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. 63/701,157, filed on Sep. 30, 2024. The disclosure of this prior application is considered part of the disclosure of this application and is hereby incorporated by reference in its entirety.

FIELD

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

BACKGROUND

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

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

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

While known 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 a sole structure that balances cushioning and responsiveness during walking, running, and side-to-side movements made during athletic activities such as basketball and tennis.

DRAWINGS

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

FIG. 1 is a perspective view of an article of footwear in accordance with the principles of the present disclosure;

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

FIG. 3 is a lateral 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 article of footwear of FIG. 1;

FIG. 6 is a cross-sectional view of the article of footwear of FIG. 1 taken along Line 6-6 of FIG. 1;

FIG. 7 is a cross-sectional view of the article of footwear of FIG. 1 taken along Line 7-7 of FIG. 1;

FIG. 8 is a perspective view of an article of footwear in accordance with the principles of the present disclosure;

FIG. 9 is a medial side view of the article of footwear of FIG. 8;

FIG. 10 is a lateral side view of the article of footwear of FIG. 8;

FIG. 11 is a top exploded view of the article of footwear of FIG. 8;

FIG. 12 is a bottom exploded view of the article of footwear of FIG. 8;

FIG. 13 is a cross-sectional view of the article of footwear of FIG. 8 taken along Line 13-13 of FIG. 8;

FIG. 14 is a perspective view of an article of footwear in accordance with the principles of the present disclosure;

FIG. 15 is a medial side view of the article of footwear of FIG. 14;

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

FIG. 17 is a top exploded view of the article of footwear of FIG. 14;

FIG. 18 is a bottom exploded view of the article of footwear of FIG. 14; and

FIG. 19 is a cross-sectional view of the article of footwear of FIG. 14 taken along Line 19-19 of FIG. 14.

Corresponding reference numerals indicate corresponding parts throughout the drawings.

DETAILED DESCRIPTION

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

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

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

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

In one configuration, a sole structure for an article of footwear includes a midsole having a first midsole surface opposing an upper of the article of footwear, a second midsole surface formed on an opposite side of the midsole than the first midsole surface, and an aperture formed through the midsole and extending between the first midsole surface and the second midsole surface, the midsole including a first thickness at the aperture. A fluid-filled chamber is received within the aperture and includes a second thickness, the second thickness substantially equal to the first thickness.

The sole structure may include one or more of the following optional features. For example, the fluid-filled chamber may include a first barrier defining a first barrier surface and a second barrier defining a second barrier surface, the first barrier surface being substantially flush with the first midsole surface and the second barrier surface being substantially flush with the second midsole surface.

The aperture may be disposed in a forefoot region of the sole structure. The aperture may be formed through a majority of the forefoot region of the sole structure.

In one configuration, the aperture may be defined by a wall of the midsole extending between the first midsole surface and the second midsole surface, the wall including a groove. A portion of the fluid-filled chamber may be received within the groove. For example, the fluid-filled chamber may include a peripheral seam extending around a perimeter of the fluid-filled chamber, the peripheral seam received within the groove.

The fluid-filled chamber may pressurized. Further, the fluid-filled chamber may include a tensile member.

An article of footwear may incorporate the sole structure.

In another configuration, an article of footwear includes an upper and a midsole attached to the upper, the midsole including a first midsole surface opposing the upper, a second midsole surface formed on an opposite side of the midsole than the first midsole surface, and an aperture formed through the midsole and extending between the first midsole surface and the second midsole surface. The article of footwear also includes a fluid-filled chamber received within the aperture and including a first barrier defining a first barrier surface and a second barrier defining a second barrier surface on an opposite side of the fluid-filled chamber than the first barrier surface, the first barrier surface being attached to the upper.

The article of footwear may include one or more of the following optional features. For example, the upper may include a strobel defining a footbed of the article of footwear. In this configuration, the first barrier surface may be attached to the strobel on an opposite side of the strobel than the footbed.

A lower portion of the upper may oppose the first midsole surface. The first barrier surface may be attached to the lower portion of the upper adjacent to the first midsole surface.

In one configuration, the aperture may be defined by a wall of the midsole extending between the first midsole surface and the second midsole surface, the wall including a groove. A portion of the fluid-filled chamber may be received within the groove. The fluid-filled chamber may include a peripheral seam extending around a perimeter of the fluid-filled chamber, the peripheral seam received within the groove.

An outsole may define a ground-engaging surface of the article of footwear, the second barrier surface being attached to the outsole on an opposite side of the outsole than the ground-engaging surface.

The fluid-filled chamber may be pressurized. Further, the fluid-filled chamber may include a tensile member.

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.

With reference to FIGS. 1-6, an article of footwear 10 includes a sole structure 100 and an upper 200 attached to the sole structure 100. The footwear 10 and, thus, the sole structure 100, may further include an anterior end 12 associated with a forward-most point of the footwear 10, and a posterior end 14 corresponding to a rearward-most point of the footwear 10. As shown in FIG. 2, a longitudinal axis A₁₀ of the footwear 10 extends along a length of the footwear 10 from the anterior end 12 to the posterior end 14 parallel to a ground surface, and generally divides the footwear 10 and the sole structure 100 into a medial side 16 and a lateral side 18. Accordingly, the medial side 16 and the lateral side 18 respectively correspond with opposite sides of the footwear 10 and extend from the anterior end 12 to the posterior end 14. As used herein, a longitudinal direction refers to the direction extending from the anterior end 12 to the posterior end 14, while a lateral direction refers to the direction transverse to the longitudinal direction and extending from the medial side 16 to the lateral side 18.

The article of footwear 10 may be divided into one or more regions. The regions may include a forefoot region 20, a mid-foot region 22, and a heel region 24. The forefoot region 20 may be subdivided into a toe portion 20_T corresponding with phalanges and a ball portion 20_B associated with metatarsal bones of a foot. The mid-foot region 22 may correspond with an arch area of the foot, and the heel region 24 may correspond with rear portions of the foot, including a calcaneus bone.

The article of footwear 10, and more particularly, the sole structure 100, may be further described as including a peripheral region 26 and an interior region 28, as indicated in FIG. 7. The peripheral region 26 is generally described as defining an outer perimeter of the sole structure 100. Particularly, the peripheral region 26 extends from the forefoot region 20 to the heel region 24 along each of the medial side 16 and the lateral side 18 and wraps around each of the forefoot region 20 and the heel region 24. The interior region 28 is circumscribed by the peripheral region 26 and extends from the forefoot region 20 to the heel region 24 along a central portion of the sole structure 100. Accordingly, each of the forefoot region 20, the mid-foot region 22, and the heel region 24 may be described as including the peripheral region 26 and the interior region 28.

The upper 200 forms an enclosure defining an interior void 30 and an ankle opening 32, which cooperate to receive and secure a foot for support on the sole structure 100. The upper 200 may be formed from one or more materials that are stitched or adhesively bonded together to define the interior void 30. Suitable materials of the upper 200 may include, but are not limited to, textiles, foam, leather, and synthetic leather. The example upper 200 may be formed from a combination of one or more substantially inelastic or non-stretchable materials and one or more substantially elastic or stretchable materials disposed in different regions of the upper 200 to facilitate movement of the article of footwear 10 between the tightened state and the loosened state. The one or more elastic materials may include any combination of one or more elastic fabrics such as, without limitation, spandex, elastane, rubber or neoprene. The one or more inelastic materials may include any combination of one or more of thermoplastic polyurethanes, nylon, leather, vinyl, or another material/fabric that does not impart properties of elasticity.

The sole structure 100 is attached to the upper 200 and includes a midsole 34, an outsole 36, and a fluid-filled chamber 38 disposed within the midsole 34. In one configuration, a strobel 40 of the upper 200 extends between the upper 200 and the midsole 34 and serves as an interface between the upper 200 and the midsole 34. In another configuration, a material forming the upper 200 extends between the upper 200 and the midsole 34 and likewise serves as an interface between the upper 200 and the midsole 34. The strobel or the portion of the upper 200 extending between the midsole 34 and the upper 200 serves as a footbed and may receive an insole or sockliner (not shown) within the interior void 30 to provide a cushioned foot-receiving surface within the interior void 30 of the upper 200.

The midsole 34 extends from the anterior end 12 to the posterior end 14 and between the medial side 16 and the lateral side 18. The midsole 34 includes a top surface 42 opposing the upper 200 and a bottom surface 44 disposed on an opposite side of the midsole 34 then the top surface 42. The top surface 42 includes a recess 46 defined by a flange 48 extending around a perimeter of the midsole 34. The recess 46 may cooperate with the upper 200 and the insole to define a footbed of the article of footwear 10. The flange 48 extends substantially uninterrupted around a perimeter of the midsole 34 from the medial side 16 to the lateral side 18. The bottom surface 44 is attached to the outsole 36 and is substantially planar from the forefoot region 20 to the heel region 24.

As shown in FIGS. 4 and 5, an aperture 50 is formed through a thickness of the midsole 34. Specifically, the aperture 50 extends from the top surface 42 of the midsole 34 to the bottom surface 44 of the midsole 34. As shown, the aperture 50 includes a substantially rectangular shape at both the top surface 42 and the bottom surface 44. The aperture 50 is disposed in the forefoot region 20 and is formed through a majority of the forefoot region 20.

The aperture 50 is defined by walls 52 of the midsole 34 that extend from the top surface 42 to the bottom surface 44. The walls 52 may define a groove 54 (FIG. 6) that receives a portion of the fluid-filled chamber 38 therein, as will be described in more detail below. The groove 54 may extend around an entire perimeter of the aperture 50 and may include a first substantially planar wall 56 joined at an apex 58 to another substantially planar wall 60. The walls 56, 60 may be formed at an angle relative to one another to define the overall shape of the groove 54. As shown in FIG. 6, the apex 58 extends into a thickness of the midsole 34 and defines a forwardmost and rearward-most point of the aperture 50 along the longitudinal axis A₁₀ of the sole structure 100. Specifically, the aperture 50 extends in a direction toward the anterior end 12 to the greatest extent at the apex 58 and extends in a direction toward the posterior end 14 to the greatest extent at the apex 58. Similarly, and as shown in FIG. 7, the aperture 50 extends in a direction toward the medial side 16 to the greatest extent at the apex 58 and extends in a direction toward the lateral side 18 to the greatest extent at the apex 58. Finally, the top surface 42 may include a series of cutouts 62 having a substantially triangular shape. The cutouts 62 allow a material of the midsole 34 to flex and move proximate to an opening of the aperture 50 at the top surface 42. The cutouts 62 inhibit the material of the midsole 34 from tearing when the midsole 34 flexes and moves during wear.

In one configuration, the midsole 34 is formed from a resilient polymeric material such as foam. Example resilient polymeric materials for the midsole 34 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., crosslinked polyurethanes and/or thermoplastic polyurethanes). Examples of suitable polyurethanes include those discussed below with respect to the cushion assembly 34. 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.

With particular reference to FIGS. 4 and 5, the outsole 36 is shown as including an upper surface 64 opposing the midsole 34 and a lower surface 66 disposed on an opposite side of the outsole 36 than the upper surface 64 and defining a ground-engaging surface 68 of the article of footwear 10. The upper surface 64 may include a rib 70 extending from the upper surface 64 in a direction toward the midsole 34. The rib 70 defines a closed loop and is wider in the forefoot region 20 that in the heel region 24 to allow the rib 70 to accommodate and engage the fluid-filled chamber 38 (FIG. 7). In one configuration, an apex of the rib 70 includes an arcuate surface 72 that opposes and contacts the fluid-filled chamber 38.

The outsole 36 additionally includes a flange 74 extending around a perimeter of the outsole 36 in a direction away from the upper surface 64. The flange 74 provides the outsole 36 with a substantially concave shape at the upper surface 64 and includes an anterior flange portion 76 disposed at the anterior end 12, a posterior flange portion 78 disposed at the posterior end 14, a medial flange portion 80 disposed at the medial side 16, and a lateral flange portion 82 disposed at the lateral side 18. As shown in FIG. 4, the medial flange portion 80 and the lateral flange portion 82 extend from the upper surface 64 to a lesser extent than the anterior flange portion 76 and the posterior flange portion 78 while the anterior flange portion 76 extends from the upper surface 64 to a lesser extent than the posterior flange portion 78. Each of the flange portions 76, 78, 80, 82 extends onto an outer perimeter surface 84 of the midsole 34, as shown in FIGS. 2 and 3.

The outsole 36 may additionally include a tread pattern 86 that provides traction with a ground surface. The tread pattern 86 may extend from the anterior end 12 to the posterior end 14 and from the medial side 16 to the lateral side 18. The outsole 36 may be formed from rubber or any suitable material that provides the ground-engaging surface 68 with traction and durability. Further, the outsole 36 may be opaque, translucent, or transparent. Forming the outsole 36 to be translucent or transparent allows the midsole 34 and fluid-filled chamber 38 to be visible at the ground-engaging surface 68.

With reference to FIGS. 4-7, the fluid-filled chamber 38 is shown as being received within the aperture 50 of the midsole within the forefoot region 20 and includes a first barrier element or layer 88 cooperating with a second barrier element or layer 90 to define an interior void 92. Specifically, the first barrier element 88 is joined to the second barrier element 90 at a peripheral seam 94 to define an outer perimeter of the fluid-filled chamber 38.

As used herein, the term “barrier layer” (e.g., barrier layers 88, 90) encompasses both monolayer and multilayer films. In some embodiments, one or both of barrier layers the 88, 90 are each produced (e.g., thermoformed or blow molded) from a monolayer film (a single layer). In other embodiments, one or both of the barrier layers 88, 90 are each produced (e.g., thermoformed or blow molded) from a multilayer film (multiple sublayers). In either aspect, each layer or sublayer can have a film thickness ranging from about 0.2 micrometers to about 1 millimeter. In further embodiments, the film thickness for each layer or sublayer can range from about 0.5 micrometers to about 500 micrometers. In yet further embodiments, the film thickness for each layer or sublayer can range from about 1 micrometer to about 100 micrometers.

One or both of the barrier layers 88, 90 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 88, 90 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′-dimethyldipheny1-4, 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 88, 90 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 88, 90 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 88, 90 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 88, 90 includes at least four (4) sublayers, at least ten (10) sublayers, at least twenty (20) sublayers, at least forty (40) sublayers, and/or at least sixty (60) sublayers.

The fluid-filled chamber 38 can be produced from the barrier layers 88, 90 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 88, 90 can be produced by co-extrusion followed by vacuum thermoforming to produce an inflatable chamber 38, which can optionally include one or more valves (e.g., one way valves) that allows the chamber 38 to be filled with the fluid (e.g., gas).

The chamber 38 can be provided in a fluid-filled (e.g., as provided in footwear 10) or in an unfilled state. The chamber 38 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 38 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 38 can result in the chamber 38 being pressurized. Alternatively, the fluid provided to the chamber 38 can be at atmospheric pressure such that the chamber 38 is not pressurized but, rather, simply contains a volume of fluid at atmospheric pressure.

The fluid-filled chamber 38 desirably has a low gas transmission rate to preserve its retained gas pressure. In some embodiments, the fluid-filled chamber 38 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, fluid-filled chamber 38 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 88, 90). 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. 4 and 5, the fluid-filled chamber 38 may include one or more welds 95 that join a material of the first barrier layer 88 and a material of the second barrier layer 90 in a similar fashion as at the peripheral seam 94. Joining the layers 88, 90 at discrete locations provides the fluid-filled chamber 38 with a first segment 96, a second segment 98, and a third segment 99. The segments 96, 98, 99 may be in fluid communication with one another or may be fluidly isolated from one another. If the welds 95 extend along an entire length of the fluid-filled chamber 38 between opposing sides of the peripheral seam 94, the segments 96, 98, 99 are fluidly isolated from one another. If the welds 95 are only localized and found at discrete locations, as shown in the figures, the segments 96, 98, 99 are not isolated from one another and, as such, are in fluid communication.

As shown, the segments 96, 98, 99 are substantially parallel to one another and each includes a longitudinal axis that extends in a direction between the medial side 16 and the lateral side 18 substantially perpendicular to the longitudinal axis A₁₀. While the fluid-filled chamber 38 is described and shown as including segments 96, 98, 99, the fluid-filled chamber 38 could alternatively be free from welds 95 in an area bound by the peripheral seam 94. Such a fluid-filled chamber 38 would have a substantially planar top surface and a substantially planar bottom surface in place of the individual segments 96, 98, 99.

The interior void 92 of the first barrier element 88 and the second barrier element 90 may receive one or more tensile elements 102 therein. The tensile elements 102 may each include a series of tensile strands 104 extending between an upper tensile sheet 106 and a lower tensile sheet 108. The upper tensile sheet 106 may be attached to the first barrier element 88 while the lower tensile sheet 108 may be attached to the second barrier element 90. In this manner, when the fluid-filled chamber 38 receives a pressurized fluid, the tensile strands 104 of the tensile element(s) 102 are placed in tension. Because the upper tensile sheet 106 is attached to the first barrier element 88 and the lower tensile sheet 108 is attached to the second barrier element 90, the tensile strands 104 retain a desired shape of the fluid-filled chamber 38 when the pressurized fluid is injected into the interior void 92.

As shown in the figures, the fluid-filled chamber 38 includes segments 96, 98, 99 that each receives a tensile element 102 therein. The tensile elements 102 of the segments 96, 98, 99 are spaced apart and separated from one another in an area of the welds 95, as shown in FIG. 6. If the fluid-filled chamber 38 is free from welds 95 and instead includes a substantially planar top surface and a substantially planar bottom surface, the interior void 92 could receive individual tensile elements 102 that are spaced apart and separated from one another or, alternatively, could include a single tensile element 102 that spans a majority of the interior void 92. Finally, if the fluid-filled chamber 38 receives more than one tensile element 102, the tensile elements 102 could all be identical or, alternatively, could include different widths depending on the size of the individual segments 96, 98, 99.

With particular reference to FIGS. 4-7, the fluid-filled chamber 38 is shown as being received within the aperture 50 of the midsole 34. When positioned within the aperture 50, a portion of the fluid-filled chamber 38 is received within the groove 54 of the walls 52 defining the aperture 50. Specifically, the peripheral seam 94 is disposed within the groove 54 and is substantially aligned with the apex 58 of the groove 54. Accordingly, cooperation between the peripheral seam 94 and the groove 54 helps retain and properly position the fluid-filled chamber 38 relative to and within the aperture 50.

The fluid-filled chamber 38 is attached to the strobel 40 at the first barrier element 88 and is attached to the upper surface 64 of the outsole 36 at the second barrier element 90. Specifically, the first barrier element 88 is attached to the strobel 40 by a suitable adhesive while the second barrier element 90 is attached to the ribs 70 at the arcuate surface 72 of each rib 70 by a suitable adhesive (FIG. 7). As such, a portion of the second barrier element 90 is spaced apart from the upper surface 64 of the outsole 36 by a gap 110. Once installed, a top surface of the fluid-filled chamber 38 is substantially flush with the top surface 42 of the midsole 34 and a bottom surface of the fluid-filled chamber 38 is substantially flush with the bottom surface 44 of the midsole 34.

While the fluid-filled chamber 38 is described and shown as being retained within the aperture 50 due to interaction between the peripheral seam 94 and the groove 54, the fluid-filled chamber 38 is not fixed for movement with the midsole 34 at the aperture 50 or otherwise. Namely, the fluid-filled chamber 38 is permitted to “float” or otherwise move within the aperture 50 relative to the midsole 34. As such, when a force is applied to the midsole 34 and the fluid-filled chamber 38, the fluid-filled chamber 38 is able to splay and move relative to the midsole 34 within the aperture 50. For example, when a downward force is applied to the fluid-filled chamber 38, the fluid-filled chamber 38 will expand in an outward direction toward the walls 52 of the midsole 34 defining the aperture 50. Because the fluid-filled chamber 38 is spaced apart from the planar walls 56, 60 of the groove 54 at a rest state (i.e., when not subjected to a load) by a gap 112, a clearance is provided that allows the fluid-filled chamber 38 to expand and at least partially fill the gap 112 without engaging a material of the midsole 34. Engaging a material of the midsole 34 would inhibit expansion of the fluid-filled chamber 38, thereby increasing the resistance to the applied load and changing the performance characteristics of the sole structure 100. In short, constricting the fluid-filled chamber 38 from freely splaying in response to an applied load produces a more rigid response and, as a result, provides a less-cushioned feel underfoot.

With particular reference to FIGS. 8-13 an article of footwear 10a is provided and includes a sole structure 100a and an upper 200 attached to the sole structure 100a. 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.

The sole structure 100a includes the fluid-filled chamber 38 disposed within the aperture 50 of the midsole 34a and additionally includes a fluid-filled chamber 114 located in the heel region 24 of the sole structure 100a. As shown in FIGS. 8 and 13, the fluid-filled chamber 114 is spaced apart from the fluid-filled chamber 38 in a direction extending along the longitudinal axis A₁₀ of the sole structure 100a. The fluid-filled chamber 114 may be constructed in the same fashion as the fluid-filled chamber 38 described above including the same materials, processes, and pressures. The fluid-filled chamber 114 only differs from the fluid-filled chamber 38 in size and shape.

The fluid-filled chamber 114 includes a first segment 116, a second segment 118, and a third segment 120 that each extends along a respective longitudinal axis between the medial side 16 and the lateral side 18. As with the segments 96, 98, 99, the segments 116, 118, 120 may be in fluid communication with one another or may be fluidly isolated from one another. These segments 116, 118, 120 may be formed by providing localized welds 95 in areas of the fluid-filled chamber 114 located between the segments 116, 118, 120 in a similar fashion as described above with respect to the fluid-filled chamber 38. Finally, while the fluid-filled chamber 114 is described and shown as including segments 116, 118, 120, the fluid-filled chamber 114 could be free from interior welds 95 such that both a top surface and a bottom surface of the fluid-filled chamber 114 are substantially planar.

The fluid-filled chamber 114 may be formed by barrier layers 88, 90 that are joined at a peripheral seam 122. The peripheral seam 122 extends around and defines a perimeter of the fluid-filled chamber in a similar fashion as the peripheral seam 94. Once the peripheral seam 122 is formed, an interior void 124 is defined and receives a pressurized fluid. Regardless of the shape of the fluid-filled chamber 114, the fluid-filled chamber 114 may receive one or more tensile elements 102 in an identical fashion as the fluid-filled chamber 38 described above.

The fluid-filled chamber 114 is received within a recess 126 formed in the midsole 34a. The recess 126 is disposed in the heel region 24 and is sized and shaped to receive the fluid-filled chamber 114 therein. The recess 126 is defined by walls 128 that terminate at a bottom surface 130. As with the walls 52 of the aperture 50, the walls 128 include a peripheral groove 132 that extends around the recess 126. The peripheral groove 132 receives the peripheral seam 122 of the fluid-filled chamber 114 when the fluid-filled chamber 114 is received within the recess 126. Once the fluid-filled chamber 114 is received within the recess 126, an outer surface of the fluid-filled chamber 114 defined by the first barrier element 88 may be attached to the bottom surface 130 of the recess 126 by a suitable adhesive. Additionally, an outer surface of the fluid-filled chamber 114 defined by the second barrier element 90 may be substantially flush with the bottom surface 44 of the midsole 34a and may be attached to the upper surface 64 of the outsole 36 by a suitable adhesive. Because the outer surface of the fluid-filled chamber 114 defined by the second barrier element 90 is substantially flush with the bottom surface 44 of the midsole 34a when the fluid-filled chamber 114 is attached to the bottom surface 130 of the recess 126, a thickness of the fluid-filled chamber 114 is substantially equal to a depth of the recess 126.

The thickness of the fluid-filled chamber 114 is maintained and controlled by the length of the tensile strands 104 of the tensile elements 102. Namely, when the fluid-filled chamber 114 is pressurized, the barrier elements 88, 90 are forced in opposite directions. The tensile elements 102 prevent the elements 88, 90 from moving away from one another by a greater distance than a length of the tensile strands 104. Accordingly, the thickness of the fluid-filled chamber 114 is controlled by a length of the strands 104. Accordingly, cooperation between the barrier elements and the tensile members 102 ensures that a thickness of the fluid-filled chamber 114 does not exceed a depth of the recess 126 and, as such, ensures that the fluid-filled chamber 114 remains fluish with the bottom surface 44 of the midsole 34a. Finally, the tensile strands 104 of the fluid-filled chamber 114 may be substantially the same or the same length as the tensile strands 104 of the fluid-filled chamber 38, thereby providing the chambers 38, 114 with approximately the same thickness. Providing the chambers 38, 114 with approximately the same or the same thickness likewise requires that a depth of the recess 126 equals a thickness of the midsole 34a at the forefoot region 20 due to the top and bottom surfaces of the chamber 38 being flush with the top and bottom surfaces 42, 44, respectively, of the midsole 34a and the bottom surface of the chamber 114 being substantially flush with the bottom surface 44 of the midsole 34a. While the tensile strands 104 of the fluid-filled chamber 114 may be substantially the same or the same length as the tensile strands 104 of the fluid-filled chamber 38, as shown in the drawings, the recess 126 could be more shallow or deeper than what is illustrated, thereby causing a thickness of the fluid-filled chamber 114 to be increased or decreased such that the thickness of the fluid-filed chamber 114 differs from a thickness of the fluid-filled chamber 38.

As with the fluid-filled chamber 38, the fluid-filled chamber 114 is not attached to the midsole 34a at the peripheral seam 122. Rather, the peripheral seam 122 is permitted to “float” within the groove 132 such that the fluid-filled chamber 114 is permitted to move laterally within the groove 132 relative to the midsole 34a when subjected to a load. For example, when a load is applied to the fluid-filled chamber 114 that causes the chamber 114 to splay outward, the peripheral seam 122 and, thus, the surrounding portions of the barrier elements 88, 90 are permitted to move relative to the midsole 34a within the groove 132. In so doing, the fluid-filled chamber 114 is more easily allowed to splay and expand in response to a load applied thereto during wear.

With particular reference to FIGS. 14-19 an article of footwear 10b is provided and includes a sole structure 100b and an upper 200 attached to the sole structure 100b. In view of the substantial similarity in structure and function of the components associated with the article of footwear 10a with respect to the article of footwear 10b, like reference numerals are used hereinafter and in the drawings to identify like components while like reference numerals containing letter extensions are used to identify those components that have been modified.

As with the article of footwear 10a, the article of footwear 10b includes the fluid-filled chamber 38 located in the aperture 50 within the forefoot region 20 and includes the fluid-filled chamber 114b located in the heel region 24. However, the fluid-filled chamber 114b is not located within a recess in the heel region 24 but, rather, is located within an aperture 134. The aperture 134 is similar to the aperture 50 apart from the size and shape of the aperture 134. Namely, the aperture 134 differs from the aperture 50 in an effort to accommodate the shape of the fluid-filled chamber 114b as well as to accommodate the thickness of the midsole 34b in the heel region 24.

The aperture 134 extends through the thickness of the midsole 34b in the heel region 24 and extends from the top surface 42 to the bottom surface 44. The aperture 134 is defined by walls 136 that extend from the top surface 42 to the bottom surface 44. As with the walls 52, the walls 136 define an annular groove 138 that receives a portion of the fluid-filled chamber 114b therein.

The fluid-filled chamber 114b includes the first barrier layer 88 and the second barrier layer 90. The layers 88, 90 are joined to one another at a periphery of the fluid-filled chamber 114b at a peripheral seam 122. The fluid-filled chamber 114b includes a first segment 116b, a second segment 118b, and a third segment 120b that each extends along a longitudinal axis between the medial side 16 of the sole structure 100b and the lateral side 18 of the sole structure 100b. The segments 116b, 118b, 120b are substantially parallel to one another and are substantially perpendicular to the longitudinal axis A₁₀ of the sole structure 100b. As with the fluid-filled chambers 38, 114, the segments 116b, 118b, 120b may be defined by welds 95 disposed between the segments 116b, 118b, 120b, whereby the welds 95 either extend across the entire width of the chamber 114b between opposing sides of the peripheral seam 122 or are only located at discrete locations. If the welds 95 extend across the entire width of the chamber 114b, the segments 116b, 118b, 120b are fluidly isolated from one another. If the welds 95 are only located at discrete locations, the segments 116b, 118b, 120b are in fluid communication with one another.

When the fluid-filled chamber 114b is installed in the midsole 34b, the chamber 114b is received by and within the aperture 134. The chamber 114b is positioned such that the peripheral seam 122 is received within the groove 138 formed in the walls 136. The peripheral seam 122 is not attached to the walls 136 within the groove 138 but, rather, is permitted to move relative to the midsole 34b within the groove 138 in a similar fashion as the fluid-filled chamber 38.

As shown in FIG. 19, a top surface of the fluid-filled chamber 114b defined by the first barrier element 88 is substantially flush with the top surface 42 of the midsole 34b and a bottom surface of the fluid-filled chamber 114b defined by the second barrier element 90 is substantially flush with the bottom surface of the midsole 34b. As such, and as described above with respect to the fluid-filled chamber 38, a thickness of the fluid-filled chamber 114b is substantially equal to a thickness of the midsole 34b at the aperture 134. As with the fluid-filled chambers 38, 114, the thickness of the fluid-filled chamber 114b may be maintained by providing the fluid-filled chamber 114b with one or more tensile elements 102. The tensile elements 102 are identical to the tensile elements 102 used in conjunction with the fluid-filled chambers 38, 114 except for the height of the tensile strands 104. Namely, because the heel region 24 of the midsole 34b is thicker than the forefoot region 20, the tensile strands 104 associated with the fluid-filled chamber 114b are longer than the tensile strands 104 associated with the fluid-filled chambers 38, 114.

The fluid-filled chamber 114b is attached to the strobel 40 at the first barrier element 88 and is attached to the upper surface 64 of the outsole 36 at the second barrier element 90. As with the fluid-filled chamber 38, the barrier elements 88, 90 may be attached to the strobel 40 and the outsole 36 by a suitable adhesive.

Once installed in the midsole 34b, the fluid-filled chamber 114b acts in a similar fashion as the fluid-filled chamber 38 located in the forefoot region 20. Namely, the fluid-filled chambers 38, 114b are permitted to “float” and move relative to and within the respective apertures 50, 134. Further, a gap 112 exists between the peripheral seam 122 and the surrounding portions of the barrier elements 88, 90 and the walls 56, 60 of the groove 138. Accordingly, when a load is applied to the fluid-filled chamber 114b that causes the chamber 114b to splay and expand, the expanding portions of the chamber 114b substantially fill the gap 112 and do not restrict movement of the chamber 114b relative to and within the aperture 134. As described above with respect to the fluid-filled chamber 38, allowing the chamber 114b to more freely move and expand when subjected to a load allows the chamber 114b to provide better cushioning properties during wear.

The following Clauses provide an exemplary configuration for a method of forming a fluid-filled chamber for an article of footwear described above.

Clause 1. A sole structure for an article of footwear including an upper, the sole structure comprising a midsole including a first midsole surface opposing the upper, a second midsole surface formed on an opposite side of the midsole than the first midsole surface, and an aperture formed through the midsole and extending between the first midsole surface and the second midsole surface, the midsole including a first thickness at the aperture and a fluid-filled chamber received within the aperture and including a second thickness, the second thickness substantially equal to the first thickness.

Clause 2. The sole structure of Clause 1, wherein the fluid-filled chamber includes a first barrier defining a first barrier surface and a second barrier defining a second barrier surface, the first barrier surface being substantially flush with the first midsole surface and the second barrier surface being substantially flush with the second midsole surface.

Clause 3. The sole structure of any of the preceding Clauses, wherein the aperture is disposed in a forefoot region of the sole structure.

Clause 4. The sole structure of Clause 3, wherein the aperture is formed through a majority of the forefoot region of the sole structure.

Clause 5. The sole structure of any of the preceding Clauses, wherein the aperture is defined by a wall of the midsole extending between the first midsole surface and the second midsole surface, the wall including a groove.

Clause 6. The sole structure of Clause 5, wherein a portion of the fluid-filled chamber is received within the groove.

Clause 7. The sole structure of Clause 6, wherein the fluid-filled chamber includes a peripheral seam extending around a perimeter of the fluid-filled chamber, the peripheral seam received within the groove.

Clause 8. The sole structure of any of the preceding Clauses, wherein the fluid-filled chamber is pressurized.

Clause 9. The sole structure of any of the preceding Clauses, wherein the fluid-filled chamber includes a tensile member.

Clause 10. An article of footwear incorporating the sole structure of any of the preceding Clauses.

Clause 11. An article of footwear comprising an upper, a midsole attached to the upper and including a first midsole surface opposing the upper, a second midsole surface formed on an opposite side of the midsole than the first midsole surface, and an aperture formed through the midsole and extending between the first midsole surface and the second midsole surface, and a fluid-filled chamber received within the aperture and including a first barrier defining a first barrier surface and a second barrier defining a second barrier surface on an opposite side of the fluid-filled chamber than the first barrier surface, the first barrier surface being attached to the upper.

Clause 12. The article of footwear of Clause 11, wherein the upper includes a strobel defining a footbed of the article of footwear.

Clause 13. The article of footwear of Clause 12, wherein the first barrier surface is attached to the strobel on an opposite side of the strobel than the footbed.

Clause 14. The article of footwear of any of the preceding Clauses, wherein a lower portion of the upper opposes the first midsole surface, the first barrier surface being attached to the lower portion of the upper adjacent to the first midsole surface.

Clause 15. The article of footwear of any of the preceding Clauses, wherein the aperture is defined by a wall of the midsole extending between the first midsole surface and the second midsole surface, the wall including a groove.

Clause 16. The article of footwear of Clause 15, wherein a portion of the fluid-filled chamber is received within the groove.

Clause 17. The article of footwear of Clause 16, wherein the fluid-filled chamber includes a peripheral seam extending around a perimeter of the fluid-filled chamber, the peripheral seam received within the groove.

Clause 18. The article of footwear of any of the preceding Clauses, further comprising an outsole defining a ground-engaging surface of the article of footwear, the second barrier surface being attached to the outsole on an opposite side of the outsole than the ground-engaging surface.

Clause 19. The article of footwear of any of the preceding Clauses, wherein the fluid-filled chamber is pressurized.

Clause 20. The article of footwear of any of the preceding Clauses, wherein the fluid-filled chamber includes a tensile member.

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.