SOLE STRUCTURE FOR AN 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. 63/690,155, filed on Sep. 3, 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 a sole structure 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 conventional sole structures provide a wearer with a degree of comfort and support during use, a continuous need exists to develop sole structures that provide targeted support and response for particular movements and activities.

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 lateral side perspective view of an article of footwear incorporating a sole structure in accordance with principles of the present disclosure;

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

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

FIG. 4 is a top exploded view of the article of footwear of FIG. 1;

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

FIG. 6 is a bottom view of the sole structure of FIG. 1;

FIG. 7 is a cross-sectional view of the sole structure of FIG. 1, taken along line 7-7 of FIG. 6;

FIG. 8 is a cross-sectional view of the sole structure of FIG. 1, taken along line 8-8 of FIG. 6; and

FIG. 9 is a cross-sectional view of the sole structure of FIG. 1, taken along line 9-9 of FIG. 6.

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 (, “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 includes a midsole chassis having a first side defining a footbed, a second side disposed on an opposite side from the first side, a first pocket formed within the midsole chassis between the first side and the second side, and a first aperture extending between the second side and the first pocket. A first interior cushioning element is disposed in the first pocket of the midsole chassis and a first barrier element is disposed within the first pocket of the midsole chassis between the first interior cushioning element and the first aperture.

The sole structure may include one or more of the following optional features. For example, the midsole chassis may further include a second pocket formed within the midsole chassis between the first side and the second side and a second aperture extending between the second side and the second pocket. A second interior cushioning element may be disposed within the second pocket of the midsole chassis and a second barrier element may be disposed within the second pocket of the midsole chassis between the second interior cushioning element and the second aperture. The first pocket may be disposed in one of a forefoot region of the sole structure or a heel region of the sole structure and the second pocket may be disposed in the other of the forefoot region of the sole structure or the heel region of the sole structure.

In another configuration, the first interior cushioning element may include a first chamber disposed on a medial side of the sole structure and a second chamber disposed on a lateral side of the sole structure. The first chamber may be separated from the second chamber by a flex joint extending along a direction of a longitudinal axis of the sole structure.

The first aperture may extend continuously from the second side of the midsole chassis to the first pocket and the first barrier element may be exposed through the aperture. Additionally or alternatively, the first pocket may extend continuously from a medial side of the sole structure to a lateral side of the sole structure.

The first interior cushioning element may be a bladder having a first barrier layer joined to a second barrier layer to define a chamber. In this configuration, the first barrier element may be disposed adjacent to the first barrier layer of the bladder. Additionally or alternatively, the first barrier element may comprise a light-transmissive material.

In another configuration, a sole structure for an article of footwear includes a lower cushioning element having a first side defining a cushion support bed, a second side disposed on an opposite side from the first side, a first channel defined by the cushion support bed on the first side, and a first aperture extending between the second side and the first channel. A first interior cushioning element may be disposed in the first channel of the lower cushioning element and a first barrier element may be disposed within the first channel of the lower cushioning element between the first interior cushioning element and the first aperture.

The sole structure may include one or more of the following optional features. For example, the lower cushioning element may further include a second channel defined by the cushion support bed on the first side and a second aperture extending between the second side and the second channel. A second interior cushioning element may be disposed within the second channel of the lower cushioning element and a second barrier element may be disposed within the second channel of the lower cushioning element between the second interior cushioning element and the second aperture. The first channel may be disposed in one of a forefoot region of the sole structure or a heel region of the sole structure and the second channel may be disposed in the other of the forefoot region of the sole structure or the heel region of the sole structure.

In another configuration, the first interior cushioning element may include a first chamber disposed on a medial side of the sole structure and a second chamber disposed on a lateral side of the sole structure. The first chamber may be separated from the second chamber by a flex joint extending along a direction of a longitudinal axis of the sole structure.

The first aperture may extend continuously from the second side of the lower cushioning element to the cushion support bed and the first barrier element may be exposed through the aperture. Additionally or alternatively, the first channel may extend continuously from a medial side of the sole structure to a lateral side of the sole structure.

The first interior cushioning element may be a bladder having a first barrier layer joined to a second barrier layer to define a chamber. In this configuration, the first barrier element may be disposed adjacent to the first barrier layer of the bladder.

In yet another configuration, a sole structure for an article of footwear includes an upper cushioning element having a first superior side defining a footbed, a first inferior side disposed on an opposite side from the first superior side, and a first channel defined by the first inferior side. A lower cushioning element may include a second superior side defining a cushion support bed, a second inferior side disposed on an opposite side from the second superior side, a second channel defined by the cushion support bed and cooperating with the first channel to define a pocket, and an aperture extending between the second inferior side and the pocket. An interior cushioning element is disposed in the pocket and a first barrier element is disposed within the second channel of the lower cushioning element between the interior cushioning element and the aperture.

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.

Referring to FIGS. 1-9, 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. 6, 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 104 in the heel region 16 may provide access to the interior void 102. For example, the ankle opening 104 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.

With reference to FIGS. 1-9, the sole structure 200 includes a midsole 202 configured to provide cushioning characteristics to the sole structure 200, and an outsole 204 configured to provide a ground-contacting surface 28 of the article of footwear 10. Unlike conventional sole structures, the midsole 202 of the sole structure 200 may be formed compositely and include a plurality of subcomponents for providing desired forms of cushioning and support throughout the sole structure 200. For example, the midsole 202 may be described as including a midsole chassis 206 having an upper cushioning element 208 and a lower cushioning element 210 that cooperate to receive and support one or more interior cushioning elements 212, 214. The midsole chassis 206 is configured to be attached to the upper 100 and provides an interface between the upper 100, the interior cushioning elements 212, 214, and the outsole 204. In the illustrated example, the interior cushioning elements 212, 214 are supported within the midsole chassis 206 between the outsole 204 and the upper 100. As discussed in greater detail below, the sole structure 200 further includes one or more barrier elements 216, 218 each associated with a respective one of the interior cushioning elements 212, 214. Particularly, the one or more barrier elements 216, 218 are each disposed within the midsole chassis 206 between a respective one of the interior cushioning elements 212, 214 and a corresponding aperture 310, 312 formed in the lower cushioning element 210, whereby the barrier elements 216, 218 are exposed to a ground surface through the apertures 310, 312 and provide a protective membrane adjacent to the interior cushioning elements 212, 214.

As best shown in FIGS. 4 and 5, a length of the upper cushioning element 208 extends from a first end 220 at the anterior end 18 of the sole structure to a second end 222 at the posterior end 20 of the sole structure 200. The upper cushioning element 208 includes a superior or top side 224 defining a top side of the midsole 202 and an opposite inferior or lower side 226 disposed on an opposite side from the top side 224, whereby a distance from the top side 224 to the lower side 226 defines a thickness of the upper cushioning element 208. A peripheral side surface 228 of the upper cushioning element 208 extends between the top side 224 and the lower side 226 and defines a peripheral profile of the upper cushioning element 208. The top side 224 of the upper cushioning element 208 defines a concave recess providing a footbed 230 of the midsole 202.

As best shown in FIG. 5, the lower side 226 of the upper cushioning element 208 includes one or more upper channels 232, 242 arranged in series between the first end 220 and the second end 222. A first upper channel 232 includes an upper forefoot channel 232 formed substantially in the forefoot region 12 on the lower side 226 of the upper cushioning element 208. A length of the upper forefoot channel 232 extends along the direction of the longitudinal axis A₁₀ from an anterior channel wall 234 adjacent to the toe portion 12_T to a posterior channel wall 236 adjacent to the mid-foot region 14. As shown in FIG. 5, an upper channel wall 238 is recessed from the lower side 226 and extends between the anterior channel wall 234 and the posterior channel wall 236. A width of the upper forefoot channel 232 extends continuously from the peripheral side surface 228 on the medial side 22 to the peripheral side surface 228 on the lateral side 24, whereby the upper forefoot channel 232 extends through an entire width of the upper cushioning element 208. Optionally, the upper channel wall 238 may include a pair of upper interior cushion sockets 240a, 240b recessed within the upper channel wall 238 and configured to mate with corresponding chambers 412, 414 of the forefoot interior cushioning element 212, as described in greater detail below. Particularly, when the sole structure is assembled, upper portions of the chambers 412, 414 of the forefoot interior cushioning element 212 mate with the sockets 240a, 240b formed in the upper channel wall 238.

A second upper channel 242 includes an upper heel channel 242 formed substantially in the heel region 16 on the lower side 226 of the upper cushioning element 208. A length of the upper heel channel 242 extends along the direction of the longitudinal axis A₁₀ from an anterior channel wall 244 adjacent to the mid-foot region 14 to a posterior channel wall 246 in the heel region 16. As shown in FIG. 5, an upper channel wall 248 is recessed from the lower side 226 and extends between the anterior channel wall 244 and the posterior channel wall 246. A width of the upper heel channel 242 extends continuously from the peripheral side surface 228 on the medial side 22 to the peripheral side surface 228 on the lateral side 24, whereby the upper heel channel 242 extends through an entire width of the upper cushioning element 208. Optionally, the upper channel wall 248 may include a pair of upper interior cushion sockets 250a, 250b recessed within the upper channel wall 248 and configured to mate with corresponding chambers 438, 440 of the heel interior cushioning element 214, as described in greater detail below. Particularly, when the sole structure is assembled, upper portions of the chambers 438, 440 of the heel interior cushioning element 214 mate with the sockets 250a, 250b formed in the upper channel wall 248.

The lower side 226 of the upper cushioning element 208 further includes a plurality of upper pads 252, 254, 256 arranged in series between the first end 220 and the second end 222. The upper pads 252, 254, 256 include an upper toe pad 252 extending between the first end 220 and the upper forefoot channel 232. Thus, a posterior end of the upper toe pad 252 terminates at and is defined by the anterior channel wall 234. An upper mid-foot pad 254 extends between the upper forefoot channel 232 and the upper heel channel 242. Thus, an anterior end of the upper mid-foot pad 254 terminates at and is defined by the posterior channel wall 236 of the upper forefoot channel 232 and a posterior end of the upper mid-foot pad 254 terminates at and is defined by the anterior channel wall 244 of the upper heel channel 242. An upper heel pad 256 extends between the upper heel channel 242 and the second end 222 of the upper cushioning element 208. Thus, an anterior end of the upper heel pad 256 terminates at and is defined by the posterior channel wall 246 of the upper heel channel 242. Optionally, and as shown in FIG. 5, each of the upper pads 252, 254, 256 extends continuously across the width of the upper cushioning element 208 and defines a substantially planar distal end surface 253, 255, 257.

Optionally, the top side 224 of the upper cushioning element 208 may include a peripheral flange 258 projecting from the footbed 230 adjacent to the peripheral side surface 228. As shown in FIG. 1, the peripheral flange 258 extends from a first end at the heel region 16 on the medial side 22, around the anterior end 18, and to a second end at the heel region on the lateral side 24. The peripheral flange 258 provides lateral support and stability along a lower portion of the upper 100 in the forefoot region 12 and the mid-foot region 14.

Referring still FIGS. 4 and 5, a length of the lower cushioning element 210 extends from a first end 260 at the anterior end 18 of the sole structure 200 to a second end 262 at the posterior end 20 of the sole structure 200. The lower cushioning element 210 includes a superior or upper side 264 defining a cushion support bed 270 within the midsole 202 and an opposite inferior or bottom side 266 disposed on an opposite side from the upper side 264, whereby a distance from the upper side 264 to the bottom side 266 defines a thickness of the lower cushioning element 210. A peripheral side surface 268 of the lower cushioning element 210 extends between the upper side 264 and the bottom side 266 and defines a peripheral profile of the lower cushioning element 210.

A best shown in FIG. 4, the upper side 264 of the lower cushioning element 210 includes one or more lower channels 272, 282 arranged in series between the first end 260 and the second end 262. A first lower channel 272 includes a lower forefoot channel 272 formed substantially in the forefoot region 12 on the upper side 264 of the lower cushioning element 210. A length of the lower forefoot channel 272 extends along the direction of the longitudinal axis A₁₀ from an anterior channel wall 274 adjacent to the toe portion 12_T to a posterior channel wall 276 adjacent to the mid-foot region 14. As shown in FIG. 4, a lower channel wall 278 is recessed from the upper side 264 and extends between the anterior channel wall 274 and the posterior channel wall 276. A width of the lower forefoot channel 272 extends continuously from the peripheral side surface 268 on the medial side 22 to the peripheral side surface 268 on the lateral side 24, whereby the lower forefoot channel 272 extends through an entire width of the lower cushioning element 210. Optionally, the lower channel wall 278 may include a lower interior cushion socket 280 recessed within the lower channel wall 278 and configured to mate with corresponding chambers 412, 414 of the forefoot interior cushioning element 212, as described in greater detail below.

A second lower channel 282 includes a lower heel channel 282 formed substantially in the heel region 16 on the upper side 264 of the lower cushioning element 210. A length of the lower heel channel 282 extends along the direction of the longitudinal axis A₁₀ from an anterior channel wall 284 adjacent to the mid-foot region 14 to a posterior channel wall 286 in the heel region 16. As shown in FIG. 4, a lower channel wall 288 is recessed from the upper side 264 and extends between the anterior channel wall 284 and the posterior channel wall 286. A width of the lower heel channel 282 extends continuously from the peripheral side surface 228 on the medial side 22 to the peripheral side surface 228 on the lateral side 24, whereby the lower heel channel 282 extends through an entire width of the lower cushioning element 210. Optionally, the lower channel wall 288 may include a lower interior cushion socket 290 recessed within the lower channel wall 288 and configured to mate with the chambers 438, 440 of the heel interior cushioning element 214, as described in greater detail below.

The upper side 264 of the lower cushioning element 210 further includes a plurality of lower pads 292, 294, 296 arranged in series between the first end 260 and the second end 262. The lower pads 292, 294, 296 include a lower toe pad 292 extending between the first end 260 and the lower forefoot channel 272. Thus, a posterior end of the lower toe pad 292 terminates at and is defined by the anterior channel wall 274. A lower mid-foot pad 294 extends between the lower forefoot channel 272 and the lower heel channel 282. Thus, an anterior end of the lower mid-foot pad 294 terminates at and is defined by the posterior channel wall 276 of the lower forefoot channel 272 and a posterior end of the lower mid-foot pad 294 terminates at and is defined by the anterior channel wall 284 of the lower heel channel 282. A lower heel pad 296 extends between the lower heel channel 282 and the second end 262 of the lower cushioning element 210. Thus, an anterior end of the lower heel pad 296 terminates at and is defined by the posterior channel wall 286 of the lower heel channel 282. Optionally, and as shown in FIG. 4, each of the lower pads 292, 294, 296 extends continuously across the width of the lower cushioning element 210 and defines a substantially planar distal end surface 293, 295, 297.

When the sole structure 200 is assembled, the upper pads 252, 254, 256 align with and abut the lower pads 292, 294, 296 such that the upper cushioning element 208 is supported upon the lower cushioning element 210. As best shown in FIGS. 2 and 3, the upper forefoot channel 232 is vertically aligned with the lower forefoot channel 272 to define a forefoot cushion pocket 298 within the midsole chassis 206 between the top side 224 and the bottom side 266. Particularly, the anterior channel wall 234 of the upper forefoot channel 232 and the anterior channel wall 274 of the lower forefoot channel 272 cooperate to define an anterior wall of the forefoot cushion pocket 298 while the posterior channel wall 236 of the upper forefoot channel 232 and the posterior channel wall 276 of the lower forefoot channel 272 cooperate to define a posterior wall of the forefoot cushion pocket 298. Similarly, the upper heel channel 242 is vertically aligned with the lower heel channel 282 to define a heel cushion pocket 300 within the midsole chassis 206 between the top side 224 and the bottom side 266. Particularly, the anterior channel wall 244 of the upper heel channel 242 and the anterior channel wall 284 of the lower heel channel 282 cooperate to define an anterior wall of the heel cushion pocket 300 while the posterior channel wall 246 of the upper heel channel 242 and the posterior channel wall 286 of the lower forefoot channel 282 cooperate to define a posterior wall of the heel cushion pocket 300.

With continued reference to FIGS. 2-5, each of the cushion pockets 298, 300 extends continuously across a width of the sole structure 200 to provide respective openings on the medial side 22 and the lateral side 24. Particularly, the forefoot cushion pocket 298 extends from a medial forefoot opening 302 formed through the peripheral side of the midsole chassis 206 on the medial side 22 to a lateral forefoot opening 304 formed through the peripheral side of the midsole chassis 206 on the lateral side 24. The heel cushion pocket 300 extends from a medial heel opening 306 formed through the peripheral side of the midsole chassis 206 on the medial side 22 to a lateral heel opening 308 formed through the peripheral side of the midsole chassis 206 on the lateral side 24. Thus, when the sole structure 200 is assembled, the interior cushioning elements 208, 210 are exposed along the medial side 22 and the lateral side 24 through each of the openings 302, 304, 306, 308.

As shown in FIG. 9, the anterior and posterior walls of the cushion pockets 298, 300 are spaced apart from the corresponding ends of the respective interior cushioning elements 212, 214. Accordingly, the outer peripheries of the interior cushioning elements 212, 214 are unconstrained within the cushion pockets 298, 300, whereby the cushioning elements 212, 214 are free to expand in the lateral direction through the respective openings 302, 304, 306, 308 and are free to expand in the longitudinal direction within the space provided adjacent to the anterior and posterior walls of the cushion pockets 298, 300.

Referring to FIGS. 4-6, the lower cushioning element 208 further includes a pair of apertures 310, 312 that extend through a thickness of the lower cushioning element 208 from the bottom side 266 to the upper side 264. The apertures 310, 312 include a forefoot aperture 310 defined by a forefoot aperture wall 316 extending continuously from the bottom side 266 and through the lower channel wall 278 of the lower forefoot channel 272. Referring to FIG. 7, a width W₃₁₀ of the forefoot aperture 310 is defined by opposing straight side portions of the forefoot aperture wall 316, which converge with each other along a direction from the bottom side 266 to the lower channel wall 278. Referring to FIG. 9, opposing end portions of the forefoot aperture wall 316 are convex and provide the forefoot aperture 310 with a tapering length along a direction from the bottom side 266 to the lower channel wall 288. As shown in FIG. 4, the lower cushioning element 210 may include a forefoot barrier element socket 314 formed around the forefoot aperture 310 in the lower channel wall 278. The forefoot barrier element socket 314 is recessed from the lower channel wall 278 and provides a receptacle for supporting the forefoot barrier element 216 within the forefoot pocket 298. Particularly, the forefoot barrier element socket 314 is configured to receive the forefoot barrier element 216 such that an upper surface associated with the top side 330 of the forefoot barrier element 216 is flush with the lower channel wall 278 to provide a continuous support bed surface for the forefoot interior cushioning element 212.

The apertures 310, 312 further include a heel aperture 312 defined by a heel aperture wall 320 extending continuously from the bottom side 266 and through the lower channel wall 288 of the lower heel channel 282. Referring to FIG. 8, a width W₃₁₂ of the heel aperture 312 is defined by opposing straight side portions of the heel aperture wall 320, which converge with each other along a direction from the bottom side 266 to the lower channel wall 288. Referring to FIG. 9, opposing end portions of the heel aperture wall 320 are convex and provide the heel aperture 312 with a tapering length along a direction from the bottom side 266 to the lower channel wall 288. As shown in FIG. 4, the lower cushioning element 210 may include a heel barrier element socket 318 formed around the heel aperture 312 in the lower channel wall 288. The heel barrier element socket 318 is recessed from the lower channel wall 288 and provides a receptacle for supporting the heel barrier element 218 within the heel pocket 300. Particularly, the heel barrier element socket 318 is configured to receive the heel barrier element 218 such that an upper surface associated with a top side 334 of the heel barrier element 218 is flush with the lower channel wall 288 to provide a continuous support bed surface for the heel interior cushioning element 214.

Referring to FIGS. 5 and 6, the lower cushioning element 210 includes an elongate bottom channel 322 extending along the direction of the longitudinal axis A₁₀ on the bottom side 266. The channel 322 extends continuously from a posterior side of the forefoot aperture wall 316 to the second end 262 of the lower cushioning element. Thus, an intermediate portion of the bottom channel 322 intersects and is interrupted by the heel aperture 312. In other words, a first portion of the bottom channel 322 extends between the forefoot aperture wall 316 and the heel aperture wall 320 and a second portion of the bottom channel 322 extends between the heel aperture wall 320 and the second end 262 of the lower cushioning element 210.

The upper cushioning element 208 and the lower cushioning element 210 may include a resilient polymeric material, such as foam or rubber, to impart properties of cushioning, responsiveness, and energy distribution to the foot of the wearer. Example resilient polymeric materials for cushioning elements 208, 210 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 for barrier layers 404, 406, 430, 432. 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.

The barrier elements 216, 218 include a forefoot barrier element 216 configured to be received within the forefoot barrier element socket 314 and a heel barrier element 218 configured to be received within the heel barrier element socket 318. The barrier elements 216, 218 may include thermoplastic polyurethane (TPU) copolymers. Optionally, the barrier elements 216, 218 may be light transmissive (e.g., translucent, transparent) to provide visibility of the interior cushioning elements 212, 214 through the apertures 310, 312. The forefoot barrier element 216 includes a top side 330 and opposite bottom side 332. When assembled within the sole structure 200, the bottom side 332 mates with the forefoot barrier element socket 314 and the top side 330 is flush with the lower channel wall 278 to provide a continuous support surface for the forefoot interior cushioning element 212 within the lower forefoot channel 272. Similarly, the heel barrier element 218 includes a top side 334 and opposite bottom side 336. When assembled within the sole structure 200, the bottom side 336 mates with the heel barrier element socket 318 and the top side 334 is flush with the lower channel wall 288 to provide a continuous support surface for the heel interior cushioning element 214 within the lower forefoot channel 282.

With reference to FIGS. 4-9, the interior cushioning elements 212, 214 include a forefoot interior cushioning element 212 disposed within the forefoot pocket 298 and a heel interior cushioning element 214 disposed within the heel pocket 300. In the illustrated example, each of the interior cushioning elements 212, 214 is embodied as a fluid-filled bladder disposed within a respective one of the pockets 298, 300, adjacent to the barrier elements 216, 218.

Turning to FIGS. 4-7, the forefoot interior cushioning element 212 includes an opposing pair of barrier layers 404, 406, which can be joined to each other at discrete locations to define a peripheral seam 408, a central weld 410, and a pair of chambers 412, 414. In the shown example, the barrier layers 404, 406 include a first, upper barrier layer 404 and a second, lower barrier layer 406. Alternatively, the forefoot interior cushioning element 212 can be produced from any suitable combination of one or more barrier layers.

In some implementations, the upper barrier layer 404 and the lower barrier layer 406 cooperate to define a geometry (e.g., thicknesses, width, and lengths) of the fluid-filled chambers 412, 414. For example, the weld 410 and the peripheral seam 408 may cooperate to bound and extend around the fluid-filled chambers 412, 414 to seal the fluid (e.g., air) within the fluid-filled chambers 412, 414. Thus, each of the fluid-filled chambers 412, 414 is associated with an area of the forefoot interior cushioning element 212 where interior surfaces of the upper and lower barrier layers 404, 406 are not joined together and, thus, are separated from one another.

With particular reference to FIGS. 4, 5, and 7, the forefoot interior cushioning element 212 is shown to include a medial chamber 412 and a lateral chamber 414. The medial chamber 412 is disposed proximate to the medial side 22 of the sole structure 200 while the lateral chamber 414 is disposed proximate to the lateral side 24 of the sole structure 200. The medial chamber 412 is physically and fluidly separated from the lateral chamber by the weld 410, where the barrier layers 404, 404 are attached one another. As best shown in FIG. 7, a distance or width measured across the medial chamber 412 from the peripheral seam 408 to the weld 410 is greater than a distance or width measured across the lateral chamber 414 from the peripheral seam 408 to the weld 410. In other words, the weld 410 is offset towards the lateral side 24 relative to the longitudinal axis A₁₀ of the article of footwear 10. The weld 410 is elongate and extends continuously along the length of the forefoot interior cushioning element 212, substantially parallel to the longitudinal axis A₁₀ of the article of footwear 10.

Providing the forefoot interior cushioning element 212 with a weld 410 that extends substantially parallel to a longitudinal axis A₁₀ of the article of footwear 10 allows the forefoot interior cushioning element 212 to more easily bend during turning movements (i.e., when making a turning or cutting movement). Thus, the weld 410 provides a longitudinal flex joint extending between the chambers 412, 414, which allows the chambers 412, 414 to articulate relative to each other. Further, offsetting the weld 410 from the center of the sole structure 200 causes the medial chamber 412 to be larger than the lateral chamber 414, thereby providing more cushion to a wearer's foot during movements in the medial direction.

The interior voids of the medial chamber 412 and the lateral chamber 414 may each receive a respective tensile element 416 therein. Each tensile element 416 may include a series of tensile strands 418 extending between an upper tensile sheet 420 and a lower tensile sheet 422. The upper tensile sheet 420 may be attached to the upper barrier layer 404 while the lower tensile sheet 422 may be attached to the lower barrier layer 406. In this manner, when the medial chamber 412 and the lateral chamber 414 receive a pressurized fluid, the tensile strands 418 of the tensile elements 416 are placed in tension. Because the upper tensile sheet 420 is attached to the upper barrier layer 404 and the lower tensile sheet 422 is attached to the lower barrier layer 406, the tensile strands 418 retain a desired shape of the medial chamber 412 and a desired shape of the lateral chamber 414 when the pressurized fluid is injected into the interior voids.

With continued reference to FIG. 8, the heel interior cushioning element 214 likewise includes an upper barrier layer 430 and a lower barrier layer 432 joined together along a peripheral seam 434 and a central weld 436 to form a medial heel chamber 438 and a lateral heel chamber 440. Similar to the forefoot interior cushioning element 214, the heel interior cushioning element 214 is formed such that a width or distance across the medial heel chamber 438 from the peripheral seam 434 to the weld 436 is greater than a width or distance across the lateral chamber 440 from the peripheral seam 434 to the weld 436. In other words, the weld 436 of the heel interior cushioning element 214 is offset towards the lateral side 24 relative to the longitudinal axis A₁₀ of the article of footwear. The weld 436 provides a flex joint between the chambers 438, 440 to permit the chambers 438, 440 to articulate relative to each other within the heel cushion pocket 300. The chambers 438, 440 of the heel interior cushioning element 214 each include respective tensile elements 442 constructed of tensile strands 444 and tensile sheets 446, 448 in substantially the same manner as discussed above with respect to the tensile elements 416 of the forefoot interior cushioning element.

As used herein, the term “barrier layer” (e.g., barrier layers 404, 406, 430, 432) encompasses both monolayer and multilayer films. In some embodiments, one or more of barrier layers 404, 406, 430, 432 is produced (e.g., thermoformed or blow molded) from a monolayer film (a single layer). In other embodiments, one or more of barrier layers 404, 406, 430, 432 is 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 404, 406, 430, 432 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 404, 406, 430, 432 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′-dimethyldiphenyl-4,4′-diisocyanate (DDDI), 4,4′-dibenzyl diisocyanate (DBDI), 4-chloro-1,3-phenylene diisocyanate, and combinations thereof. In some embodiments, the copolymer chains are substantially free of aromatic groups.

In particular aspects, the polyurethane polymer chains are produced from diisocynates including HMDI, TDI, MDI, H12 aliphatics, and combinations thereof. In an aspect, the thermoplastic TPU 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 404, 406, 430, 432 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 404, 406, 430, 432 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 404, 406, 430, 432 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 404, 406, 430, 432 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 interior cushioning elements 208, 210 can be produced from the barrier layers 404, 406, 430, 432 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 404, 406, 430, 432 can be produced by co-extrusion followed by vacuum thermoforming to produce inflatable chambers 412, 414, which can optionally include one or more valves (e.g., one way valves) that allows the chambers 412, 414 to be filled with the fluid (e.g., gas).

The interior cushioning elements 208, 210 can be provided in a fluid-filled (e.g., as provided in footwear 10) or in an unfilled state. The chambers 412, 414, 438, 440 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 412, 414, 438, 440 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 412, 414, 438, 440 can result in the chambers 412, 414, 438, 440 being pressurized. Alternatively, the fluid provided to the chambers 412, 414, 438, 440 can be at atmospheric pressure such that the chambers 412, 414, 438, 440 is not pressurized but, rather, simply contains a volume of fluid at atmospheric pressure.

The fluid-filled chambers 412, 414, 438, 440 desirably have a low gas transmission rate to preserve its retained gas pressure. In some embodiments, the fluid-filled chambers 412, 414, 438, 440 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 412, 414, 438, 440 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 404, 406, 430, 432). 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.

Referring to FIGS. 5-9, the outsole 204 is attached to the bottom side 266 of the lower cushioning element 210 and includes a forefoot outsole aperture 340 corresponding to and exposing the forefoot aperture 310 of the lower cushioning element 210, a heel outsole aperture 342 corresponding to and exposing the heel aperture 312 of the lower cushioning element 210, and an outsole slot corresponding to and exposing the bottom channel 322 of the lower cushioning element 210. Thus, when assembled, the outsole 204 cooperates with the lower cushioning element 210 to permit the lower cushioning element 210 to articulate around the interior cushioning elements 212, 214 during lateral movements.

The following Clauses provide an exemplary configuration for a sole structure for an article of footwear described above.

Clause 1. A sole structure for an article of footwear, the sole structure comprising a midsole chassis including a first side defining a footbed, a second side disposed on an opposite side from the first side, a first pocket formed within the midsole chassis between the first side and the second side, and a first aperture extending between the second side and the first pocket. A first interior cushioning element is disposed in the first pocket of the midsole chassis and a first barrier element is disposed within the first pocket of the midsole chassis between the first interior cushioning element and the first aperture.

Clause 2. The sole structure of any of the preceding Clauses, wherein the midsole chassis further includes a second pocket formed within the midsole chassis between the first side and the second side, and a second aperture extending between the second side and the second pocket, the sole structure further comprising: a second interior cushioning element disposed within the second pocket of the midsole chassis and a second barrier element disposed within the second pocket of the midsole chassis between the second interior cushioning element and the second aperture.

Clause 3. The sole structure of Clause 2, wherein the first pocket is disposed in one of a forefoot region of the sole structure or a heel region of the sole structure and the second pocket is disposed in the other of the forefoot region of the sole structure or the heel region of the sole structure.

Clause 4. The sole structure of any of the preceding Clauses, wherein the first interior cushioning element includes a first chamber disposed on a medial side of the sole structure and second chamber disposed on a lateral side of the sole structure.

Clause 5. The sole structure of Clause 4, wherein the first chamber is separated from the second chamber by a flex joint extending along a direction of a longitudinal axis of the sole structure.

Clause 6. The sole structure of any of the preceding Clauses, wherein the first aperture extends continuously from the second side of the midsole chassis to the first pocket and the first barrier element is exposed through the aperture.

Clause 7. The sole structure of any of the preceding Clauses, wherein the first pocket extends continuously from a medial side of the sole structure to a lateral side of the sole structure.

Clause 8. The sole structure of any of the preceding Clauses, wherein the first interior cushioning element is a bladder having a first barrier layer joined to a second barrier layer to define a chamber.

Clause 9. The sole structure of Clause 8, wherein the first barrier element is disposed adjacent to the first barrier layer of the bladder.

Clause 10. The sole structure of any of the preceding Clauses, wherein the first barrier element comprises a light-transmissive material.

Clause 11. A sole structure for an article of footwear, the sole structure comprising a lower cushioning element including a first side defining a cushion support bed, a second side disposed on an opposite side from the first side, a first channel defined by the cushion support bed on the first side, and a first aperture extending between the second side and the first channel. A first interior cushioning element is disposed in the first channel of the lower cushioning element and a first barrier element is disposed within the first channel of the lower cushioning element between the first interior cushioning element and the first aperture.

Clause 12. The sole structure of any of the preceding Clauses, wherein the lower cushioning element further includes a second channel defined by the cushion support bed on the first side, and a second aperture extending between the second side and the second channel, the sole structure further comprising: a second interior cushioning element disposed within the second channel of the lower cushioning element and a second barrier element disposed within the second channel of the lower cushioning element between the second interior cushioning element and the second aperture.

Clause 13. The sole structure of Clause 12, wherein the first channel is disposed in one of a forefoot region of the sole structure or a heel region of the sole structure and the second channel is disposed in the other of the forefoot region of the sole structure or the heel region of the sole structure.

Clause 14. The sole structure of any of the preceding Clauses, wherein the first interior cushioning element includes a first chamber disposed on a medial side of the sole structure and second chamber disposed on a lateral side of the sole structure.

Clause 15. The sole structure of Clause 14, wherein the first chamber is separated from the second chamber by a flex joint extending along a direction of a longitudinal axis of the sole structure.

Clause 16. The sole structure of any of the preceding Clauses, wherein the first aperture extends continuously from the second side of the lower cushioning element to the cushion support bed and the first barrier element is exposed through the aperture.

Clause 17. The sole structure of any of the preceding Clauses, wherein the first channel extends continuously from a medial side of the sole structure to a lateral side of the sole structure.

Clause 18. The sole structure of any of the preceding Clauses, wherein the first interior cushioning element is a bladder having a first barrier layer joined to a second barrier layer to define a chamber.

Clause 19. The sole structure of Clause 18, wherein the first barrier element is disposed adjacent to the first barrier layer of the bladder.

Clause 20. A sole structure for an article of footwear, the sole structure comprising an upper cushioning element including a first superior side defining a footbed, a first inferior side disposed on an opposite side from the first superior side, and a first channel defined by the first inferior side. A lower cushioning element includes a second superior side defining a cushion support bed, a second inferior side disposed on an opposite side from the second superior side, a second channel defined by the cushion support bed and cooperating with the first channel to define a pocket, and an aperture extending between the second inferior side and the pocket. An interior cushioning element is disposed in the pocket and a first barrier element is disposed within the second channel of the lower cushioning element between the interior cushioning element and the aperture.

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.