SOLE STRUCTURE FOR ARTICLE OF FOOTWEAR

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority under 35 U.S. C. § 119(e) to U.S. Provisional Application No. 63/680,229, filed on Aug. 7, 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 and include an outsole. The outsole may include a sole plate formed of a rigid or semi-rigid material that provides rigidity and energy distribution across the sole structure. The sole plate may be provided with one or more ground-engaging members for engagement with a ground surface.

While known sole structures have proven acceptable for their intended purposes, a continuous need for improvement in the relevant art remains. For example, a need exists for an outsole that provides improved traction with the ground surface when forces having varying magnitude and direction are applied from the midsole or the upper to the outsole. A need also exists for an article of footwear having improved overall comfort and fit while providing such improved traction.

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 bottom perspective view showing an article of footwear incorporating a sole structure according to the principles of the present disclosure;

FIG. 2 is a top perspective view of the article of footwear of FIG. 1;

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

FIG. 4 is a medial side elevation view of the article of footwear of FIG. 1;

FIG. 5 is an exploded top perspective view of the sole structure of FIG. 1;

FIG. 6 is an exploded bottom perspective view of the sole structure of FIG. 1;

FIG. 7 is a top plan view of the sole structure of FIG. 1;

FIG. 8 is a bottom plan view of the sole structure of FIG. 1;

FIG. 9 is a cross-sectional view of the sole structure of FIG. 1, taken along Line 9-9 of FIG. 8;

FIG. 10 is a cross-sectional view of the sole structure of FIG. 1, taken along Line 10-10 of FIG. 8;

FIG. 11 is a cross-sectional view of the sole structure of FIG. 1, taken along Line 11-11 of FIG. 8;

FIG. 12 is a cross-sectional view of the sole structure of FIG. 1, taken along Line 12-12 of FIG. 8;

FIG. 13 is a cross-sectional view of the sole structure of FIG. 1, taken along Line 13-13 of FIG. 8;

FIG. 14 is a bottom perspective view showing an article of footwear incorporating a sole structure according to the principles of the present disclosure;

FIG. 15 is a top perspective view of the article of footwear of FIG. 14;

FIG. 16 is a lateral side elevation view of the article of footwear of FIG. 14;

FIG. 17 is a medial side elevation view of the article of footwear of FIG. 14;

FIG. 18 is an exploded top perspective view of the sole structure of FIG. 14;

FIG. 19 is an exploded bottom perspective view of the sole structure of FIG. 14;

FIG. 20 is a top plan views of the sole structure of FIG. 14;

FIG. 21 is a bottom plan view of the sole structure of FIG. 14;

FIG. 22 is a cross-sectional view of the sole structure of FIG. 14, taken along Line 22-22 of FIG. 21;

FIG. 23 is a cross-sectional view of the sole structure of FIG. 14, taken along Line 23-23 of FIG. 21;

FIG. 24 is a cross-sectional view of sole structure of FIG. 14, taken along Line 24-24 of FIG. 21;

FIG. 25 is a cross-sectional view of the sole structure of FIG. 14, taken along Line 25-25 of FIG. 21;

FIG. 26 is a cross-sectional view of the sole structure of FIG. 14, taken along Line 26-26 of FIG. 21;

FIG. 27 is a cross-sectional view of the sole structure of FIG. 14, taken along Line 27-27 of FIG. 21;

FIG. 28 is a cross-sectional view of the sole structure of FIG. 14, taken along Line 28-28 of FIG. 21;

FIG. 29 is a cross-sectional view of the sole structure of FIG. 14, taken along Line 29-29 of FIG. 21;

FIG. 30 is a cross-sectional view of the sole structure of FIG. 14, taken along Line 30-30 of FIG. 21;

FIG. 31 is a cross-sectional view of the sole structure of FIG. 14, taken along Line 31-31 of FIG. 21; and

FIG. 32 is a cross-sectional view of the sole structure of FIG. 14, taken along Line 32-32 of FIG. 21.

Corresponding reference numerals indicate corresponding parts throughout the drawings.

DETAILED DESCRIPTION

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

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

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

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

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

An aspect of the disclosure provides a sole structure for an article of footwear. The sole structure includes an inner frame including a first frame member disposed in a forefoot region and a second frame member formed independently from the first frame member and disposed in a heel region. The sole structure further includes an outer shell attached to and encapsulating each of the first frame member and the second frame member.

Aspects of the disclosure may include one or more of the following optional features. In some examples, the outer shell has a thickness ranging from 0.1 mm to 1 mm and a hardness ranging from 80 A to 100 A Shore hardness. In some implementations, the first frame member includes a first material having a first stiffness and the second frame member includes a second material having a second stiffness that is greater than the first stiffness. In some configurations, the first stiffness is selected from a range of 0.2 gigapascals to 40 gigapascals and the second stiffness is selected from a range of 0.2 gigapascals to 40 gigapascals.

In some implementations, the second frame member includes a central spine and a plurality of ribs extending from the central spine to define a support bed in the heel region. Optionally, the second frame member includes a first arm extending from the central spine to a first distal end in a mid-foot region on a medial side of the sole structure and a second arm extending from the central spine to a second distal end in the mid-foot region on a lateral side of the sole structure. In some examples, the plurality of ribs includes an annular heel rib connected to the central spine and disposed in the heel region. In some implementations, the plurality of ribs includes a first heel connecting member extending from the annular heel rib to the first arm on the medial side of the central spine and a second heel connecting member extending from the annular heel rib to the second arm on the lateral side of the central spine. In some configurations, the plurality of ribs includes a first mid-foot connecting member extending from the first heel connecting member to the first arm on the medial side and a second mid-foot connecting member extending from the second heel connecting member to the second arm on the lateral side. In some examples, the first frame member includes a forefoot support portion in the forefoot region and a tail portion extending from the forefoot support portion to a terminal end in the mid-foot region.

Another aspect of the disclosure provides a sole structure having an inner frame including a first frame member disposed in a forefoot region and a second frame member disposed in a heel region, and an outer shell attached to the inner frame and extending from a first end in a mid-foot region of the sole structure to a second end at a posterior end of the sole structure, the first frame member extending from and being exposed at the first end of the outer shell.

Aspects of the disclosure may include one or more of the following optional features. In some examples, the outer shell has a thickness ranging from 0.1 mm to 1 mm and a hardness ranging from 80 A to 100 A Shore hardness. In some implementations, the first frame member includes a first material having a first stiffness and the second frame member includes a second material having a second stiffness that is greater than the first stiffness. In some configurations, the first stiffness is selected from a range of 0.2 gigapascals to 40 gigapascals and the second stiffness is selected from within a range of 0.2 gigapascals to 40 gigapascals.

In some examples, the second frame member includes a central spine and a plurality of ribs extending from the central spine to define a support bed in the heel region. In some configurations, the second frame member includes a first arm extending from the central spine to a first distal end in the mid-foot region on a medial side and a second arm extending from the central spine to a second distal end in the mid-foot region on a lateral side. In some implementations, the plurality of ribs includes an annular heel rib connected to the central spine and disposed in the heel region. Optionally, the plurality of ribs includes a first heel connecting member extending from the annular heel rib to the first arm on the medial side of the central spine and a second heel connecting member extending from the annular heel rib to the second arm on the lateral side of the central spine. In some examples, the plurality of ribs includes a first mid-foot connecting member extending from the first heel connecting member to the first arm on the medial side and a second mid-foot connecting member extending from the second heel connecting member to the second arm on the lateral side. In some configurations, the first frame member includes a forefoot support portion in the forefoot region and a tail portion extending from the forefoot support portion to a terminal end in the mid-foot region.

Another aspect of the disclosure provides a sole structure for an article of footwear. The sole structure includes an inner frame including a first frame member defining a socket disposed in a forefoot region and a second frame member disposed in a heel region, the second frame member including a central spine and a plurality of ribs extending from the central spine to define a support bed in the heel region. The sole structure further includes an outer shell attached to the inner frame and extending from a first end in a mid-foot region of the sole structure to a second end at a posterior end of the sole structure, the first frame member extending from and being exposed at the first end of the outer shell. The sole structure further includes a cushion pocket disposed within the socket in the forefoot region of the inner frame. The sole structure further includes a cushioning element received within the cushion pocket.

Aspects of the disclosure may include one or more of the following optional features. In some examples, the outer shell has a thickness ranging from 0.1 mm to 1 mm and a hardness ranging from 80 A to 100 A Shore hardness. In some implementations, the first frame member includes a first material having a first stiffness and the second frame member includes a second material having a second stiffness that is greater than the first stiffness. In some configurations, the first stiffness is selected from a range of 0.2 gigapascals to 40 gigapascals and the second stiffness is selected from within a range of 0.2 gigapascals to 40 gigapascals.

In some implementations, the second frame member includes a central spine and a plurality of ribs extending from the central spine to define a support bed in the heel region. In some examples, the second frame member includes a first arm extending from the central spine to a first distal end in the mid-foot region on a medial side and a second arm extending from the central spine to a second distal end in the mid-foot region on a lateral side. Optionally, the plurality of ribs includes an annular heel rib connected to the central spine and disposed in the heel region. In some configurations, the plurality of ribs includes a first heel connecting member extending from the annular heel rib to the first arm on the medial side of the central spine and a second heel connecting member extending from the annular heel rib to the second arm on the lateral side of the central spine. In some examples, the plurality of ribs includes a first mid-foot connecting member extending from the first heel connecting member to the first arm on the medial side and a second mid-foot connecting member extending from the second heel connecting member to the second arm on the lateral side. In some configurations, the first frame member includes a forefoot support portion in the forefoot region and a tail portion extending from the forefoot support portion to a terminal end in the mid-foot region.

Referring to FIGS. 1-8, an article of footwear 10 includes an upper 100 and sole structure 200. 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 12_T corresponding with phalanges, and a ball portion 12_B associated with metatarsal bones of a foot. The mid-foot region 14 may correspond with an arch area of the foot, and the heel region 16 may correspond with rear portions of the foot, including a calcaneus bone. The footwear 10 may further include an anterior end 18 associated with a forward-most point of the forefoot region 12, and a posterior end 20 corresponding to a rearward-most point of the heel region 16. As shown in FIG. 7, a longitudinal axis A₁₀ of the footwear 10 extends along a length of the footwear 10 from the anterior end 18 to the posterior end 20, and generally divides the footwear 10 into a medial side 22 and a lateral side 24. Accordingly, the medial side 22 and the lateral side 24 respectively correspond with opposite sides of the footwear 10 and extend through the regions 12, 14, 16.

The upper 100 includes interior surfaces that define an interior void 102 configured to receive and secure a foot for support on sole structure 200. The upper 100 may be formed from one or more materials that are stitched or adhesively bonded together to form the interior void 102. 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 includes a strobel (not shown) having a bottom surface opposing the sole structure 200 and an opposing top surface defining a footbed of the interior void 102. 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 (not shown) that may be disposed upon the strobel and reside within the interior void 102 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 in the heel region 16 may provide access to the interior void 102. For example, the ankle opening may receive a foot to secure the foot within the void 102 and to facilitate entry and removal of the foot from and to the interior void 102.

Referring to FIGS. 1-8, the sole structure 200 includes an inner frame 202 and an outer shell 204 disposed on a bottom side of the upper 100. The outer shell 204 forms an exterior portion of the article of footwear 10 and defines at least a portion of a ground-engaging surface 26 of the sole structure 200. Optionally, the sole structure 200 includes a plurality of traction elements 206a-206k attached to at least one of the inner frame 202 and the outer shell 204.

As best shown in FIGS. 2 and 5-8, the inner frame 202 is provided as a modular structure including a first frame member 208 and a second frame member 210. The first frame member 208 is disposed substantially in the forefoot region 12 and extends partially into the mid-foot region 14, while the second frame member 210 is disposed substantially in the mid-foot region 14 and the heel region 16 and extends partially into the forefoot region 12. In other words, the first frame member 208 defines the entirety of the inner frame 202 in the toe portion 12_T, a majority of the inner frame 202 in the ball portion 12_B, and extends partially into the mid-foot region 14. The second frame member 210 defines the entirety of the inner frame 202 in the heel region 16, a majority of the inner frame 202 in the mid-foot region 14, and extends partially into the ball portion 12_B of the forefoot region 12.

The inner frame 202 extends along an entire length of the sole structure 200 from a first end 212 at the anterior end 18 of the article of footwear 10 to a second end 214 at the posterior end 20 of the article of footwear 10. Features of the inner frame 202 and/or the individual frame members 208, 210 forming the inner frame 202 may be described as including a top side 216 configured to interface with the strobel of the upper 100 and an opposite bottom side 218 formed on an opposite side from the top side 216 and configured to interface with the outer shell 204 when the sole structure 200 is assembled. A distance from the top side 216 to the bottom side 218 defines an overall thickness of the inner frame 202. The inner frame 202 further includes a peripheral edge 220 extending between the top side 216 and the bottom side 218 and defining an outer peripheral profile of the inner frame 202 when the first frame member 208 and the second frame member 210 are assembled.

With reference to FIGS. 5 and 6, the first frame member 208 extends from a first end 222 corresponding to, and defining, the first end 212 of the inner frame 202 to a second end 224 in the mid-foot region 14. The first frame member 208 includes a forefoot support portion 225 extending from the first end 222, through the toe portion 12_T, and at least partially into the ball portion 12_B of the forefoot region 12. The forefoot support portion 225 extends across an entire width of the sole structure 200 from the medial side 22 to the lateral side 24 and provides support along the forefoot region 12 of the sole structure 200. The first frame member 208 further includes a tail portion 226 that extends from the forefoot support portion 225 in the ball portion 12_B to a terminal end at the second end 224 of the first frame member 208. As shown in FIG. 5, the tail portion 226 of the first frame member 208 includes a first tail side 228 and an opposite second tail side 230 that cooperate to define a peripheral profile of the tail portion 226. A distance from the first tail side 228 to the second tail side 230 in the lateral direction (i.e., perpendicular to the longitudinal axis A₁₀) defines a width W₂₂₆ of the tail portion 226, which tapers continuously along the longitudinal direction from the forefoot support portion 225 to the second end 224 of the first frame member 208. Optionally, each of the first tail side 228 and the second tail side 230 define a half lap or shelf 232 extending continuously along the peripheral profile of the tail portion 226 and configured for mating with a corresponding portion of the second frame member 210 to form a lap joint between the frame members 208, 210. The shelf 232 is formed as a step along the peripheral edge of the tail portion 226 where a thickness of the first frame member 208 is less than the overall thickness of the inner frame 202.

Each of the first tail side 228 and the second tail side 230 may include an initial curved or concave segment 234a extending from the forefoot support portion 225 and a straight segment 234b extending from the concave segment to the second end 224. Thus, the tail portion 226 may be described as having a compound taper, whereby the width W₂₂₆ of the tail portion 226 defined between the arcuate segments 234a tapers at a variable rate (i.e., rate of taper decreases along direction from forefoot support portion 225 to the second end 224) and the width W₂₂₆ of the tail portion 226 defined between the straight segments 234b tapers at a constant rate (i.e., rate of taper remains constant along direction from forefoot support portion 225 to the second end 224).

The forefoot support portion 225 of the first frame member 208 includes a medial side portion 236 disposed on the medial side 22 of the longitudinal axis A₁₀ and a lateral side portion 238 disposed on the lateral side 24 of the longitudinal axis A₁₀, as best shown in FIG. 7. The medial side portion 236 of the forefoot support portion 225 is continuous and uninterrupted (i.e., free of apertures), while the lateral side portion 238 is provided as a webbed structure including a plurality of ribs 239, 240a-240c, 242.

The lateral side portion 238 includes a peripheral rib 239 that is laterally spaced from the medial side portion 236 by a gap and extends continuously along the peripheral edge 220 of the first frame member 208 from the first end 222 to the second end 224. The lateral side portion 238 further includes a series of lateral ribs 240a-240c each extending across the gap to connect the medial side portion 236 to the peripheral rib 239. The lateral ribs 240a include a first lateral rib 240a in the toe portion 12_T of the forefoot support portion 225, a second lateral rib 240b in the ball portion 12_B of the forefoot support portion 225, and a third lateral rib 240c in the tail portion 226. The lateral side portion 238 may further include a linking rib 242 extending between and connecting an intermediate portion of the second lateral rib 240b and a lateral end of the first lateral rib 240a.

With continued reference to FIGS. 5 and 6, the second frame member 210 is formed independently of the first frame member 208 and extends from a first end 250 configured to mate with the second end 224 of the first frame member 208 to a second end 252 corresponding to, and defining, the second end 214 of the inner frame 202. The second frame member 210 is configured as a skeletal structure including a central spine 254 and a plurality of elongate arms and ribs extending from and connected to the central spine 254 to define an overall geometry of a support bed of the second frame member 210. As shown, unlike the first frame member 208, which is substantially formed as a flat plate structure having a constant thickness, the second frame member 210 is formed with interior reinforcing structures to increase rigidity while maintaining a relatively light weight. For example, the central spine 254 and the various structural elements are formed with complex geometries (i.e., not flat) including polygonal cross-sections and/or interior channels having a plurality of reinforcing elements (e.g., webbing, structural ribs) arranged within the channels to provide increased strength.

With reference to FIG. 7, the central spine 254 extends from a first end 256 disposed in an intermediate portion of the mid-foot region 16 to a second end 258 disposed at the second end 252 of the second frame member 210. A size of the cross-section of the central spine 254 tapers along the direction from the first end 256 to the second end 258. For example, as indicated by FIGS. 12 and 13, a width of the central spine 254 is smaller at the second end 258 than at the first end 256. The central spine 254 has a triangular cross-sectional shape, whereby a width of the central spine 254 is defined by opposite sides converging in a direction extending from the bottom side 218 of the inner frame 202.

The second frame member 210 further includes a pair of arms 260, 264 extending from the first end 256 of the central spine 254 to the first end 250 of the second frame member 210. Particularly, the pair of arms 260, 264 includes a first arm 260 extending from the first end 256 of the central spine 254 to a distal end 262 at the first end 250 of the second frame member 210 along the medial side 22 of the sole structure 200. The pair of arms 260, 264 includes a second arm 264 extending from the first end 256 of the central spine 254 to a distal end 266 at the first end 250 of the second frame member 210 along the lateral side 24 of the sole structure 200. Thus, the second arm 264 diverges from the first arm 260 along the direction from the first end 256 of the central spine 254 to the first end 250 of the second frame member 210. As best shown in FIG. 6, inward-facing edges of the arms 260, 264 cooperate to define a socket 263 configured to mate with the tail portion 226 of the first frame member 208. The edges defining the socket 263 may include a half lap or lip 265 configured to interface with the tail shelf 266 to form a lap joint between the first frame member 208 and the second frame member 210.

The second frame member 210 further includes a heel support structure including an annular heel rib 268 and a heel cross-member 269. The annular heel rib 268 is a continuous rib that extends along an annular path in the heel region 16, whereby a central axis A₂₆₈ about which the annular heel rib 268 extends (i.e., a center point) is configured to align with a calcaneus bone of the foot such that the annular heel rib 268 surrounds the calcaneus bone when the article of footwear 10 is donned. The heel cross-member 269 extends laterally across the second frame member 210 from a medial end attached to the annular heel rib 268 on the medial side 22 to a lateral end attached to the annular heel rib 268 on the lateral side 24. As shown in FIG. 7, the heel cross-member 269 extends along an arcuate path from the medial end to the lateral end, whereby the curvature defines a concave profile facing the anterior end 18 and a convex profile facing the posterior end 20. An intermediate portion of the heel cross-member 269 intersects the central spine 254 between the central axis A₂₆₈ of the annular heel rib 268 and the second end 252 of the second frame member 210.

The second frame member 210 further includes a pair of heel connecting members 270, 276 that extend between and connect the annular heel rib 268 and each of the arms 260, 264. A medial heel connecting member 270 extends from a first end 272 connected to the medial arm 260 immediately adjacent to the first end 256 of the central spine 254 to a second end 274 attached to the annular heel rib 268 on the medial side 22. Thus, the second end 274 of the medial heel connecting member 270 and the medial end of the heel cross-member 269 each connect to the annular heel rib 268 at the same point on the medial side 22. A lateral heel connecting member 276 extends from a first end 278 connected to the lateral arm 264 immediately adjacent to the first end 256 of the central spine 254 to a second end 280 attached to the annular heel rib 268 on the lateral side 24. Thus, the second end 280 of the lateral heel connecting rib member 276 and the lateral end of the heel cross-member 269 each connect to the annular heel rib 268 at the same point on the lateral side. As shown in FIG. 7, each of the heel connecting members 270, 276 extends substantially tangentially from the opposite sides of the annular heel rib 268 and along opposing arcuate paths to the respective first ends 272, 278. Thus, each of the heel connecting members 270, 276 extends along an arcuate path defining a concave edge facing the central spine 254 and a convex edge facing the outer periphery.

With continued reference to FIG. 7, the second frame member 210 includes a pair of mid-foot connecting members 286, 292 that extend between and connect intermediate portions of the heel connecting members 270, 276 and respective ones of the arms 260, 264. A medial mid-foot connecting member 286 extends from a first end 288 attached to an intermediate portion of the medial arm 260 between the first end 272 of the medial heel connecting member 270 and the distal end 262 of the medial arm 260 to a second end 290 attached to an intermediate portion of the medial heel connecting member 270 in the mid-foot region 16. A lateral mid-foot connecting member 292 extends from a first end 294 attached to an intermediate portion of the lateral arm 264 between the first end 278 of the lateral heel connecting member 276 and the distal end 266 of the lateral arm 264 to a second end 296 attached to an intermediate portion of the lateral heel connecting member 276 in the mid-foot region 16. As shown in FIG. 7, each of the mid-foot connecting members 286, 292 extends along opposing arcuate paths between the arms 260, 264 and the respective heel connecting members 270, 276. Thus, each of the heel connecting members 270, 276 extends along an arcuate path defining a concave edge facing the longitudinal axis A₁₀ and a convex edge facing the outer periphery.

Referring now to FIGS. 5-7, the second frame member 210 includes a plurality of ribs 298, 304, 310 that each project from the top side 216 of the second frame member 210 in the heel region 16 to surround an outer periphery of the heel region 16. Particularly, the second frame member 210 includes a medial wing rib 298 that extends from a first end 300 attached to a medial side of the central spine 254 between the first end 256 of the central spine 254 and an anterior end of the annular heel rib 268 to a second end 302 attached to the annular heel rib 268 on the medial side 22. The second frame member 210 includes a lateral wing rib 304 that extends from a first end 306 attached to a lateral side of the central spine 254 between the first end 256 of the central spine 254 and an anterior end of the annular heel rib 268 to a second end 308 attached to the annular heel rib 268 on the lateral side 24. As shown in FIGS. 5, 6, and 13, intermediate portions of the wing ribs 298, 304 include arcuate portions that extend outwardly and upwardly relative to the top side 216 to define lateral supports on opposite sides of the second frame member 210 in the heel region 16. The second frame member 210 further includes a heel counter rib 310 extending from a first end 312 attached to the medial wing rib 298 on the medial side 22 to a second end 314 attached to the lateral wing rib 304 on the lateral side 24. Similar to the wing ribs 298, 304, the heel counter rib 310 extends along an arcuate path that projects upwardly from the second end 252 of the second frame member 210. Thus, the wing ribs 298, 304 and the heel counter rib 310 cooperate to form a heel cup at the second end 252 of the second frame member 210.

The inner frame 202 includes a plurality of stud bases 316a-316k configured for attaching corresponding cleat tips 340 to define the traction elements 206a-206k of the sole structure 200. Thus, while the locations of the stud bases 316a-316k are described here, it should be understood that the corresponding traction elements 206a-206k are configured the same, and merely include the corresponding cleat tip 340 attached to the stud base 316a-316k. Referring to FIGS. 6 and 8, the stud bases 316a-316k include a first medial toe stud base 316a extending from the medial side portion 236 of the forefoot support portion 225 in the toe portion 12_T and a first lateral toe stud base 316b extending from the peripheral rib 239 in the toe portion 12 at the anterior end. The stud bases 316a-316k further include a second medial toe stud base 316c extending from the medial side portion 236 of the forefoot support portion 225 in the toe portion 12_T and a second lateral ball stud base 316d extending from the peripheral rib 239 in the toe portion 12_T, adjacent to the ball portion 12_B. The stud bases 316a-316k further include a central forefoot stud base 316e extending from the second lateral rib 240b adjacent to the medial side portion 236 in the forefoot region 12. The stud bases 316a-316e may be referred to as the forefoot stud bases 316a-316e and are each formed as part of the first frame member 208. Further, each of the forefoot stud bases 316a-316e is configured as a chevron-shaped stud base with a pointed front side facing the anterior end 18 and a cupped rear side facing towards the posterior end 20. This configuration provides the forefoot stud bases 316a-316e (and the corresponding traction elements 206a-206e) with increased traction during forward accelerating movements while allowing the forefoot region 12 of the sole structure 200 to generally pivot about the heel region 16 along lengthwise directions of the traction elements 206a-206e.

Referring still to FIGS. 6 and 8, the stud bases 316a-316k further include a medial mid-foot stud base 316f extending from the distal end 262 of the medial arm 260 and a lateral mid-foot stud base 316g extending from the distal end 266 of the lateral arm 264. A plurality of heel stud bases 316h-316k are arranged in series along the annular heel rib 268. While the mid-foot stud bases 316f, 316g are configured as chevron-shaped stud bases having pointed front sides facing the central forefoot stud base 316e, the heel stud bases 316h-316k are substantially straight and are arranged with straight inner sides facing the heel axis A₂₆₈.

Referring still to FIGS. 1-6, the outer shell 204 extends the full length of the article of footwear 10 from a first end 320 at the anterior end 18 of the article of footwear 10 to a second end 322 at the posterior end 20 of the article of footwear 10. The outer shell 204 includes a top side 324 that is configured to face the inner frame 202 and the strobel of the upper 100 when the sole structure 200 is assembled with the upper 100. The outer shell 204 includes a bottom side 326 formed on an opposite side from the top side 324, whereby a distance from the top side 324 to the bottom side 326 defines a thickness T₂₀₄ (FIG. 10) of the outer shell 204. In the illustrated example, the outer shell 204 has a substantially constant thickness T₂₀₄ ranging from 0.1 mm to 1 mm, and more preferably from 0.3 mm to 0.5 mm. Except for the cleat tips 340 of the traction elements 206a-206k, the bottom side 326 of the outer shell 204 defines a first portion of the ground-engaging surface 26 of the article of footwear 10 when then sole structure 200 is assembled with the upper 100.

A peripheral edge 328 extends between the top side 324 and the bottom side 326 and defines an outer peripheral profile of the outer shell 204. The peripheral edge 328 defines convex curvatures along each of the first end 320 and the second end 322, whereby a radius of the curvature at the first end 320 corresponds to a ball of the foot and a radius of the curvature at the second end 322 corresponds to a heel of the foot and is generally smaller than the radius at the first end. The peripheral edge 328 may include a first continuous concave curvature extending along the lateral side 24 between the first end 320 and the second end 322. The peripheral edge 328 includes a concave portion extending continuously from a first end adjacent to the forefoot region 12 to a second end adjacent to the heel region 16 on the medial side 22.

The sole structure 200 may be manufactured using an injection molding process, whereby the materials of one or more of the sole structure components 204, 208, 210, 340 are molded or co-molded using an injection molding process. As shown in FIG. 1, the outer shell 204 at least partially encapsulates the bottom side 218 of the inner frame 202, whereby the central spine 254 and the various arms and ribs of the second frame member 210 are embedded within the material of the outer shell 204 on the bottom side 218, while the top side 216 of the inner frame 202 is exposed along the top side 324 of the outer shell 204.

Materials of the outer shell 204 and each of the frame members 208, 210 may be selected to provide enhanced bonding properties between the outer shell 204 and the frame members 208, 210 during molding. For example, the outer shell 204 may include a thermoplastic polyurethane (TPU) material to enhance bonding between the components. Examples of suitable polymers for forming the frame members 208, 210 include polyamides (e.g., amorphous polyamides, polyamide 6, polyamide 6.6, polyamide 11, polyamide 12), polyether block amide (PEBA), polyethylene, TPU, and/or polycarbonate. In some examples, the materials of the frame members 208, 210 may include one or more fillers such as fibers comprising up to 50% of the material by weight. Examples of suitable fibers include glass and/or carbon fibers ranging from 0.1 mm to 20 mm in length.

The material of the outer shell 204 may have a Shore hardness ranging from 80 A to 95 A, the material of the frame members 208, 210 may have a Shore hardness ranging from 90 A to 95 A and/or an elastic modulus (i.e., stiffness) ranging from 0.2 gigapascals to 40 gigapascals, and the material of the traction elements 340 may have a Shore hardness ranging from 80 A to 85 A. Thus, the outer shell 204 provides a relatively hard, yet thin layer providing a ground-engaging surface 26 and a support body for the frame members 208, 210. The material(s) of the first frame member 208 and the second frame member 210 are selected such that the stiffness of the material(s) forming the second frame member 210 is equal to or greater than a stiffness of the material(s) forming the first frame member 208. Thus, the first frame member 208 provides the inner frame 202 with more flexibility (i.e., less stiffness) in the forefoot region 12 while the second frame member 210 provides the inner frame 202 with increased rigidity (i.e., greater stiffness) in the mid-foot and heel regions 14, 16.

With particular reference to FIGS. 14-32, an article of footwear 10a is provided and includes the upper 100 and a sole structure 200a attached to the upper 100. 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.

Referring to FIGS. 14-20, the sole structure 200a includes an inner frame 202a and an outer shell 204a disposed on a bottom side of the strobel of the upper 100. The outer shell 204a forms an exterior portion of the article of footwear 10a and defines at least a portion of a ground-engaging surface 26 of the sole structure 200a. The sole structure 200a includes the plurality of traction elements 206a-206k attached to at least one of the inner frame 202a and the outer shell 204a.

As best shown in FIGS. 18-21, the inner frame 202a is provided as a modular structure including a first frame member 208a, a second frame member 210a integrally formed with the first frame member 208a, and a cushion pocket 350 received within the first frame member 208a. The first frame member 208a is formed substantially in the forefoot region 12 and extends partially into the mid-foot region 14, while the second frame member 210a is formed substantially in the mid-foot region 14 and the heel region 16 and extends partially into the forefoot region 12. In other words, the first frame member 208a defines the entirety of the inner frame 202a in the toe portion 12_T, a majority of the inner frame 202a in the ball portion 12_B, and extends partially into the mid-foot region 14. The second frame member 210a defines the entirety of the inner frame 202a in the heel region 16, a majority of the inner frame 202a in the mid-foot region 14, and extends partially into the ball portion 12_B of the forefoot region 12.

The inner frame 202a extends along an entire length of the sole structure 200a from the first end 212 at the anterior end 18 of the article of footwear 10a to the second end 214 at the posterior end 20 of the article of footwear 10a. Features of the inner frame 202a and/or the individual frame members 208a, 210a forming the inner frame 202a may be described as including a top side 216a configured to interface with the strobel of the upper 100 and an opposite bottom side 218a formed on an opposite side from the top side 216a and configured to interface with the outer shell 204a when the sole structure 200a is assembled. A distance from the top side 216a to the bottom side 218a defines an overall thickness of the inner frame 202a. The inner frame 202a further includes the peripheral edge 220a extending between the top side 216a and the bottom side 218a and defining an outer peripheral profile of the inner frame 202a when the first frame member 208a and the second frame member 210a are assembled.

With reference to FIGS. 18 and 19, the first frame member 208a extends from a first end 222a corresponding to, and defining, the first end 212 of the inner frame 202a to a second end 224a in the mid-foot region 14 that is integrally formed with the second frame member 210a. The first frame member 208a includes a forefoot support portion 225a extending from the first end 222a through the toe portion 12_T. The forefoot support portion 225a extends across an entire width of the sole structure 200a from the medial side 22 to the lateral side 24 and provides support along the toe portion 12_T of the sole structure 200a.

The first frame member 208a further includes a medial side portion 236a disposed on the medial side 22 of the longitudinal axis A₁₀ and a lateral side portion 238a disposed on the lateral side 24 of the longitudinal axis A_10a, as best shown in FIG. 19. The medial side portion 236a includes a first portion of a peripheral rib 239a that extends continuously along the peripheral edge 220a of the first frame member 208a from the first end 222a to the second end 224a along the medial side 22. The lateral side portion 238a includes a second portion of a peripheral rib 239a that is laterally spaced from the medial side portion 236a by a portion of a socket 263a and extends continuously along the peripheral edge 220a of the first frame member 208a from the first end 222a to the second end 224a along the lateral side. Optionally, the first frame member 208a may include a step or lip 244 extending continuously along the peripheral edge 220a in the forefoot region 12, which is configured to mate with a corresponding flange 246 that is attached to the portion of the peripheral edge 220a defined by the first frame member 208a.

With continued reference to FIGS. 18 and 19, the second frame member 210a extends from a first end 250a integrally formed with the second end 224a of the first frame member 208a to a second end 252a corresponding to, and defining, the second end 214 of the inner frame 202a. The second frame member 210a is configured substantially the same as the second frame member 210 discussed previously. However, in this configuration, the distal ends 262, 266 of the arms 260, 264 are integrally formed with the medial side portion 236a and the lateral side portion 236b of the first frame member 208a, respectively.

As best shown in FIG. 18, the first frame member 208a and the second frame member 210a cooperate to define a socket 263a configured to removably receive the cushion pocket 350. Particularly, inward-facing edges of the arms 260, 264 cooperate to define a rear portion of the socket 263a configured to mate with a tail portion 360 of the pocket 350. The periphery of the socket 263a is defined by the forefoot support portion 225a, the medial side portion 236a, the lateral side portion 238a, and the second frame member 210a and has a profile corresponding to a peripheral profile of the cushion pocket 350, as described below. The interior edges of inner frame 202a defining the socket 263a may include a half lap or lip 265a configured to interface with the tail shelf 266 to form a lap joint between the first frame member 208 and the second frame member 210.

The cushion pocket 350 is provided as a modular component configured to mate with the corresponding socket 263a formed in the inner frame 202a. The cushion pocket 350 includes a top side 352 defining a recess 354 configured for receiving a cushioning element 380. The cushion pocket 350 further includes a bottom side 356 disposed on an opposite side from the top side 352 and a peripheral edge 358 extending between the top side 352 and the bottom side 356 and defining a peripheral profile of the cushion pocket 350. As best shown in FIGS. 14 and 22, the bottom side 356 of the cushion pocket 350 includes one of the traction elements 206e extending or protruding from an intermediate portion of the cushion pocket 350. The traction element 206e provides the benefit of functioning as an actuator for the cushion element 380. Here, the traction element 206e provides an initial engagement point between the cushion pocket 350 and a ground surface, whereby a force applied to the traction element 206e by the ground surface creates a point load in an intermediate portion of the cushion pocket 350. This point load causes the intermediate portion of the cushion pocket 350 to deflect and compress the cushion element 380 between the top side 352 of the cushion pocket 350 and a plantar surface of the foot.

The peripheral edge 358 defines a tail portion 360 that is substantially similar in shape to the tail portion 226 described previously, whereby the tail portion 360 is configured to mate with the portion of the socket 263a defined between the arms 260, 264 of the second frame member 210a. Thus, the tail portion 360 extends from the forefoot region 12 to a terminal end 361 in the mid-foot region 14. As shown in FIG. 18, the tail portion 360 of the cushion pocket 350 includes a first tail side 362 and an opposite second tail side 364 that cooperate to define a peripheral profile of the tail portion 360. A distance from the first tail side 362 to the second tail side 364 in the lateral direction (i.e., perpendicular to the longitudinal axis A₁₀) defines a width W₃₆₀ of the tail portion 360, which tapers continuously along the longitudinal direction from a forefoot support portion 359 to the terminal end 361 of the cushion pocket 350. Optionally, each of the first tail side 362 and the second tail side 364 defines a half lap or shelf 366 (FIG. 27) extending continuously along the peripheral profile of the tail portion 360 and configured for mating with a corresponding portion of the inner frame 202a to form a lap joint between the cushion pocket 350 and the inner frame 202a. The shelf 366 is formed as a step along the peripheral edge 358 of the tail portion 360 where a thickness of the cushion pocket 350 is less than the overall thickness T₃₅₀ of the cushion pocket 350.

Each of the first tail side 362 and the second tail side 364 may include an initial curved or concave segment 368a and a straight segment 368b extending from the concave segment 368a to the terminal end 361. Thus, the tail portion 360 may be described as having a compound taper, whereby the width W₃₆₀ of the tail portion 360 defined between the arcuate segments 368a tapers at a variable rate (i.e., a rate of taper decreases along a direction towards the terminal end 361) and the width W₃₆₀ of the tail portion 360 defined between the straight segments 368b tapers at a constant rate (i.e., a rate of taper remains constant along a direction to the terminal end 361).

With reference to FIGS. 19, 22, 27, and 28, the cushioning element 380 is configured as a bladder having an opposing pair of barrier layers 382a, 382b, which can be joined to each other at discrete locations to define the cushioning element 380. In the shown implementation, the barrier layers 382a, 382b include a first, upper barrier layer 382a and a second, lower barrier layer 382b. Alternatively, the cushioning element 380 can be produced from any suitable combination of one or more barrier layers.

As used herein, the term “barrier layer” (e.g., barrier layers 382a, 382b) encompasses both monolayer and multilayer films. In some implementations, one or both of barrier layers the 382a, 382b are each produced (e.g., thermoformed or blow molded) from a monolayer film (a single layer). In other implementations, one or both of the barrier layers 382a, 382b 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 implementations, the film thickness for each layer or sublayer can range from about 0.5 micrometers to about 500 micrometers. In yet further implementations, 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 382a, 382b 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 382a, 382b 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 implementations, 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 382a, 382b 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 implementations where the barrier layers 382a, 382b 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 implementations, barrier layers 382a, 382b 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 382a, 382b 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 cushioning element 380 can be produced from the barrier layers 382a, 382b 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 382a, 382b can be produced by co-extrusion followed by vacuum thermoforming to produce an inflatable chamber 380, which can optionally include one or more valves (e.g., one way valves) that allows the chamber 380 to be filled with the fluid (e.g., gas).

The chamber 380 can be provided in a fluid-filled (e.g., as provided in footwear 10) or in an unfilled state. The chamber 380 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 chamber 380 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 chamber 380 can result in the chamber 380 being pressurized. Alternatively, the fluid provided to the chamber 380 can be at atmospheric pressure such that the chamber 380 is not pressurized but, rather, simply contains a volume of fluid at atmospheric pressure.

The cushioning element 380 desirably has a low gas transmission rate to preserve its retained gas pressure. In some implementations, the cushioning element 380 has 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, cushioning element 380 has 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 382a, 382b). 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.

In some implementations, the upper barrier layer 382a and the lower barrier layer 382b cooperate to define a geometry (e.g., thicknesses, width, and lengths) of the cushioning element 380. As shown in FIG. 27, a space formed between opposing interior surfaces of the upper and lower barrier layers 382a, 382b defines an interior void 384 of the cushioning element 380.

Similarly, exterior surfaces of the upper and lower barrier layers 382a, 382b define an exterior profile of the cushioning element 380.

In some implementations, the upper and lower barrier layers 382a, 382b are formed by respective mold portions each defining various surfaces for forming depressions and pinched surfaces when the lower barrier layer 382b and the upper barrier layer 382a are joined and bonded together. In some implementations, adhesive bonding joins the upper barrier layer 382a and the lower barrier layer 382b. In other implementations, the upper barrier layer 382a and the lower barrier layer 382b are joined by thermal bonding. In some examples, one or both of the barrier layers 382a, 382b are heated to a temperature that facilitates shaping and melding. In some examples, the barrier layers 382a, 382b are heated prior to being located between their respective molds. In other examples, the mold may be heated to raise the temperature of the barrier layers 382a, 382b. In some implementations, a molding process used to form the cushioning element 380 incorporates vacuum ports within mold portions to remove air such that the upper and lower barrier layers 382a, 382b 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 layers 382a, 382b such that pressure increases cause the barrier layers 382a, 382b to engage with surfaces of their respective mold portions.

The interior void 384 of the cushioning element 380 may receive a tensile element 386 therein. The tensile element 386 may include a series of tensile strands 388 extending between an upper tensile sheet 390 and a lower tensile sheet 392. The upper tensile sheet 390 may be attached to the first barrier layer 382a while the lower tensile sheet 392 may be attached to the second barrier layer 382b. In this manner, when the chamber 380 receives a pressurized fluid, the tensile strands 388 of the tensile element 386 are placed in tension. Because the upper tensile sheet 390 is attached to the first barrier layer 382a and the lower tensile sheet 392 is attached to the second barrier layer 382b, the tensile strands 388 retain a desired shape of the chamber 380 when the pressurized fluid is injected into the interior void 384.

Referring still to FIGS. 14-19, the outer shell 204a extends the partial length of the article of footwear 10a from a first end 320a at the first end 350a of the second frame member 210a to a second end 322a at the posterior end 20 of the article of footwear 10a. The outer shell 204a includes a top side 324a that is configured to face the inner frame 202a and the upper 100 when the sole structure 200a is assembled with the upper 100. The outer shell 204a includes a bottom side 326a formed on an opposite side from the top side 324, whereby a distance from the top side 324a to the bottom side 326a defines a thickness T_204a (FIG. 10) of the outer shell 204a. In the illustrated example, the outer shell 204 has a substantially constant thickness T_204a ranging from 0.1 mm to 1 mm, and more preferably from 0.3 mm to 0.5 mm. The bottom side 326a of the outer shell 204a defines a first portion of the ground-engaging surface 26 of the article of footwear 10a in the mid-foot region 14 and heel region 16 when then sole structure 200 is assembled with the upper 100, while the first frame member 208a and the cushion pocket 350 define the ground-engaging surface 26 in the forefoot region 12.

A peripheral edge 328a extends between the top side 324a and the bottom side 326a and defines an outer peripheral profile of the outer shell 204a. As shown in FIG. 19, the first end 320a of the outer shell 204a has a profile corresponding to the second frame member 210a, whereby the outer shell 204a does not extend onto the portion of the inner frame 202a defined by the first frame member 208a or the cushion pocket 350. Thus, unlike the outer shell 204 discussed previously, which encompasses the entire bottom side of the sole structure 200, the outer shell 204a only covers a portion of the sole structure 200a. In other words, the first frame member 208a extends from and is exposed at the first end 320a of the outer shell 204a to define a portion of the ground-engaging surface 26 in the mid-foot region 14 and the forefoot region 12.

The sole structure 200a may be manufactured using an injection molding process, whereby the materials of one or more of the sole structure components 202a, 204a, 340, 350 are molded or co-molded using an injection molding process. As shown in FIG. 14, the outer shell 204a at least partially encapsulates the bottom side 218a of the inner frame 202a, whereby the central spine 254 and the various arms and ribs of the second frame member 210a are embedded within the material of the outer shell 204a on the bottom side 218, while the top side 216a of the inner frame 202a is exposed along the top side 324a of the outer shell 204. Materials of the outer shell 204a and the inner frame 202a may be selected to provide enhanced bonding properties between the outer shell 204a and the frame members 208a, 210a during molding. For example, the outer shell 204a and the frame members 208a, 210a may each include a thermoplastic polyurethane (TPU) material to enhance bonding between the components. The material of the outer shell 204a may have a Shore hardness ranging from 80 A to 100 A, the material of the frame members 208a, 210a may have a Shore hardness ranging from 90 A to 95 A, and the material of the traction elements 340a may have a Shore hardness ranging from 80 A to 85 A. Thus, the outer shell 204 provides a relatively hard, yet thin layer providing a ground-engaging surface 26 and a support body for the frame members 208a, 210a. Further, the cushion pocket 350 may be formed of a relatively soft material relative to the outer shell 204a and the inner frame 202a, whereby the cushion pocket 350 provides a resilient interface between the cushioning element 380 and the ground surface in the forefoot region 12.

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.