are shown and described as being large, pinned, fluid-filled chambers 100, the pinned, fluid-filled chambers 100 of the cushion assembly 20g could be all small or all medium-size, pinned, fluid-filled chambers 100.

With particular reference to FIG. 26, a cushion assembly 20h is provided. The cushion assembly 20h includes two fluid-filled chambers 100 that are disposed in the heel region 32 and are laterally aligned with one another across a width of a midsole 16h. Specifically, the fluid-filled chambers 100 are large-size, pinned, fluid-filled chambers 100 that are aligned with one another in a direction extending across a width of the sole structure 12 from the medial side 26 to the lateral side 34. While the fluid-filled chambers 100 are shown and described as being large-size, pinned, fluid-filled chambers 100, the pinned, fluid-filled chambers 100 could be small or medium-size.

With particular reference to FIG. 27, a cushion assembly 20i is shown as including four fluid-filled chambers 100 disposed in the heel region 32 and three fluid-filled chambers 100 disposed in the forefoot region 28 of a midsole 16i. As shown, the fluid-filled chambers 100 are large-size but could equally be small or medium-size, as described above with respect to the cushion assemblies 20c-20h. As shown, two pinned, fluid-filled chambers 100 are aligned and extend along the lateral side 34 within the forefoot region 28 while a single fluid-filled chamber 100 extends along the medial side 26 within the forefoot region 28. The single fluid-filled chamber 100 is aligned with the pair of pinned, fluid-filled chambers 100 disposed along the lateral side 34 such that a mid-point of the fluid-filled chamber 100 located at the medial side 26 is disposed approximately between the pinned, fluid-filled chambers 100 disposed at the lateral side 34.

The cushion assembly 20i additionally includes a pair of fluid-filled chambers 100 disposed within the heel region 32 and extending along the lateral side 34. A pinned, fluid-filled chamber 100 is also disposed along the lateral side 34 and is aligned with the fluid-filled chambers 100 such that three chambers 100 are aligned with one another and extend along the lateral side 34 of the midsole 16i within the heel region 32. The pinned, fluid-filled chamber 100 is disposed rearward of the fluid-filled chambers 100 at the lateral side 34 within the heel region 32. Finally, a pinned, fluid-filled chamber 100 is disposed at the medial side 26 of the midsole 16i and is aligned with one of the fluid-filled chambers 100 disposed at the lateral side 34 within the heel region 32. Specifically, the pinned, fluid-filled chamber 100 disposed at the medial side 26 may be aligned with the fluid-filled chamber 100 that is disposed between the fluid-filled chamber 100 and the pinned, fluid-filled chamber 100 at the lateral side 34.

It should be noted that for the configurations shown in FIGS. 21-27, a material similar to that of the outsole 18 would extend between each fluid-filled chamber 100 and the respective midsole 16, 16d, 16e, 16g, 16h, 16i to act as a moderator plate in a similar fashion as the outsole 18 described above with respect to the sole structure 12. Further, an outsole similar to the third portion 92 of the outsole 18 would extend over each fluid-filled chamber 100 and provide a ground-engaging surface in a similar fashion as the third portion 92 of the outsole 18 described above with respect to the sole structure 12. Accordingly, each fluid-filled chamber 100 extends between portions of the outsole 18 in a similar fashion as the sole structure 12.

With particular reference to FIG. 28, a schematic view of an article of footwear 124 is provided. In FIG. 28, the article of footwear 124 is shown as including a cushion assembly 20j having the various fluid-filled chambers 100 aligned such that the peripheral seam 106 joining the barrier layers 102, 104 is disposed proximate to a midsole 16j.

With reference to FIG. 29, an article of footwear 126 is provided and includes a cushion assembly 20k including a series of fluid-filled chambers 100, whereby the peripheral seam 106 joining the barrier layers 102, 104 is disposed proximate to the outsole 18. Accordingly, the fluid-filled chambers 100 shown in FIG. 29 are rotated 180 degrees (180°) relative to the fluid-filled chambers 100 shown in FIG. 28. Finally, one of the fluid-filled chambers 100 shown in FIG. 29 is shown as including a tensile element 128 disposed within the interior void 108 of the fluid-filled chamber 100. While a single fluid-filled chamber 100 is shown as including a tensile element 128, any of the fluid-filled chambers 100 described above with respect to FIGS. 1-28 could include a tensile element 128. The various sole structures 12, 12a, 12b described above could have fluid-filled chambers 100 with each peripheral seam 106 disposed proximate to the various midsoles 16-16i, could have fluid-filled chambers 100 with each peripheral seam 106 disposed proximate to the various outsoles 18-18b, or could have a configuration where some of the fluid-filled chambers 100 include peripheral seams 106 disposed proximate to the various midsoles 16-16i and some with peripheral seams 106 disposed proximate to the various outsoles 18-18b. Finally, any of the fluid-filled chambers 100 described above with respect to the various sole structures 12, 12a, 12b could include a tensile element 128 such that all fluid-filled chambers 100 in the same sole structure 12, 12a, 12b include a tensile element 128 or only select fluid-filled chambers 100 include a tensile element 128.

Various sole structures 12, 12a, 12b are described in conjunction with various cushion assemblies 20, 20a-20i to provide an article of footwear 10, 10a, 10b with desired cushioning characteristics. Because the cushion assemblies 20, 20a-20i include discreet fluid-filled chambers 100 having varying sizes and constructions, use of the fluid-filled chambers 100 in the sole structures 12, 12a, 12b provides the sole structures 12, 12a, 12b with customizable and localized cushioning properties and, further, allows the individual fluid-filled chambers 100 to work in conjunction with one another to provide a desired cushioning effect to the sole structures 12, 12a, 12b and, thus, the articles of footwear 10, 10a, 10b in which these sole structures 12, 12a, 12b are installed.

Materials

Example resilient polymeric materials for the midsole 16 may include those based on foaming or molding one or more polymers, such as one or more elastomers (e.g., thermoplastic elastomers (TPE)). The one or more polymers may include aliphatic polymers, aromatic polymers, or mixtures of both; and may include homopolymers, copolymers (including terpolymers), or mixtures of both.

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

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

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

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

In further aspects, the one or more polymers may include one or more polyamide copolymers (e.g., polyamide-polyether copolymers) and/or one or more polyurethanes (e.g., cross-linked polyurethanes and/or thermoplastic polyurethanes). Examples of suitable polyurethanes include those discussed below with respect to the cushion assembly 20. Alternatively, the one or more polymers may include one or more natural and/or synthetic rubbers, such as butadiene and isoprene.

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

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

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

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

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

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

As used herein, the term “barrier layer” (e.g., barrier layers 102, 104) encompasses both monolayer and multilayer films. In some embodiments, one or both of the barrier layers 102, 104 are each produced (e.g., thermoformed or blow molded) from a monolayer film (a single layer). In other embodiments, one or both of the barrier layers 102, 104 are each produced (e.g., thermoformed or blow molded) from a multilayer film (multiple sublayers). In either aspect, each layer or sublayer can have a film thickness ranging from about 0.2 micrometers to about 1 millimeter. In further embodiments, the film thickness for each layer or sublayer can range from about 0.5 micrometers to about 500 micrometers. In yet further embodiments, the film thickness for each layer or sublayer can range from about 1 micrometer to about 100 micrometers.

One or both of the barrier layers 102, 104 can independently be transparent, translucent, and/or opaque. As used herein, the term “transparent” for a barrier layer and/or a fluid-filled chamber means that light passes through the barrier layer in substantially straight lines and a viewer can see through the barrier layer. In comparison, for an opaque barrier layer, light does not pass through the barrier layer and one cannot see clearly through the barrier layer at all. A translucent barrier layer falls between a transparent barrier layer and an opaque barrier layer, in that light passes through a translucent layer but some of the light is scattered so that a viewer cannot see clearly through the layer.

The barrier layers 102, 104 can each be produced from an elastomeric material that includes one or more thermoplastic polymers and/or one or more cross-linkable polymers. In an aspect, the elastomeric material 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′-dimethyldipheny 1-4,4′-diisocyanate (DDDI), 4,4 ′-dibenzyl diisocyanate (DBDI), 4-chloro-1,3-phenylene diisocyanate, and combinations thereof. In some embodiments, the copolymer chains are substantially free of aromatic groups.

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

In another aspect, 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 barrier layers 102, 104 may include two or more sublayers (multilayer film) such as shown in Mitchell et al., U.S. Pat. No. 5,713,141 and Mitchell et al., U.S. Pat. No. 5,952,065, the disclosures of which are incorporated by reference in their entirety. In embodiments where the barrier layers 102, 104 include two or more sublayers, examples of suitable multilayer films include microlayer films, such as those disclosed in Bonk et al., U.S. Pat. No. 6,582,786, which is incorporated by reference in its entirety. In further embodiments, barrier layers 102, 104 may each independently include alternating sublayers of one or more TPU copolymer materials and one or more EVOH copolymer materials, where the total number of sublayers in each of the barrier layers 102, 104 includes at least four (4) sublayers, at least ten (10) sublayers, at least twenty (20) sublayers, at least forty (40) sublayers, and/or at least sixty (60) sublayers.

The fluid-filled chambers 100 can be produced from the barrier layers 102, 104 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, the barrier layers 102, 104 can be produced by co-extrusion followed by vacuum thermoforming to produce an inflatable chamber, which can optionally include one or more valves (e.g., one way valves) that allows the chambers 100 to be filled with the fluid (e.g., gas).

The chambers 100 can be provided in a fluid-filled (e.g., as provided in footwear 10) or in an unfilled state. The chambers 100 can be filled to include any suitable fluid, such as a gas or liquid. In an aspect, the gas can include air, nitrogen (N2), or any other suitable gas. In other aspects, the chambers 100 can alternatively include other media, such as pellets, beads, ground recycled material, and the like (e.g., foamed beads and/or rubber beads). The fluid provided to the chambers 100 can result in the chambers 100 being pressurized. Alternatively, the fluid provided to the chambers 100 can be at atmospheric pressure such that the chambers 100 are not pressurized but, rather, simply contains a volume of fluid at atmospheric pressure.

The fluid-filled chambers 100 desirably have a low gas transmission rate to preserve their retained gas pressure. In some embodiments, the fluid-filled chambers 100 have a gas transmission rate for nitrogen gas that is at least about ten (10) times lower than a nitrogen gas transmission rate for a butyl rubber layer of substantially the same dimensions. In an aspect, fluid-filled chambers 100 have a nitrogen gas transmission rate of 15 cubic-centimeter/square-meter atmosphere day (cm3/m2·atm·day) or less for an average film thickness of 500 micrometers (based on thicknesses of the barrier layers 102, 104). In further aspects, the transmission rate is 10 cm3/m2·atm·day or less, 5 cm3/m2·atm·day or less, or 1 cm3/m2·atm·day or less.

The upper 14 may be formed from one or more materials that are stitched or adhesively bonded together to define an interior void. Suitable materials of the upper 14 may include, but are not limited to, textiles, foam, leather, and synthetic leather. The example upper 14 may be formed from a combination of one or more substantially inelastic or non-stretchable materials and one or more substantially elastic or stretchable materials disposed in different regions of the upper 14 to facilitate movement of the article of footwear 10 between the tightened state and the loosened state. The one or more elastic materials may include any combination of one or more elastic fabrics such as, without limitation, spandex, elastane, rubber or neoprene. The one or more inelastic materials may include any combination of one or more of thermoplastic polyurethanes, nylon, leather, vinyl, or another material/fabric that does not impart properties of elasticity.

In some examples, the plate 120 is a composite material manufactured using fiber sheets or textiles, including pre-impregnated (i.e., “prepreg”) fiber sheets or textiles. Alternatively or additionally, the plate 120 may be manufactured by strands formed from multiple filaments of one or more types of fiber (e.g., fiber tows) by affixing the fiber tows to a substrate or to each other to produce a plate having the strands of fibers arranged predominately at predetermined angles or in predetermined positions. When using strands of fibers, the types of fibers included in the strand can include synthetic polymer fibers which can be melted and re-solidified to consolidate the other fibers present in the strand and, optionally, other components such as stitching thread or a substrate or both. Alternatively or additionally, the fibers of the strand and, optionally the other components such as stitching thread or a substrate or both, can be consolidated by applying a resin after affixing the strands of fibers to the substrate and/or to each other.

In some configurations, the plate 120 may be formed from one or more layers of tows of fibers and/or layers of fibers including at least one of carbon fibers, boron fibers, glass fibers, and polymeric fibers. In a particular configuration, the fibers include carbon fibers, or glass fibers, or a combination of both carbon fibers and glass fibers. The tows of fibers may be affixed to a substrate. The tows of fibers may be affixed by stitching or using an adhesive. Additionally or alternatively, the tows of fibers and/or layers of fibers may be consolidated with a thermoset polymer and/or a thermoplastic polymer. Accordingly, the plate 120 may have a tensile strength or flexural strength in a transverse direction substantially perpendicular to the longitudinal axis of the article of footwear (i.e., the axis extending from the anterior end 22 to the posterior end 24). The stiffness of the plate 120 may be selected for a particular wearer based on the wearer's tendon flexibility, calf muscle strength, and/or metatarsophalangeal (MTP) joint flexibility. Moreover, the stiffness of the plate 120 may also be tailored based upon a running motion of the athlete. In other configurations, the plate 120 is formed from one or more layers/plies of unidirectional tape. In some examples, each layer in the stack includes a different orientation than the layer disposed underneath. The plate may be formed from unidirectional tape including at least one of carbon fibers, boron fibers, glass fibers, and polymeric fibers. In some examples, the one or more materials forming the plate 120 result in the plate 120 having a Young's modulus of at least 70 gigapascals (GPa).

In some implementations, the plate 120 includes a substantially uniform thickness T. In some examples, the thickness T of the plate 120 ranges from about 0.6 millimeters (mm) to about 3.0 mm. In one example, the thickness T of the plate 120 is substantially equal to one 1.0 mm. In other implementations, the thickness T of the plate 120 is non-uniform such that the plate 120 may have a greater thickness T in one region of the sole structure 12 than the thicknesses T in another region.

The foregoing description has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular configuration are generally not limited to that particular configuration, but, where applicable, are interchangeable and can be used in a selected configuration, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.

Claims

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

a first outsole portion defining a first ground-engaging surface and extending from a first end to a second end, the second end extending in a first direction away from the first ground-engaging surface;
a second outsole portion disposed adjacent to the first outsole portion, defining a second ground-engaging surface, and extending from a third end to a fourth end, the fourth end extending in a second direction away from the second ground-engaging surface; and
a channel disposed between and separating the first outsole portion and the second outsole portion.

2. The sole structure of claim 1, wherein the first end of the first outsole portion and the third end of the second outsole portion are disposed in a forefoot region of the sole structure.

3. The sole structure of claim 1, wherein the first end of the first outsole portion is attached to the third end of the second outsole portion proximate to an anterior end of the sole structure.

4. The sole structure of claim 3, wherein a junction of the first end of the first outsole portion and the third end of the second outsole portion is disposed proximate to a terminal end of the channel.

5. The sole structure of claim 1, wherein the first outsole portion extends in a direction toward a heel region of the sole structure to a greater extent than the second outsole portion.

6. The sole structure of claim 1, wherein the second end of the first outsole portion extends in the first direction away from the first ground-engaging surface to a greater extent than the fourth end of the second outsole portion extends in the second direction away from the second ground-engaging surface.

7. The sole structure of claim 1, wherein the first outsole portion includes a substantially planar region spaced apart from the first ground-engaging surface and located in a different plane than the first ground-engaging surface, the second end of the first outsole portion disposed within the substantially planar region.

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

a first outsole portion disposed in a heel region of the sole structure and defining a first ground-engaging surface;
a second outsole portion extending from a first end defining a second ground-engaging surface disposed in a forefoot region of the sole structure to a second end disposed in the heel region of the sole structure, the second end spaced apart from the first ground-engaging surface;
a third outsole portion extending from a third end defining a third ground-engaging surface disposed in the forefoot region of the sole structure to a fourth end; and
a channel extending between and separating at least a portion of the second ground-engaging surface from the third ground-engaging surface in the forefoot region of the sole structure.

9. The sole structure of claim 8, wherein the first end of the first outsole portion is attached to the third end of the second outsole portion proximate to an anterior end of the sole structure.

10. The sole structure of claim 9, wherein a junction of the first end of the first outsole portion and the third end of the second outsole portion is disposed proximate to a terminal end of the channel.

11. The sole structure of claim 8, wherein the first outsole portion extends in a direction toward a heel region of the sole structure to a greater extent than the second outsole portion.

12. The sole structure of claim 8, wherein the fourth end is disposed in a midfoot region of the sole structure.

13. The sole structure of claim 8, wherein the second outsole portion includes a substantially planar region disposed in the heel region of the sole structure, the second end of the second outsole portion disposed within the substantially planar region.

14. The sole structure of claim 8, wherein the channel includes a variable width along its length.

15. The sole structure of claim 8, wherein the channel is arcuate.

16. A sole structure for an article of footwear having an upper, the sole structure comprising:

a first outsole portion including a first portion defining a first ground-engaging surface in a forefoot region of the sole structure and a second portion disposed closer to the upper than the first portion;
a second outsole portion including a third portion and a fourth portion extending from the third portion, the third portion joined to the first portion of the first outsole portion at a junction in the forefoot region of the sole structure and defining a second ground-engaging surface and the fourth portion disposed closer to the upper than the third portion; and
a channel extending between and separating the first portion of the first outsole portion from the third portion of the second outsole portion in the forefoot region of the sole structure.

17. The sole structure of claim 16, wherein the fourth portion of the second outsole portion extends from the third portion of the second outsole portion in a direction toward the upper.

18. The sole structure of claim 16, wherein the second portion of the first outsole portion is substantially planar.

19. The sole structure of claim 16, further comprising a third outsole portion defining a third ground-engaging surface, the second portion of the first outsole portion being substantially parallel to the third ground-engaging surface.

20. The sole structure of claim 16, wherein the channel extends from a midfoot region of the sole structure to a distal end disposed proximate to the junction of the first outsole portion and the second outsole portion.

Patent History
Publication number: 20260144331
Type: Application
Filed: Nov 24, 2025
Publication Date: May 28, 2026
Applicant: NIKE, Inc. (Beaverton, OR)
Inventors: Fidencio Campos Il (Dallas, OR), Zachary M. Elder (Portland, OR), Laura E. Flores Sandoval (Hillsboro, OR), Jonathan Kosenick (Portland, OR), Matthew W. Thornton (Beaverton, OR)
Application Number: 19/399,365
Classifications
International Classification: A43B 13/22 (20060101); A43B 7/1425 (20220101); A43B 7/144 (20220101); A43B 13/20 (20060101);