U.S. patent application number 17/479468 was filed with the patent office on 2022-04-28 for sole structure having an outsole with integrated traction elements.
This patent application is currently assigned to NIKE, Inc.. The applicant listed for this patent is NIKE, Inc.. Invention is credited to Koosha Aslani, Juliana Flores Baza, Kevin Becker, Michael Hui, Matthew J. Plumb, Thomas J. Rushbrook.
Application Number | 20220125160 17/479468 |
Document ID | / |
Family ID | |
Filed Date | 2022-04-28 |
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United States Patent
Application |
20220125160 |
Kind Code |
A1 |
Baza; Juliana Flores ; et
al. |
April 28, 2022 |
SOLE STRUCTURE HAVING AN OUTSOLE WITH INTEGRATED TRACTION
ELEMENTS
Abstract
A sole structure including an outsole and a midsole disposed
over the outsole. The outsole includes an outsole plate and a
plurality of traction elements molded to the outsole plate. Each of
the plurality of traction elements includes a plurality of
overhangs. Each of the plurality of overhangs is cantilevered from
the outsole plate. The midsole includes a plurality of discrete
pods. Each of the plurality of discrete pods includes a midsole
fluid-filled bladder. The midsole fluid-filled bladder defines an
interior cavity and includes a first polymeric layer, a second
polymeric layer, and a plurality of midsole tethers interconnecting
the first polymeric layer and the second polymeric layer. Each of
the plurality of midsole tethers is disposed in the interior cavity
of the midsole fluid-filled bladder. Each of the plurality of
discrete pods is disposed over and aligned with one of the
plurality of traction elements.
Inventors: |
Baza; Juliana Flores;
(Hillsboro, OR) ; Becker; Kevin; (Portland,
OR) ; Hui; Michael; (Lake Oswego, OR) ; Plumb;
Matthew J.; (Portland, OR) ; Rushbrook; Thomas
J.; (Portland, OR) ; Aslani; Koosha; (Taipei,
TW) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
NIKE, Inc. |
Beaverton |
OR |
US |
|
|
Assignee: |
NIKE, Inc.
Beaverton
OR
|
Appl. No.: |
17/479468 |
Filed: |
September 20, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
63104617 |
Oct 23, 2020 |
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International
Class: |
A43B 13/22 20060101
A43B013/22; A43B 13/04 20060101 A43B013/04; A43B 13/20 20060101
A43B013/20; A43B 13/18 20060101 A43B013/18; A43B 13/12 20060101
A43B013/12 |
Claims
1. A sole structure, comprising: an outsole including an outsole
plate and a plurality of traction elements molded to the outsole
plate, each of the plurality of traction elements includes a
plurality of overhangs, each of the plurality of overhangs is
cantilevered from the outsole plate; and a midsole disposed over
the outsole, the midsole including a plurality of discrete pods,
each of the plurality of discrete pods includes a midsole
fluid-filled bladder, the midsole fluid-filled bladder defines an
interior cavity, the midsole fluid-filled bladder includes a first
polymeric layer, a second polymeric layer, and a plurality of
midsole tethers interconnecting the first polymeric layer and the
second polymeric layer, each of the plurality of midsole tethers is
disposed in the interior cavity of the midsole fluid-filled
bladder; and wherein each of the plurality of discrete pods is
disposed over and aligned with one of the plurality of traction
elements to maximize an energy efficiency of the sole
structure.
2. The sole structure of claim 1, wherein the outsole is made of
thermoplastic polyurethane, the thermoplastic polyurethane has a
hardness measured in Shore A, and the hardness of the thermoplastic
polyurethane is between 85 and 95 to promote flexion of the sole
structure.
3. The sole structure of claim 1, further comprising a foam layer
and a strobel board, wherein the strobel board is disposed over the
foam layer, and the foam layer is disposed between the strobel
board and the plurality of discrete pods.
4. The sole structure of claim 3, wherein the strobel board
includes a strobel fluid-filled bladder, and the strobel
fluid-filled bladder includes a first strobel layer, a second
strobel layer, and a plurality of strobel tethers interconnecting
the first strobel layer and the second strobel layer.
5. The sole structure of claim 4, further comprising a string
having a first string terminus and a second string terminus
opposite the first string terminus, wherein the first string
terminus is directly coupled to the midsole, and the second string
terminus is configured to be directly coupled to an upper.
6. The sole structure of claim 1, wherein the plurality of traction
elements includes solely three traction elements.
7. The sole structure of claim 1, wherein the outsole has a
forefoot region, a heel region, and a midfoot region disposed
between the forefoot region and the heel region, the plurality of
traction elements solely includes a first forefoot traction
element, a second forefoot traction element, and a heel traction
element, the first forefoot traction element and the second
forefoot traction element are disposed in the forefoot region of
the outsole, and the heel traction element is disposed in the heel
region of the outsole, and none of the plurality of traction
elements is disposed in the midfoot region of the outsole.
8. The sole structure of claim 7, wherein the heel traction element
covers a majority of the heel region of the outsole, and the heel
traction element is larger than the first forefoot traction element
and the second forefoot traction element.
9. The sole structure of claim 8, wherein adjacent overhangs of the
plurality of overhangs of each of the plurality of traction
elements are spaced apart from one another by a void.
10. The sole structure of claim 9, wherein the void between the
adjacent overhangs defines an acute angle from one of the adjacent
overhangs to another of the adjacent overhangs to facilitate
flexion along predefined flex lines.
11. An article of footwear, comprising: an upper; a sole structure
coupled to the upper, wherein the sole structure includes: an
outsole including an outsole plate and a plurality of traction
elements molded to the outsole plate, each of the plurality of
traction elements includes a plurality of overhangs, each of the
plurality of overhangs is cantilevered from the outsole plate; and
a midsole disposed over the outsole, the midsole including a
plurality of discrete pods, each of the plurality of discrete pods
includes a midsole fluid-filled bladder, the midsole fluid-filled
bladder defines an interior cavity, the midsole fluid-filled
bladder includes a first polymeric layer and a second polymeric
layer, and a plurality of midsole tethers interconnecting the first
polymeric layer and the second polymeric layer, each of the
plurality of midsole tethers is disposed in the interior cavity of
the midsole fluid-filled bladder; and wherein each of the plurality
of discrete pods is disposed over and aligned with one of the
plurality of traction elements to maximize an energy efficiency of
the sole structure.
12. The article of footwear of claim 11, wherein the outsole is
made of thermoplastic polyurethane, the thermoplastic polyurethane
has a hardness measured in Shore A, and the hardness of the
thermoplastic polyurethane is between 85 and 95 to promote flexion
of the sole structure.
13. The article of footwear of claim 11, further comprising a foam
layer and a strobel board disposed over the foam layer, wherein the
foam layer is disposed between the strobel board and the plurality
of discrete pods.
14. The article of footwear of claim 13, wherein the strobel board
includes a strobel fluid-filled bladder, and the strobel
fluid-filled bladder includes a first strobel layer, a second
strobel layer, and a plurality of strobel tethers interconnecting
the first strobel layer and the second strobel layer.
15. The article of footwear of claim 14, further comprising a
string having a first string terminus and a second string terminus
opposite the first string terminus, the first string terminus is
directly coupled to the midsole, and the second string terminus is
directly coupled to the upper.
16. The article of footwear of claim 11, wherein the plurality of
traction elements includes solely three traction elements.
17. The article of footwear of claim 11, wherein the outsole has a
forefoot region, a heel region, and a midfoot region disposed
between the forefoot region and the heel region, the plurality of
traction elements solely includes a first forefoot traction
element, a second forefoot traction element, and a heel traction
element, the first forefoot traction element and the second
forefoot traction element are disposed in the forefoot region of
the outsole, and the heel traction element is disposed in the heel
region of the outsole, and none of the plurality of traction
elements is disposed in the midfoot region of the outsole.
18. The article of footwear of claim 17, wherein the heel traction
element covers a majority of the heel region of the outsole, and
the heel traction element is larger than the first forefoot
traction element and the second forefoot traction element.
19. The article of footwear of claim 18, wherein adjacent overhangs
of the plurality of overhangs of each of the plurality of traction
elements are spaced apart from one another by a void, and the void
between the adjacent overhangs defines an acute angle from one of
the adjacent overhangs to another of the adjacent overhangs to
facilitate flexion along predefined flex lines.
20. A method of manufacturing an outsole, comprising: injecting a
molten polymeric material into a mold cavity of a mold, wherein the
mold includes a mold body and a plurality of inserts detachably
coupled to the mold body, the mold body defines the mold cavity,
and the mold cavity is shaped as the outsole, wherein the plurality
of inserts are shaped to form a plurality of gaps between an
outsole plate of the outsole and each of a plurality of traction
elements of the outsole; cooling the polymeric material until the
polymeric material solidifies; and removing the plurality of
inserts from the polymeric material after the polymeric material
solidifies to form the plurality of gaps.
21. The method of claim 20, wherein the removing the plurality of
inserts includes hand picking the inserts from the polymeric
material after the polymeric material solidifies.
22. The method of claim 21, wherein removing the plurality of
inserts includes applying a magnetic field toward the plurality of
inserts to withdraw the plurality of inserts from the polymeric
material after the polymeric material solidifies.
23. A sole structure, comprising: an outsole having a forefoot
region, a heel region, and a midfoot region disposed between the
forefoot region and the heel region, wherein the outsole includes:
an outsole plate; and a plurality of traction elements molded to
the outsole plate, wherein each of the plurality of traction
elements includes a plurality of overhangs, and each of the
plurality of overhangs is cantilevered from the outsole plate, the
plurality of traction elements includes a first forefoot traction
element, a second forefoot traction element, and a heel traction
element, the first forefoot traction element and the second
forefoot traction element are disposed in the forefoot region of
the outsole, the heel traction element is disposed in the heel
region of the outsole.
24. The sole structure of claim 23, wherein the outsole is made of
thermoplastic polyurethane, the thermoplastic polyurethane has a
hardness measured in Shore A, and the hardness of the thermoplastic
polyurethane is between 85 and 95 to promote flexion of the sole
structure.
25. The sole structure of claim 23, wherein adjacent overhangs of
the plurality of overhangs of each of the plurality of traction
elements are spaced apart from one another by a void.
26. The sole structure of claim 25, wherein the void between the
adjacent overhangs defines an acute angle from one of the adjacent
overhangs to another of the adjacent overhangs to facilitate
flexion along predefined flex lines.
27. The sole structure of claim 23, wherein the heel traction
element covers a majority of the heel region of the outsole, and
the heel traction element is larger than the first forefoot
traction element and the second forefoot traction element.
28. The sole structure of claim 23, wherein the outsole plate
extends through the forefoot region, the heel region, and the
midfoot region of the outsole.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to, and the benefit of,
U.S. Provisional Patent Application 63/104,617, filed on Oct. 23,
2020, the entire disclosure of which is hereby incorporated by
reference.
TECHNICAL FIELD
[0002] The present teachings generally relate to a sole structure
for an article of footwear and, more particularly, to a footwear
sole structure having an outsole with integrated traction
elements.
BACKGROUND
[0003] This section provides background information related to the
present disclosure which is not necessarily prior art.
[0004] Articles of footwear 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.
[0005] Sole structures include a layered arrangement extending
between a ground surface and the upper. One layer of the sole
structure includes an outsole that provides abrasion-resistance and
traction with the ground surface. The outsole may be formed from
rubber or other materials that impart durability and
wear-resistance, as well as enhancing traction with the ground
surface. Another layer of the sole structure includes a midsole
disposed between the outsole and the upper. The midsole provides
cushioning for the foot and is at least partially formed from a
polymer foam material that compresses resiliently under an applied
load to cushion the foot by attenuating ground-reaction forces. The
midsole may define a bottom surface on one side that opposes the
outsole and a footbed on the opposite side that may be contoured to
conform to a profile of the bottom surface of the foot. Sole
structures may also include a comfort-enhancing insole or a
sockliner located within a void proximate to the bottom portion of
the upper.
[0006] The metatarsophalangeal (MTP) joint of the foot is known to
absorb energy as it flexes through dorsiflexion during running
movements. As the foot does not move through plantarflexion until
the foot is pushing off of a ground surface, the MTP joint returns
little of the energy it absorbs to the running movement and, thus,
is the source of an energy drain during running movements.
Embedding flat and rigid plates having longitudinal stiffness
within a sole structure increases the overall stiffness
thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a schematic illustration in lateral side view of
an article of footwear.
[0008] FIG. 2 is a schematic illustration in exploded, rear view of
the article of footwear shown in FIG. 1.
[0009] FIG. 3 is a schematic illustration in an exploded, lateral
view of the article of footwear of FIG. 1, including an upper and a
sole structure.
[0010] FIG. 4 is a schematic illustration in perspective view of
the sole structure of the article of footwear shown in FIG. 3,
taken along section line 4-4 of FIG. 3.
[0011] FIG. 5 is a schematic illustration in perspective, rear view
of an outsole of the sole structure of the article of footwear of
FIG. 3.
[0012] FIG. 6 is a schematic illustration in bottom view of the
outsole of the sole structure of the article of footwear of FIG.
1.
[0013] FIG. 7 is a schematic illustration in rear view of the
outsole of the sole structure of FIG. 3.
[0014] FIG. 8 is a schematic illustration in front view of the
outsole of the sole structure of FIG. 3.
[0015] FIG. 9 is a schematic illustration in top view of the
outsole of the sole structure of FIG. 3.
[0016] FIG. 10 is a schematic illustration in top view of a strobel
board of the sole structure shown in FIG. 3.
[0017] FIG. 11 is a schematic illustration in cross-sectional side
view of the strobel board of FIG. 10, taken along section line
11-11 of FIG. 10.
[0018] FIG. 12 is a flowchart of the outsole of the sole structure
shown in FIG. 3.
[0019] FIG. 13 is a schematic illustration in cross-sectional view
of a mold including a mold body, a mold cavity, and inserts inside
the mold cavity.
DESCRIPTION
[0020] The present disclosure describes an article of footwear. In
an aspect of the present disclosure, the sole structure includes an
outsole including an outsole plate and a plurality of traction
elements molded to the outsole plate. Each of the plurality of
traction elements includes a plurality of overhangs, each of the
plurality of overhangs is cantilevered from the outsole plate. The
sole structure further includes a midsole disposed over the
outsole. The midsole includes a plurality of discrete pods. Each of
the plurality of discrete pods includes a midsole fluid-filled
bladder. The midsole fluid-filled bladder defines an interior
cavity. The midsole fluid-filled bladder includes a first polymeric
layer, a second polymeric layer, and a plurality of midsole tethers
interconnecting the first polymeric layer and the second polymeric
layer, each of the plurality of midsole tethers is disposed in the
interior cavity of the midsole fluid-filled bladder. Each of the
plurality of discrete pods is disposed over and aligned with one of
the plurality of traction elements to maximize an energy efficiency
of the sole structure.
[0021] The outsole may be made of thermoplastic polyurethane. The
thermoplastic polyurethane has a hardness measured in Shore A. The
hardness of the thermoplastic polyurethane may be between 85 and 95
to promote flexion of the sole structure. The sole structure may
further include a foam layer and a strobel disposed over the foam
layer. The foam layer may be disposed between the strobel and the
plurality of discrete pods. The strobel may include a strobel
fluid-filled bladder, and the strobel fluid-filled bladder includes
a first strobel layer, a second strobel layer, and a plurality of
strobel tethers interconnecting the first strobel layer and the
second strobel layer.
[0022] The plurality of traction elements may include solely three
traction elements. The outsole has a forefoot region, a heel
region, and a midfoot region disposed between the forefoot region
and the heel region. The plurality of traction elements may solely
include a first forefoot traction element, a second forefoot
traction element, and a heel traction element. The first forefoot
traction element and the second forefoot traction element are
disposed in the forefoot region of the outsole. The heel traction
element is disposed in the heel region of the outsole. None of the
plurality of traction elements is disposed in the midfoot region of
the outsole.
[0023] The heel traction element may cover a majority of the heel
region of the outsole, and the heel traction element is larger than
the first forefoot traction element and the second forefoot
traction element. The adjacent overhangs of the plurality of
overhangs of each of the plurality of traction elements may be
spaced apart from one another by a void. The void between the
adjacent overhangs may define an acute angle from one of the
adjacent overhangs to another of the adjacent overhangs to
facilitate flexion along predefined flex lines.
[0024] In an aspect of the present disclosure, an article of
footwear includes an upper and a sole structure coupled to the
upper. The sole structure includes an outsole including an outsole
plate and a plurality of traction elements molded to the outsole
plate. Each of the plurality of traction elements includes a
plurality of overhangs. Each of the plurality of overhangs is
cantilevered from the outsole plate. The sole structure further
includes a midsole disposed over the outsole. The midsole includes
a plurality of discrete pods. Each of the plurality of discrete
pods includes a midsole fluid-filled bladder. The midsole
fluid-filled bladder defines an interior cavity. The midsole
fluid-filled bladder includes a first polymeric layer and a second
polymeric layer. The midsole includes a plurality of midsole
tethers interconnecting the first polymeric layer and the second
polymeric layer. Each of the plurality of midsole tethers is
disposed in the interior cavity of the midsole fluid-filled
bladder. Each of the plurality of discrete pods is disposed over
and aligned with one of the plurality of traction elements to
maximize the energy efficiency of the sole structure.
[0025] The outsole may be made of thermoplastic polyurethane. The
thermoplastic polyurethane has a hardness measured in Shore A. The
hardness of the thermoplastic polyurethane is between 85 and 95 to
promote flexion of the sole structure. The article of footwear may
further include a foam layer and a strobel disposed over the foam
layer. The foam layer is disposed between the strobel and the
plurality of discrete pods.
[0026] The strobel may include a strobel fluid-filled bladder. The
strobel fluid-filled bladder may include a first strobel layer, a
second strobel layer, and a plurality of strobel tethers
interconnecting the first strobel layer and the second strobel
layer.
[0027] The article of footwear may further a string having a first
string terminus and a second string terminus opposite the first
string terminus. The first string terminus is directly coupled to
the midsole, and the second string terminus is configured to be
directly coupled to an upper.
[0028] The plurality of traction elements may solely include three
traction elements. The outsole has a forefoot region, a heel
region, and a midfoot region disposed between the forefoot region
and the heel region. The plurality of traction elements may solely
include a first forefoot traction element, a second forefoot
traction element, and a heel traction element. The first forefoot
traction element and the second forefoot traction element are
disposed in the forefoot region of the outsole. The heel traction
element may be disposed in the heel region of the outsole. None of
the plurality of traction elements is disposed in the midfoot
region of the outsole.
[0029] The heel traction element may cover a majority of the heel
region of the outsole. The heel traction element is larger than the
first forefoot traction element and the second forefoot traction
element. Adjacent overhangs of the plurality of overhangs of each
of the plurality of traction elements may be spaced apart from one
another by a void. The void between the adjacent overhangs may
define an acute angle from one of the adjacent overhangs to another
of the adjacent overhangs to facilitate flexion along predefined
flex lines.
[0030] The present disclosure also describes a method of
manufacturing an outsole. The method includes injecting a molten
polymeric material into a mold cavity of a mold. The mold includes
a mold body and a plurality of inserts detachably coupled to the
mold body. The mold body defines the mold cavity. The mold cavity
is shaped as the outsole. The plurality of inserts is shaped to
form a plurality of gaps between an outsole plate of the outsole
and each of a plurality of traction elements of the outsole. The
method further includes cooling the polymeric material until the
polymeric material solidifies and removing the plurality of inserts
from the polymeric material after the polymeric material solidifies
to form the plurality of gaps.
[0031] Removing the plurality of inserts may include hand picking
the inserts from the polymeric material after the polymeric
material solidifies. Removing the plurality of inserts may include
applying a magnetic field toward the plurality of inserts to
withdraw the plurality of inserts from the polymeric material after
the polymeric material solidifies.
[0032] The present disclosure also describes a sole structure
including an outsole. The outsole has a forefoot region, a heel
region, and a midfoot region disposed between the forefoot region
and the heel region. The outsole includes an outsole plate and a
plurality of traction elements molded to the outsole plate. Each of
the plurality of traction elements includes a plurality of
overhangs. Each of the plurality of overhangs is cantilevered from
the outsole plate. The plurality of traction elements may include
at least a first forefoot traction element, a second forefoot
traction element, and a heel traction element. The first forefoot
traction element and the second forefoot traction element are
disposed in the forefoot region of the outsole, and the heel
traction element is disposed in the heel region of the outsole.
[0033] The outsole may be made of thermoplastic polyurethane. The
thermoplastic polyurethane has a hardness measured in Shore A, and
the hardness of the thermoplastic polyurethane may be between 85
and 95 to promote flexion of the sole structure.
[0034] Adjacent overhangs of the plurality of overhangs of each of
the plurality of traction elements may be spaced apart from one
another by a void. The void between the adjacent overhangs may
define an acute angle from one of the adjacent overhangs to another
of the adjacent overhangs to facilitate flexion along predefined
flex lines. The heel traction element may cover the majority of the
heel region of the outsole, and the heel traction element is larger
than the first forefoot traction element and the second forefoot
traction element. The outsole plate may extend through the forefoot
region, the heel region, and the midfoot region of the outsole.
[0035] The above features and advantages and other features and
advantages of the present teachings are readily apparent from the
following detailed description of the modes for carrying out the
present teachings when taken in connection with the accompanying
drawings.
[0036] 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.
[0037] To assist and clarify the description of various
embodiments, various terms are defined herein. Unless otherwise
indicated, the following definitions apply throughout this
specification (including the claims). Additionally, all references
referred to are incorporated herein in their entirety.
[0038] An "article of footwear", a "footwear article of
manufacture", and "footwear" may be considered to be both a machine
and a manufacture. Assembled, ready to wear footwear articles
(e.g., shoes, sandals, boots, etc.), as well as discrete components
of footwear articles (such as a midsole, an outsole, an upper
component, etc.) prior to final assembly into ready to wear
footwear articles, are considered and alternatively referred to
herein in either the singular or plural as "article(s) of footwear"
or "footwear".
[0039] "A", "an", "the", "at least one", and "one or more" are used
interchangeably to indicate that at least one of the items is
present. A plurality of such items may be present unless the
context clearly indicates otherwise. All numerical values of
parameters (e.g., of quantities or conditions) in this
specification, unless otherwise indicated expressly or clearly in
view of the context, including the appended claims, are to be
understood as being modified in all instances by the term "about"
whether or not "about" actually appears before the numerical value.
"About" indicates that the stated numerical value allows some
slight imprecision (with some approach to exactness in the value;
approximately or reasonably close to the value; nearly). If the
imprecision provided by "about" is not otherwise understood in the
art with this ordinary meaning, then "about" as used herein
indicates at least variations that may arise from ordinary methods
of measuring and using such parameters. As used in the description
and the accompanying claims, unless stated otherwise, a value is
considered to be "approximately" equal to a stated value if it is
neither more than 5 percent greater than nor more than 5 percent
less than the stated value. In addition, a disclosure of a range is
to be understood as specifically disclosing all values and further
divided ranges within the range.
[0040] The terms "comprising", "including", and "having" are
inclusive and therefore specify the presence of stated features,
steps, operations, elements, or components, but do not preclude the
presence or addition of one or more other features, steps,
operations, elements, or components. Orders of steps, processes,
and operations may be altered when possible, and additional or
alternative steps may be employed. As used in this specification,
the term "or" includes any one and all combinations of the
associated listed items. The term "any of" is understood to include
any possible combination of referenced items, including "any one
of" the referenced items. The term "any of" is understood to
include any possible combination of referenced claims of the
appended claims, including "any one of" the referenced claims.
[0041] For consistency and convenience, directional adjectives may
be employed throughout this detailed description corresponding to
the illustrated embodiments. Those having ordinary skill in the art
will recognize that terms such as "above", "below", "upward",
"downward", "top", "bottom", etc., may be used descriptively
relative to the figures, without representing limitations on the
scope of the invention, as defined by the claims.
[0042] The term "longitudinal" refers to a direction extending
along a length of a component. For example, a longitudinal
direction of an article of footwear extends between a forefoot
region and a heel region of the article of footwear. The term
"forward" or "anterior" is used to refer to the general direction
from a heel region toward a forefoot region, and the term
"rearward" or "posterior" is used to refer to the opposite
direction, i.e., the direction from the forefoot region toward the
heel region. In some cases, a component may be identified with a
longitudinal axis as well as a forward and rearward longitudinal
direction along that axis. The longitudinal direction or axis may
also be referred to as an anterior-posterior direction or axis.
[0043] The term "transverse" refers to a direction extending along
a width of a component. For example, a transverse direction of an
article of footwear extends between a lateral side and a medial
side of the article of footwear. The transverse direction or axis
may also be referred to as a lateral direction or axis or a
mediolateral direction or axis.
[0044] The term "vertical" refers to a direction generally
perpendicular to both the lateral and longitudinal directions. For
example, in cases where a sole structure is planted flat on a
ground surface, the vertical direction may extend from the ground
surface upward. It will be understood that each of these
directional adjectives may be applied to individual components of a
sole structure. The term "upward" or "upwards" refers to the
vertical direction pointing towards a top of the component, which
may include an instep, a fastening region, and/or a throat of an
upper. The term "downward" or "downwards" refers to the vertical
direction pointing opposite the upwards direction, toward the
bottom of a component and may generally point towards the bottom of
a sole structure of an article of footwear.
[0045] The "interior" of an article of footwear, such as a shoe,
refers to portions at the space that is occupied by a wearer's foot
when the article of footwear is worn. The "inner side" of a
component refers to the side or surface of the component that is
(or will be) oriented toward the interior of the component or
article of footwear in an assembled article of footwear. The "outer
side" or "exterior" of a component refers to the side or surface of
the component that is (or will be) oriented away from the interior
of the article of footwear in an assembled article of footwear. In
some cases, other components may be between the inner side of a
component and the interior in the assembled article of footwear.
Similarly, other components may be between an outer side of a
component and the space external to the assembled article of
footwear. Further, the terms "inward" and "inwardly" refer to the
direction toward the interior of the component or article of
footwear, such as a shoe, and the terms "outward" and "outwardly"
refer to the direction toward the exterior of the component or
article of footwear, such as the shoe. In addition, the term
"proximal" refers to a direction that is nearer a center of a
footwear component, or is closer toward a foot when the foot is
inserted in the article of footwear as it is worn by a user.
Likewise, the term "distal" refers to a relative position that is
further away from a center of the footwear component or is further
from a foot when the foot is inserted in the article of footwear as
it is worn by a user. Thus, the terms proximal and distal may be
understood to provide generally opposing terms to describe relative
spatial positions.
[0046] 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.
[0047] 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.
[0048] 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.
[0049] Referring to FIGS. 1-3, an article of footwear 100 may be a
golf shoe and includes an upper 102 and a sole structure 200, which
is partially formed by the upper 102. The article of footwear 100
(and its components, such as the upper 102 and the sole structure
200) may be divided into one or more portions. The portions may
include a forefoot portion 12, a midfoot portion 14, and a heel
portion 16. The forefoot portion 12 may correspond with toes and
joints connecting metatarsal bones with phalanx bones of a foot
during use of the footwear 100. The forefoot portion 12 may
correspond with the metatarsophalangeal (MTP) joint of the foot.
The midfoot portion 14 may correspond with an arch area of the
foot, and the heel portion 16 may correspond with rear portions of
the foot, including a calcaneus bone, during use of the article of
footwear 100. The footwear 100 may include lateral and medial sides
18, 20, respectively, corresponding with opposite sides of the
footwear 100 and extending through the portions 12, 14, 16.
[0050] The upper 102 includes interior surfaces that define an
interior void 103 (FIG. 2) that receives and secures a foot for
support on the sole structure 200, during use of the article of
footwear 100. An ankle opening 104 in the heel portion 16 may
provide access to the interior void 103. For example, the ankle
opening 104 may receive a foot to secure the foot within the
interior void 103 and facilitate entry and removal of the foot to
and from the interior void 103. In some examples, one or more
fasteners 106 extend along the upper 102 to adjust a fit of the
interior void 103 around the foot while concurrently accommodating
entry and removal of the foot therefrom. The upper 102 may include
apertures such as eyelets and/or other engagement features such as
fabric or mesh loops that receive the fasteners 106. The fasteners
106 may include laces, straps, cords, hook-and-loop, or any other
suitable type of fastener. For example, the fasteners 106 include
flexible laces, and the upper 102 further includes a retaining tube
107 coupled to the fasteners 106 (e.g., laces). During use, the
wearer of the article of footwear 100 can pull the retaining tube
107 to adjust and tighten the fasteners 106.
[0051] The upper 102 may also include a heel cup 115 at the heel
portion 16 to support the heel of the footwear user. The upper 102
may include a tongue portion 110 that extends between the interior
void 103 and the fasteners 106. The upper 102 may be formed from
one or more materials (i.e., the upper material) that are stitched
or adhesively bonded together to form the interior void 103.
Suitable materials of the upper may include, but are not limited,
textiles, fabrics, foam, leather, and synthetic leather. The
materials may be selected and located to impart properties of
durability, air-permeability, wear-resistance, flexibility, and
comfort. For example, the upper 102 may be wholly or partially made
of a waterproof knitted textile to protect the wearer's foot from
moisture.
[0052] The sole structure 200 is secured to the upper 102 and is
spaced apart from the upper 102 along a vertical direction VT. The
sole structure 200 may include a midsole 202 for providing
cushioning to the footwear user. To this end, the midsole 202 may
be made of a polymeric material, such as rubber or foam. As a
non-limiting example, the midsole 202 may be wholly or partially
made of an ethylene-vinyl acetate (EVA) foam to enhance cushioning
of the sole structure 200. The midsole 202 may continuously extend
along the forefoot portion 12, the midfoot portion 14, and the heel
portion 16 to provide cushioning to the entire foot of the footwear
wearer.
[0053] As a non-limiting example, the midsole 202 may include a
foam layer 204 extending through the forefoot portion 12, the
midfoot portion 14, and the heel portion 16 to provide cushioning
to the entire foot of the footwear wearer. The foam layer 204 may
be wholly or partly made of a foam to provide cushioning to the
footwear wearer. For example, the foam layer 204 may be wholly or
partly made of EVA foam. The midsole 202 may define one or more
midsole openings 206 extending through the part or the entire
thickness of the foam layer 204. Each of the midsole openings 206
may be configured as thru-holes or recesses. Regardless of the
specific configuration, each of the midsole openings 206 is
configured, shaped, and sized to receive at least one discrete pod
208, which are described in detail below.
[0054] As discussed above, one or more of the midsole openings 206
may be a thru-hole to enhance the energy efficiency of the midsole
202. Further, the midsole openings 206 may have a hexagonal shape
or a substantially hexagonal shape to tightly accommodate each
discrete pod 208, thereby preventing the discrete pods 208 from
moving lateral or longitudinally relative to the upper 102. By
limiting the lateral and longitudinal movement of the discrete pods
208 relative to the upper 102, the energy efficiency of the
discrete pods 208 can be enhanced.
[0055] In order to simplify manufacturing, the midsole 202 may
solely include three midsole openings 206, namely: a first midsole
opening 206a, a second midsole opening 206b, and a third midsole
opening 206c. The first midsole opening 206a and the second midsole
opening 206b are entirely located in the forefoot portion 12,
whereas the third midsole opening 206c is entirely located in heel
portion 16. The third midsole opening 206c is spaced apart from the
first midsole opening 206a and the second midsole opening 206b
along a longitudinal direction LG. The first midsole opening 206a
is spaced apart from the second midsole opening 206b along the
longitudinal direction LG and the lateral direction LT. The lateral
direction LT is perpendicular to the longitudinal direction LG and
the vertical direction VT. Each of the first midsole opening 206a,
the second midsole opening 206b, and the third midsole opening 206c
has a respective opening center, namely: the first opening center
207a, the second opening center 207b, and the third opening center
207c. A first central axis 209a intersects the first opening center
207a of the first midsole opening 206a. A second central axis 209b
intersects the second opening center 207b of the second midsole
opening 206b. A third central axis 209c intersects the third
opening center 207c of the third midsole opening 206c. Each of the
first central axis 209a, the second central axis 209b, and the
third central axis 209c is parallel with the vertical direction VT.
Because each of the midsole openings 206 receives one of the
discrete pods 208, the location of the midsole openings 206 as
described above assist in enhancing the energy efficiency of the
sole structure 200 during the heel strike and the toe-off of the
gait cycle. No midsole opening 206 or discrete pod 208 is located
in the midfoot portion 14 of the sole structure 200 to minimize
costs and facilitate manufacturing of the article of footwear
100.
[0056] In order to simplify manufacturing, the midsole 202 may
include solely three discrete pods 208, namely: a first discrete
pod 208a, a second discrete pod 208b, and a third discrete pod
208c. It is contemplated, however, that the midsole 202 may include
more or fewer discrete pods 208. The first discrete pod 208a and
the second discrete pod 208b are entirely located in the forefoot
portion 12, whereas the third discrete pod 208c is entirely located
in heel portion 16. The third discrete pod 208c is spaced apart
from the first discrete pod 208a and the second discrete pod 208b
along the longitudinal direction LG. The first discrete pod 208a is
spaced apart from the second discrete pod 208b along the
longitudinal direction LG and the lateral direction LT. Each of the
first discrete pod 208a, the second discrete pod 208b, and the
third discrete pod 208c has a respective pod center, namely: the
first pod center 212a, the second pod center 212b, and the third
pod center 212c. The first central axis 209a intersects the first
opening center 207a of the first midsole opening 206a and the first
pod center 212a of the first discrete pod 208a to tightly fit the
first discrete pod 208a in the first midsole opening 206a. The
second central axis 209b intersects the second opening center 207b
of the second midsole opening 206b and the second pod center 212b
of the second discrete pod 208b to tightly fit the second discrete
pod 208b in the second midsole opening 206b. The third central axis
209c intersects the third opening center 207c of the third midsole
opening 206c and the third pod center 212c of the third discrete
pod 208c to tightly fit the third discrete pod 208c in the third
midsole opening 206c. Each of the first central axis 209a, the
second central axis 209b, and the third central axis 209c is
parallel with the vertical direction VT as discussed above. Because
each of the midsole openings 206 receives one of the discrete pods
208, the location of the midsole openings 206 as described above
assist in enhancing the energy efficiency of the sole structure 200
during the heel strike and the toe-off of the gait cycle. No
discrete pod 208 is located in the midfoot portion 14 of the sole
structure 200 to minimize costs and facilitate manufacturing of the
article of footwear 100. It is envisioned, however, that one or
more discrete pods 208 may be located in the midfoot portion 14 of
the sole structure 200. Further, the discrete pods 208 are not
necessarily encased. Moreover, the discrete pods 208 may be
exposed. As such, the discrete pods 208 may be visible from the
bottom of the sole structure 200.
[0057] The article of footwear 100 may further include one or more
strings 108 interconnected between the upper 102 and the midsole
202 to enhance the connection between the upper 102 and the midsole
202. As a non-limiting example, the article of footwear 100
includes a plurality of strings 108 each directly connected to the
upper 102 and directly connected to the midsole 202 to enhance the
structure integrity of the connection between the upper 102 and the
midsole 202. For example, each of the strings 108 has a first
string terminus 108a and a second string terminus 108b opposite the
first string terminus 108a. The first string terminus 108a is
directly coupled to the midsole 202, and the second string terminus
108b is directly coupled to the upper 102. Further, one or more of
the strings 108 are in tension between the upper 102 and the
midsole 202 to enhance the structural integrity of the article of
footwear 100. The sole structure 200 further includes an outsole
214 below (and directly connected to the midsole 202).
[0058] The sole structure 200 further includes a strobel board 210
disposed between the midsole 202 and the upper 102. Thus, the
strobel board 210 is disposed between the foam layer 204 and the
upper 102. Accordingly, the upper 102 is spaced apart from the
strobel board 210 along the vertical direction VT, and the midsole
202 is spaced apart from the strobel board 210 along the vertical
direction VT. The foam layer 204 is disposed between the strobel
board 210 and the discrete pods 208 to provide cushioning to the
footwear wearer while maximizing the energy efficiency of the sole
structure 200. As described in detail below, the strobel board 210
enhances the energy efficiency of the sole structure 200 and may
extend through the forefoot portion 12, the midfoot portion 14, and
the heel portion 16 of the sole structure 200 to provide such
enhanced energy efficiency throughout the sole structure 200.
[0059] With reference to FIG. 4, each of the discrete pods 208
includes a midsole fluid-filled bladder 230 to provide cushioning
to the sole structure 200. The fluid-filled bladder 230 of each of
the discrete pods 208 is sealed, thereby preventing fluid from
escaping the fluid-filled bladder 230. By maintaining the fluid
inside the fluid-filled chamber 230, the cushioning properties of
the midsole 202 are preserved. The fluid-filled chamber 230 defines
an interior cavity 234. Further, the fluid-filled chamber 230 of
each discrete pod 208 includes a first polymeric layer 236 and a
second polymeric layer 238 surrounding the interior cavity 234. The
first polymeric layer 236 includes a first peripheral edge 240, and
the second polymeric layer 238 includes a second peripheral edge
242. The first peripheral edge 240 is directly connected, through
for example thermal bonding, to the second peripheral edge 242
sealed a fluid inside the interior cavity 234 of the fluid-filled
bladder 230. The fluid-filled bladder 230 may further include one
or more midsole tethers 244 interconnecting the first polymeric
layer 236 and the second polymeric layer 238 to maintain the first
polymeric layer 236 and the second polymeric layer 238 spaced apart
from one another when no load is applied to the discrete pod 208,
thereby maximizing the energy efficiency of the sole structure 200.
As a non-limiting example, each of the midsole tethers 244 are
tensioned and directly connected to the first polymeric layer 236
and directly to the second polymeric layer 238 to maximize the
energy efficiency of the sole structure 200.
[0060] With reference to FIGS. 5-9, the outsole 214 has an outsole
plate 216 and a plurality of traction elements 218 integrally
coupled to the outsole plate 216. As such, the outsole plate 216
and the traction elements 218 form a one-piece structure to enhance
the structural integrity of the outsole 214. The outsole 214 has a
forefoot region 220, a heel region 222, and a midfoot region 224
disposed between the forefoot region 220 and the heel region 222.
The outsole 214 has a lateral side 226 and a medial side 228
opposite the lateral side 226. The lateral side 226 is spaced apart
from the medial side 228 along the lateral direction LT. The
outsole 214 includes treads 231 disposed along forefoot region 220,
the midfoot region 224 and the heel region 222 of the outsole plate
216 to enhance traction when the sole structure 200 contacts a
ground surface. Each of the treads 231 extends from the lateral
side 226 to the medial side 228 of the outsole plate 216 and can be
configured as curved ridges and grooves.
[0061] As discussed above, the outsole 214 includes a lip 245
extending upwardly from the forefoot region 220 of the outsole
plate 216 to protect the footwear wearer's toes from impacts. In
addition to the lip 245, the outsole 214 includes one or more
traction elements 218 as discussed above. Regardless of the
specific quantity, each of the traction elements 218 is integrally
coupled to the outsole plate 216. As such, the traction elements
218 and the outsole plate 216 form a one-piece structure, thereby
maximizing the structural integrity of the outsole 214. As a
non-limiting example, each of the traction elements 218 is molded
to the outsole plate 216. In present disclosure, the term "molded"
means that two or more parts are integrally coupled to one another,
by a molding process, such that the two or more parts form a
one-piece structure. To facilitate traction with a ground surface,
the outsole 214 may be wholly or partly made of a thermoplastic
polyurethane. The thermoplastic polyurethane may have a hardness
(measured in the Shore A scale) that is between 84 and 95 to
promote flexion of the sole structure 200.
[0062] As a non-limiting example, the outsole 214 may include
solely three traction elements 218 to minimize costs and facilitate
manufacturing, namely: a first forefoot traction element 218a, a
second forefoot traction element 218b, and a heel traction element
218c. It is envisioned, however, that the outsole 214 may include
more or fewer traction elements 218. The first forefoot traction
element 218a and the second forefoot traction element 218b are
entirely located in the forefoot portion 12, whereas the heel
traction element 218c is entirely located in heel portion 16. The
heel traction element 218c is spaced apart from the first forefoot
traction element 218a and the second forefoot traction element 218b
along the longitudinal direction LG. The first forefoot traction
element 218a is spaced apart from the second forefoot traction
element 218b along the longitudinal direction LG and the lateral
direction LT. Each of the first forefoot traction element 218a, the
second forefoot traction element 218b, and the heel traction
element 218c has a respective pod center, namely: the first
traction center 246a, the second traction center 246b, and the
third traction center 246c. Each of the discrete pods 208 is
disposed over and aligned with one of the traction elements 218 to
maximize the energy efficiency of the sole structure 200. For
example, the first central axis 209a may intersect the first
opening center 207a of the first midsole opening 206a, the first
pod center 212a of the first discrete pod 208a, and the first
traction center 246 of the first forefoot traction element 218a to
maximize the energy efficiency of the sole structure 200. The
second central axis 209b may intersect the second opening center
207b of the second midsole opening 206b, the second pod center 212b
of the second discrete pod 208b, and the second traction center
246b of the second forefoot traction element 218b to maximize the
energy efficiency of the sole structure 200. The third central axis
209c may intersect the third opening center 207c of the third
midsole opening 206c, the third pod center 212c of the third
discrete pod 208c, and the third traction center 246c of the heel
traction element 218c to maximize the energy efficiency of the sole
structure 200. No traction element 218 is located in the midfoot
portion 14 of the sole structure 200 to minimize costs and
facilitate manufacturing of the article of footwear 100.
[0063] The heel traction element 218c covers the majority of the
heel region 222 of the outsole 214 and is larger than the first
forefoot traction element 218a and the second forefoot traction
element 218b to maintain the footwear wearer's foot to stationary
during the backswing and downswing of a golf swing. Each of the
first traction element 218a and the second forefoot traction
element 218b are smaller than the heel traction element 218c and
solely cover less than half of the forefoot region 220 of the
outsole 214 to maintain the footwear wearer's foot stationary
during the backswing and downswing of a golf swing, while allowing
rotation of the footwear's foot during the follow-thru state of the
golf swing.
[0064] Each of the traction elements 218 includes a plurality of
overhangs 248 integrally coupled to the outsole plate 216. As such,
the overhangs 248 and the outsole plate 216 form a one-piece
structure to enhance the structural integrity of the outsole 214.
The overhangs 248 may be referred to as flanges, and each of the
overhangs 248 is cantilevered from the outsole plate 216 to enhance
the energy efficiency of the sole structure 200. The plurality of
overhangs 248 includes a plurality of adjacent overhangs 248p. The
adjacent overhangs 248p may be a pair to minimize costs. Each
traction element 218 may include solely three pairs of adjacent
overhangs 248p to maximize flexion of the sole structure 200, while
facilitating manufacturing of the sole structure 200. It is
contemplated, however, that the traction elements 218 may include
more or fewer overhangs 248. Each pair of adjacent overhangs 248p
is spaced apart from another pair of adjacent overhangs 248p by a
void 250 to enhance the flexion of the sole structure 200. The void
250 between the pairs of adjacent overhangs 248p may define an
acute angle AA to facilitate flexion along predefined flexion lines
FL. The acute angle AA is defined from one pair of adjacent
overhangs 248p to another pair of adjacent overhangs 248p. All the
predefined flexion lines FL intersect a corresponding center of the
traction elements 218 (i.e., the first traction center 246a, the
second traction center 246b, and the third traction center 246c) to
maximize flexion of the sole structure 200.
[0065] As shown in FIGS. 4 and 9, each of the overhangs 248 is
obliquely angled relative to outsole plate 216 to form gaps 217
between the outsole plate 216 and the overhangs 248 to enhance the
energy efficiency of the outsole 214. For instance, an oblique
angle OA (e.g., acute angle) is defined from the outsole plate 216
to the overhang 248 to enhance the energy efficiency of the outsole
214. The outsole plate 216 has a first plate surface 252 and a
second plate surface 254 opposite the first plate surface 252. The
first plate surface 252 is in direct contact with the midsole 202
to enhance the structural integrity of the sole structure 200,
whereas the second plate surface 254 is directly connected to each
of the traction elements 218 to enhance the structural integrity of
the outsole 214.
[0066] With reference to FIGS. 10 and 11, the strobel board 210
includes one or more strobel fluid-filled bladders 316 wholly or
partly made of a polymeric material to enhance the energy
efficiency of the sole structure 200. The strobel fluid-filled
bladder 316 defines a strobel interior cavity 318 (FIG. 11) and is
configured to retain a fluid in the strobel interior cavity 318.
The strobel fluid-filled bladder 316 has a peripheral flange 320
extending around at least a portion of a perimeter 321 of the
interior cavity 318. In the embodiment shown, the peripheral flange
320 extends around the entire perimeter 321 (e.g., outwardly
surrounding the strobel interior cavity 318) generally in an X-Y
plane (defined by the X direction and the Y direction) of the
strobel fluid-filled bladder 316, where the Z plane (defined by the
Z direction) is the height of the strobel fluid-filled bladder 316
from a proximal surface 324 of the strobel fluid-filled bladder 316
to a distal surface 326 of the strobel fluid-filled bladder 316.
The peripheral flange 320 extends around a strobel forefoot region
325, a strobel midfoot region 327, and a strobel heel region 329 of
the strobel fluid-filled bladder 316.
[0067] The peripheral flange 320 defines a groove 322 extending
along the peripheral flange 320. As further discussed herein, the
groove 322 serves as a guide path for an operator or for a machine,
including a robotic machine. In some of the embodiments shown and
described herein, the strobel board 210 is secured to the upper 102
by stitching that extends through the peripheral flange 320. When
the strobel board 210 is secured to the upper 102, the strobel
board 210 and the upper 102 together define interior void 103.
Dynamic compressive loading of the sole structure 200 by a foot in
the interior void 103 may cause tension in the strobel board 210
around the peripheral flange 320 in an outward direction, creating
a trampoline like effect as the tension is subsequently relieved
and strobel tethers 360 of the strobel board 210 return to their
tensioned state.
[0068] The strobel fluid-filled bladder 316 includes a first
strobel layer 328 and a second strobel layer 330. Each of the first
strobel layer 328 and the second strobel layer 330 may be partly or
wholly made of a polymeric material. The first strobel layer 328 is
secured to the second strobel layer 330 at the peripheral flange
320 to enclose the interior cavity 318. Stated differently, when
the first strobel layer 328 and the second strobel layer 330 are
secured together at the peripheral flange 320 and the strobel
fluid-filled bladder 316 is sealed, the first strobel layer 328 and
the second strobel layer 330 retain a fluid in the interior cavity
318. As used herein, the term "fluid" means a gas, such as air,
nitrogen, another gas, or a combination thereof.
[0069] The first strobel layer 328 and the second strobel layer 330
can be made a variety of polymeric materials that can resiliently
retain a fluid such as nitrogen, air, or another gas. Examples of
polymeric materials for the first strobel layer 328 and the second
strobel layer 330 include thermoplastic urethane, polyurethane,
polyester, polyester polyurethane, and polyether polyurethane.
Moreover, the first strobel layer 328 and the second strobel layer
330 can each be formed of layers of different materials including
polymeric materials. In one embodiment, each of the first strobel
layer 328 and the second strobel layer 330 is formed from thin
films having one or more thermoplastic polyurethane layers with one
or more barrier layers of a copolymer of ethylene and vinyl alcohol
(EVOH) that is impermeable to the pressurized fluid contained
therein such as a flexible microlayer membrane that includes
alternating layers of a gas barrier material and an elastomeric
material. Alternatively, the first strobel layer 328 and the second
strobel layer 330 may include ethylene-vinyl alcohol copolymer,
thermoplastic polyurethane, and a regrind material of the
ethylene-vinyl alcohol copolymer and thermoplastic polyurethane.
Further suitable materials for the first strobel layer 328 and the
second strobel layer 330 include thermoplastic films containing a
crystalline material, and polyurethane including a polyester
polyol. In selecting materials for the strobel board 210,
engineering properties such as tensile strength, stretch
properties, fatigue characteristics, dynamic modulus, and loss
tangent can be considered. For example, the thicknesses of the
first strobel layer 328 and the second strobel layer 330 used to
form the strobel board 210 can be selected to provide these
characteristics.
[0070] As best shown in FIG. 11, a tensile component 350 is
disposed in the strobel interior cavity 318. The tensile component
350 is secured to opposing inner surfaces 352, 354 of the strobel
fluid-filled bladder 316. The tensile component 350 includes a
first tensile layer 356, a second tensile layer 358, and a
plurality of strobel tethers 360 spanning the strobel interior
cavity 318 from the first tensile layer 356 to the second tensile
layer 358. The strobel tethers 360 connect the first tensile layer
356 to the second tensile layer 358. Therefore, the tethers 360
interconnect the first strobel layer 328 and the second strobel
layer 330. Only some of the strobel tethers 360 are indicated with
reference numbers in FIG. 11. The strobel tethers 360 may also be
referred to as fabric tensile members or threads and may be in the
form of drop threads that connect the first tensile layer 356 and
the second tensile layer 358. The tensile component 350 may be
formed as a unitary, one-piece textile element having a spacer-knit
textile.
[0071] The first tensile layer 356 is bonded to the inner surface
352 of the first strobel layer 328, and the second tensile layer
358 is bonded to the inner surface 354 of the second strobel layer
330. More specifically, a first surface bond 362 joins the inner
surface 352 of the first strobel layer 328 to the outer surface 364
of the first tensile layer 356. A second surface bond 366 joins the
inner surface 354 of the second strobel layer 330 to the outer
surface 368 of the second tensile layer 358, opposite the first
tensile layer 356. Entire interfacing portions of the surfaces 352,
364 and of the surfaces 354, 368 are bonded to one another.
[0072] The strobel tethers 360 restrain separation of the first
strobel layer 328 and the second strobel layer 330 to the maximum
separated positions shown in FIG. 11, which depicts the strobel
fluid-filled bladder 316 with the strobel interior cavity 318
inflated and sealed under a given inflation pressure of gas in the
interior cavity 318, so that the strobel fluid-filled bladder 316
is in an inflated state. The outward force on the first strobel
layer 328 and the second strobel layer 330 due to the pressurized
gas in the strobel interior cavity 318 places the strobel tethers
360 in tension, and the strobel tethers 360 prevent the first and
second tensile layers 356, 358 and first strobel layer 328 and the
second strobel layer 330 from further outward movement away from
one another. However, the strobel tethers 360 do not present
resistance to compression when under a compressive load. When
pressure is exerted on the strobel fluid-filled bladder 316 such as
due to compressive forces of a dynamic load of a wearer when the
article of footwear 100 impacts the ground during running or other
movements. Rather, upon exertion of compressive forces on the
article of footwear 100, the strobel fluid-filled bladder 316 is
compressed, and the first strobel layer 328 and the second strobel
layer 330 move closer together as the strobel tethers 360 collapse
(e.g., go slack) in proportion to the load on the first strobel
layer 328 and the second strobel layer 330 adjacent the particular
strobel tethers 360.
[0073] One or more inwardly-protruding bonds 370 joins the first
strobel layer 328 to the first tensile layer 356 and protrudes
inward from the first strobel layer 328 toward the second strobel
layer 330 directly into a region of the strobel interior cavity 318
occupied by some of the strobel tethers 360. The plurality of
inwardly-protruding bonds 370 protrude inward from the first
strobel layer 328 only partially across the plurality of strobel
tethers 360 toward the second strobel layer 330, and the strobel
fluid-filled bladder 316 is narrowed at the inwardly-protruding
bonds 370. For example, the inwardly-protruding bonds 370 may be
formed by a welding process, such as radio frequency or ultrasonic
welding using tooling that results in thermal bonds in the strobel
fluid-filled bladder 316. The inwardly-protruding bonds 370 result
in depressed grooves 374 at the proximal surface 324 of the first
strobel layer 328.
[0074] Because the inwardly-protruding bonds 370 at least partially
traverse the plurality of strobel tethers 360 and the plurality of
strobel tethers 360 includes first strobel tethers 360A aligned
with one of the inwardly-protruding bonds 370, the second strobel
tethers 360B displaced each of the inwardly-protruding bonds 370.
Only some of the first and second strobel tethers 360A, 360B are
labelled in FIG. 11. The first strobel tethers 360A that are
aligned with an inwardly-protruding bond 370 are deformed by heat,
by compression of the overlaying of material of the first tensile
layer 356, and/or by the overlaying material of the first tensile
layer 356 coating the first strobel tethers 360A such that the
first strobel tethers 360A are shorter, thicker, or both shorter
and thicker at the inwardly-protruding bonds 370 than elsewhere.
The first tensile layer 356 is spaced apart from the second tensile
layer 358 by a first distance D1 at the second strobel tethers 360B
adjacent to the inwardly-protruding bond 370, and the
inwardly-protruding bond 370 is spaced apart from the second
tensile layer 358 by a second distance D2, which may be the minimum
distance between the inwardly-protruding bond 370 and the second
tensile layer 358 (i.e., the distance at the most narrowed portion
of the interior cavity 318 under the inwardly-protruding bond
370).
[0075] With reference to FIGS. 12 and 13, the present disclosure
also describes a method 400 of manufacturing an outsole 214. The
method 400 begins at block 402. At block 402, a molten polymeric
material 410 is injected into a mold cavity 502 of a mold 500. The
mold 500 includes a mold body 504 and a plurality of inserts 506
detachably coupled to the mold body 504. The mold body 504 defines
the mold cavity 502. The mold cavity 502 is shaped as the outsole
214. The inserts 506 may be made of a metallic material and are
shaped to form gaps 217 between the outsole plate 216 of the
outsole 214 and each of the traction elements 218. After injecting
the polymeric material 410, the method 400 proceeds to block 404.
At block 404, the polymer material 410 is cooled until the
polymeric material 410 solidifies. Then, the method 400 proceeds to
block 406. At block 406, the inserts 506 are removed from polymeric
material 410 after the polymeric material 410 solidifies to form
the gaps 217. To remove the inserts 506, the inserts 506 may be
handpicked from the polymeric material 410 after the polymeric
material 410 solidifies. Alternately or additionally, removing the
plurality of inserts may include applying a magnetic field toward
the inserts 506 to withdraw the inserts 506 from the polymeric
material 410 after the polymeric material 410 has solidified.
[0076] While various embodiments have been described, the
description is intended to be exemplary, rather than limiting and
it will be apparent to those of ordinary skill in the art that many
more embodiments and implementations are possible that are within
the scope of the embodiments. Any feature of any embodiment may be
used in combination with or substituted for any other feature or
element in any other embodiment unless specifically restricted.
Accordingly, the embodiments are not to be restricted except in
light of the attached claims and their equivalents. Also, various
modifications and changes may be made within the scope of the
attached claims.
[0077] While several modes for carrying out the many aspects of the
present teachings have been described in detail, those familiar
with the art to which these teachings relate will recognize various
alternative aspects for practicing the present teachings that are
within the scope of the appended claims. It is intended that all
matter contained in the above description or shown in the
accompanying drawings shall be interpreted as illustrative and
exemplary of the entire range of alternative embodiments that an
ordinarily skilled artisan would recognize as implied by,
structurally and/or functionally equivalent to, or otherwise
rendered obvious based upon the included content, and not as
limited solely to those explicitly depicted and/or described
embodiments.
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