CN115399547A - Sole structure for an article of footwear - Google Patents

Abstract

A sole structure for an article of footwear having an upper includes a cushioning member and a base. The cushioning member includes a first series of lobes alternating with a first series of recesses along a length of the cushioning member. The first series of lobes and the first series of recesses extend along one of a medial side of the sole structure and a lateral side of the sole structure. The base is disposed between the cushioning member and the upper and includes a series of first supports alternating with a second series of recesses. The supports of the first series of supports are aligned with and in contact with respective lobes of the first series of lobes, and the second series of recesses are aligned with the first series of recesses.

Description

Sole structure for an article of footwear

Cross Reference to Related Applications

This application claims priority from 35 u.s.c. § 119 (e) to: U.S. provisional patent application serial No. 63/300,259, filed on day 17 of 2022, month 1, 2022, U.S. provisional patent application serial No. 63/300,246, filed on day 17 of 2022, month 1, U.S. provisional patent application serial No. 63/300,252, filed on day 6 of 2021, month 10, U.S. provisional patent application serial No. 63/253,022, filed on day 28 of 2021, month 5, U.S. provisional patent application serial No. 63/194,327, filed on day 28 of 2021, month 5, and U.S. provisional patent application serial No. 63/194,314, filed on day 28 of 2021, month 5, the entire contents of which are hereby incorporated by reference in their entirety.

Technical Field

The present disclosure relates generally to sole structures for articles of footwear, and more particularly, to sole structures that include a base for receiving a fluid-filled bladder.

Background

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

An article of footwear generally includes an upper and a sole structure. The upper may be formed from any suitable material(s) to receive, secure, and support the foot on the sole structure. The upper may be fitted with laces, straps, or other fasteners to adjust the fit of the upper around the foot. A bottom portion of the upper, proximate a bottom surface of the foot, is attached to the sole structure.

The sole structure generally includes a layered arrangement that extends between the ground and the upper. One layer of the sole structure includes an outsole that provides both wear-resistance and traction to the ground. The outsole may be formed of rubber or other materials that impart durability and wear-resistance, as well as enhanced traction to the ground. Another layer of the sole structure includes a midsole disposed between the outsole and the upper. The midsole provides cushioning for the foot and may be formed, in part, from a polymer foam material that resiliently compresses under an applied load to cushion the foot by attenuating ground reaction forces. The midsole may additionally or alternatively incorporate a cushioning member to increase the durability of the sole structure and to provide cushioning to the foot by elastically compressing under applied loads to attenuate ground reaction forces. The cushioning member may be a fluid-filled bladder or a foam element. The sole structure may also include a comfort-enhancing insole or sockliner located within the void near the bottom portion of the upper, and the sole structure includes a lasting (strobel) attached to the upper and disposed between the midsole and the insole or sockliner.

Midsoles that use fluid-filled bladders typically include a bladder formed from two barrier layers of polymeric material that are sealed or bonded together. Fluid-filled bladders are pressurized with a fluid, such as air, and may incorporate tensile members within the bladder to maintain the shape of the bladder when elastically compressed under an applied load, such as during athletic activities. In general, the design of the bladder emphasizes balancing the support and cushioning characteristics of the foot, which are related to the responsiveness of the bladder to elastic compression under an applied load. In such an aspect, the midsole may include a base for engaging the bladder to form a unitary structure.

Drawings

The drawings described herein are for illustrative purposes only of selected configurations and are not intended to limit the scope of the present disclosure. In the drawings:

FIG. 1 is a perspective view of an article of footwear including a sole structure according to the principles of the present invention;

FIG. 2A is an exploded top perspective view of the sole structure of FIG. 1;

FIG. 2B is an exploded bottom perspective view of the sole structure of FIG. 1;

FIG. 3 is a top perspective view of a first aspect of a cushioning member used in the sole structure of FIG. 1;

FIG. 4 is a bottom perspective view of the cushioning member of FIG. 3;

FIG. 5A is a top view of the cushioning member of FIG. 3;

FIG. 5B is a top view of another aspect of a cushioning member used in the sole structure of FIG. 1;

FIG. 5C is a top view of yet another aspect of a cushioning member for use in the sole structure of FIG. 1;

FIG. 6A is a cross-sectional view of the cushioning member shown in FIG. 5A, taken along line 6A-6A;

FIG. 6B is a cross-sectional view of the cushioning member of FIG. 5B taken along line 6B-6B of FIG. 5B;

FIG. 6C is a cross-sectional view of the cushioning member of FIG. 5C, taken along line 6C-6C of FIG. 5C;

FIG. 7 is a cross-sectional view of the cushioning member of FIG. 3, taken along line 7-7 of FIG. 5A;

FIG. 8 is a cross-sectional view of the cushioning member of FIG. 3, taken along line 8-8 of FIG. 5A;

FIG. 9 is a top view of the sole structure of FIG. 1;

FIG. 10 is a bottom view of the sole structure of FIG. 1;

FIG. 11 is a cross-sectional view of the sole structure of FIG. 1, taken along line 11-11 of FIG. 10;

FIG. 12 is a cross-sectional view of the sole structure of FIG. 1, taken along line 12-12 of FIG. 10;

FIG. 13 is a cross-sectional view of the sole structure of FIG. 1, taken along line 13-13 of FIG. 10;

FIG. 14 is a cross-sectional view of the sole structure of FIG. 1, taken along line 14-14 of FIG. 10; and

figure 15 is a cross-sectional view of the sole structure of figure 1, taken along line 15-15 of figure 10.

Corresponding reference characters indicate corresponding parts throughout the drawings.

Detailed Description

Example configurations will now be described more fully with reference to the accompanying drawings. Example embodiments are provided so that this disclosure will be thorough and will fully convey the scope of the disclosure to those skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods to provide a thorough understanding of the construction of the present disclosure. It will be apparent to those skilled 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 example configurations should not be construed as limiting the scope of the disclosure.

The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms "a", "an" and "the" are 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 stated 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 (e.g., "between" and "directly between", "adjacent" and "directly adjacent", etc.) should be interpreted in a similar manner. 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 and the like may be used herein to describe various elements, components, regions, layers and/or sections. These elements, 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 used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.

One aspect of the invention provides a sole structure. The sole structure includes a cushioning member and a base. In some configurations, the buffer is a fluid-filled chamber including a buffer material. In another aspect, the buffer is a solid body comprising a buffer material. In yet another aspect, the cushion includes a solid, fabric, or foam element encapsulated in a barrier film.

The bumper comprises or consists essentially of a bumper material comprising one or more polymers. In many examples, including when the buffer is a fluid-filled chamber, the buffer material includes or consists essentially of a barrier film that includes a barrier material that includes one or more gas barrier compounds. The cushioning member extends from a forefoot region of the sole structure to a heel region of the sole structure. The cushioning member may include a first series of lobes alternating with a first series of recesses along a length of the cushioning member. The first series of lobes and the first series of recesses extend along one of a medial side of the sole structure and a lateral side of the sole structure. The base is disposed between the cushioning member and the upper. The base includes a series of first supports alternating along a length of the base with a second series of recesses, the supports of the series of first supports being aligned with and in contact with respective lobes of the first series of lobes, and the second series of recesses being aligned with the first series of recesses.

Implementations of the invention may include one or more of the following optional features. In some embodiments, the base includes a cushioning support. The base may also include a plate mounted to the top surface of the cushioning support between the upper and the cushioning support. The plate may be longer than the cushioning support.

In some configurations, at least one support of the series of first supports may include an upper portion extending from a body of the at least one support in a direction toward the upper and outward.

In some configurations, the plate may be made of a material that is more rigid than the material forming the cushion support, which may be made of foam. The series of first supports may include a pair of rear supports configured to align with and contact a pair of toe lobes of the first series of lobes. The toe lobe is disposed in the forefoot region and is formed only on the plate. The series of first supports includes a plurality of forefoot supports and a plurality of heel supports, which may be integrally formed from the cushioning support. In other aspects, the cushioning support includes a continuous recess extending the width of the cushioning support and separating the heel region from the midfoot region. An article of footwear may incorporate a sole structure.

Another aspect of the invention provides a sole structure. The chassis may be incorporated as part of a sole structure of an article of footwear. An article of footwear includes an upper. The sole structure includes a cushioning member that extends from a forefoot region of the sole structure to a heel region of the sole structure. The cushioning member includes a first series of lobes alternating with a first series of recesses along a length of the cushioning member. The first series of lobes and the first series of recesses extend along one of a medial side of the sole structure and a lateral side of the sole structure. The base includes a cushioning support disposed between the cushioning member and the upper, and includes a series of first supports alternating with a second series of recesses along a length of the cushioning support. The supports of the first series of supports are aligned with and in contact with respective lobes of the first series of lobes, and the second series of recesses are aligned with the first series of recesses.

Implementations of the invention may include one or more of the following optional features. In some embodiments, the base may further include a plate mounted to a top surface of the cushioning support between the upper and the cushioning support. The plate may be longer than the cushioning support.

In some configurations, at least one support of the series of first supports includes an upper portion extending from a body of the at least one support in a direction toward the upper and outward. One of the first series of recesses may be configured to extend across a width of the cushioning support, thereby separating the heel region from the medial region.

In some configurations, the cushioning support includes a series of ridges configured to be located within a respective one of a series of pockets formed on the top side of the cushioning member. The cushioning support may include a series of wings extending along a perimeter of the cushioning support, the series of wings configured to rest on the bottom surface of the plate. In yet another configuration, the series of first supports includes a plurality of forefoot supports and a plurality of heel supports, which may be integrally formed from a cushioning member. The article of footwear may incorporate a chassis.

The materials described herein may differ in one or more of appearance, physical properties, and composition. These materials may differ in appearance in color (including hue or brightness or both), or in transparency or translucency level, or in both color and transparency or translucency level. These materials may differ in one or more physical properties, such as hardness or elongation, or hardness and elongation. The one or more physical properties may differ by at least 5% or at least 10% or at least 20%. The composition of these materials may be different. For example, the material may differ based on the type or kind of polymer present, may differ based on the concentration of the type or kind of polymer, or both. The composition of the material may differ based on the additives present, or based on the concentration of the additives present, or both. Alternatively, the concentration of the one or more polymers and/or the one or more additives may differ by at least 5 wt.% or at least 10 wt.% or at least 20 wt.% of the material.

Referring to fig. 1-16, an article of footwear 10 is provided that includes a sole structure 100 and an upper 200 attached to the sole structure 100. Article of footwear 10 may be divided into one or more regions. The regions may include forefoot region 12, midfoot region 14, and heel region 16 (shown in fig. 5A-5C). Forefoot region 12 may be further described as including a toe portion 12T corresponding with the phalanges of the foot and a ball portion 12B corresponding with the Metatarsophalangeal (MTP) joint. Midfoot region 14 may correspond to the arch region of the foot, while heel region 16 may correspond to a rear portion of the foot, including the calcaneus bone. Footwear 10 may also include a forward end 18 associated with a forward-most point of forefoot region 12 and a rearward end 20 corresponding with a rearward-most point of heel region 16. As shown in fig. 10, a longitudinal axis a10 of footwear 10 extends along the length of footwear 10 from a forward end 18 to a rearward end 20, and generally divides footwear 10 into a medial side 22 and a lateral side 24. Accordingly, medial side 22 and lateral side 24 correspond with opposite sides of footwear 10 and extend through regions 12, 14, 16, respectively.

Article of footwear 10, and more particularly sole structure 100, may be further described as including a peripheral region 28 and an interior region 26, as shown in fig. 1. Peripheral region 28 is generally depicted as the region between interior region 26 and the outer periphery of sole structure 100. In particular, peripheral region 28 extends along each of medial side 22 and lateral side 24 from forefoot region 12 to heel region 16 and around each of forefoot region 12 and heel region 16. Accordingly, interior region 26 is circumscribed by peripheral region 28 and extends along a central portion of sole structure 100 from forefoot region 12 to heel region 16.

Referring to fig. 2A and 2B, sole structure 100 includes a midsole 102 configured to provide cushioning features to sole structure 100 and an outsole 104 configured to provide ground-engaging surface 30 of article of footwear 10. Unlike conventional sole structures, the midsole 102 of the sole structure 100 may be compositionally formed and include a plurality of subcomponents for providing a desired form of cushioning and support throughout the sole structure 100. For example, midsole 102 includes a cushioning member 106 and a base 108, wherein base 108 is attached to upper 200 and provides an interface between upper 200 and cushioning member 106.

Referring to fig. 1-5C, a longitudinal axis a106 of cushioning member 106 (shown in fig. 5A-5C) extends from a first end 110 in forefoot region 12 to a second end 112 in heel region 16. Cushioning member 106 may be further described as including a top or top side 114 and a bottom or bottom side 116, bottom or bottom side 116 being formed on a side of cushioning member 106 opposite top side 114. As discussed in more detail below with reference to fig. 6A-8, a thickness T106 of cushioning member 106, or a thickness T106 of an element of cushioning member 106, is defined by the distance from top side 114 to bottom side 116.

Cushioning members 106 are configured to provide cushioning to the foot by attenuating ground reaction forces. In one aspect, cushioning member 106 is a fluid-filled bladder 106A, and in another aspect, cushioning member 106 is a foam element 106B. The difference between fluid-filled bladder 106A and foam element 106B is the attenuation of ground reaction forces. For example, when cushioning member 106 is a fluid-filled bladder 106A, fluid (air) is contained within fluid-filled bladder 106A itself. Thus, fluid within fluid-filled bladder 106A is displaced at the location(s) of ground reaction and forced into other areas of fluid-filled bladder 106A in the form of a reaction force. However, where the cushioning member 106 is a foam element 106B, the ground reaction forces are absorbed by the foam element at the point of impact. In this way, the remainder of foam element 106B is not subjected to reactive forces in the same manner as fluid-filled bag 106A. This feature may be preferred for users who desire a better cushioning response than the cushioning provided by fluid-filled bladder 106A.

As shown in fig. 6A and the cross-sectional views of fig. 7-8, cushioning component 106 is shown as a fluid-filled bladder 106A. Fluid-filled bladder 106A may be formed from an opposing pair of barrier layers 118, and barrier layers 118 may be bonded to one another at discrete locations to define the overall shape of bladder 106A. Alternatively, bladder 106A may be made from any suitable combination of one or more barrier layers. As used herein, the term "barrier layer" (e.g., barrier layer 118) includes both monolayer and multilayer films. In some embodiments, one or both of the barrier layers 118 are made (e.g., thermoformed or blow molded) from a single film (monolayer). In other embodiments, one or both of the barrier layers 118 are made (e.g., thermoformed or blow molded) from a multilayer film(s). In either aspect, each layer or sub-layer may have a film thickness ranging from about 0.2 microns to about 1 millimeter. In further embodiments, the film thickness of each layer or sub-layer may be in the range of about 0.5 microns to about 500 microns. In further embodiments, the film thickness of each layer or sub-layer may be in the range of about 1 micron to about 100 microns.

One or both of the barrier layers 118 may independently be transparent, translucent, and/or opaque. As used herein, the term "transparent" with respect to the barrier layer and/or the pouch means that light passes through the barrier layer in a substantially straight line and the barrier layer is visible to an observer. In contrast, for an opaque barrier layer, light does not pass through the barrier layer and the barrier layer cannot be clearly seen at all. The translucent barrier layer falls between the transparent barrier layer and the opaque barrier layer because light passes through the translucent layer, but some light is scattered so that the layer is not clearly seen through by a viewer.

In one aspect, the balloons or bladders disclosed herein comprise or consist of a barrier film. As used herein, a barrier film is understood to be a film having a relatively low fluid transmission rate. The barrier film elastically retains fluid when used alone or in combination with other materials in the balloon or bladder. Depending on the structure and use of the balloon or bladder, the barrier membrane may retain fluid at pressures above, at, or below atmospheric pressure. In some aspects, the fluid is a liquid or a gas. Examples of the gas include air, oxygen (O2), and nitrogen (N2), and inert gases. In one aspect, the barrier film is a nitrogen barrier material.

The barrier film may have a gas transmission rate of less than 4, or less than 3, or less than 2 cubic centimeters per square meter per atmosphere per day, when measured at 23 degrees celsius and 0% relative humidity, for films having a thickness of about 72 microns to about 320 microns. In another example, the barrier film has a gas transmission rate of about 0.1 to about 3, or about 0.5 to about 3 cubic centimeters per square meter per atmosphere per day for a film having a thickness of about 72 microns to about 320 microns when measured at 23 degrees celsius and 0% relative humidity. Gas transmission rates, such as oxygen or nitrogen transmission rates, may be measured using ASTM D1434.

In one aspect, the barrier film comprises a multilayer film comprising a plurality of layers including one or more barrier layers comprising a barrier material comprising or consisting essentially of one or more gas barrier compounds. The multilayer film comprises at least 5 layers or at least 10 layers. Alternatively, the multilayer film comprises from about 5 to about 200 layers, from about 10 to about 100 layers, from about 20 to about 80 layers, from about 20 to about 50 layers, or from about 40 to about 90 layers.

In one aspect of the multilayer film, the plurality of layers comprises a series of alternating layers, wherein alternating layers comprise two or more barrier layers, each of the two or more barrier layers individually comprising a barrier material comprising or consisting essentially of one or more gas barrier compounds. In the series of alternating layers, adjacent layers are each formed of materials that differ from each other at least in chemical composition based on: the individual components present (e.g., the materials of adjacent layers may differ based on whether a gas barrier compound is present or not, or based on the type or type of gas barrier compound present), the concentration of the individual components present (e.g., the materials of adjacent layers may differ based on the concentration of the particular type of gas barrier compound present); or may differ based on the components present and their concentrations.

The plurality of layers of the multilayer film may include a first barrier layer comprising a first barrier material and a second barrier layer comprising a second barrier material, wherein the first and second barrier materials are different from each other, as described above. The first barrier material may be described as comprising a first gas barrier component consisting of all the gas barrier compounds present in the first barrier material and the second barrier material may be described as comprising a second barrier material component consisting of all the gas barrier compounds present in the second barrier material. In a first example, the first barrier component consists only of one or more gas barrier polymers and the second barrier component consists only of one or more inorganic gas barrier compounds. In a second example, the first barrier component is composed of a first one or more gas barrier polymers and the second component is composed of a second one or more gas barrier polymers, where the first one or more gas barrier polymers differ from the second one or more gas barrier polymers in polymer type, or concentration. In a third example, the first barrier component and the second barrier component both comprise the same type of gas barrier compound, but the concentrations of the gas barrier compounds are different, optionally by at least 5 wt% based on the weight of the barrier material. In these multilayer films, the first barrier layer and the second barrier layer may alternate with each other, or may alternate with additional barrier layers (e.g., a third barrier layer comprising a third barrier layer material, a fourth barrier layer comprising a fourth barrier layer material, etc.), where each of the first, second, third, and fourth barrier materials, etc. are different from each other as described above.

The barrier materials (including the first barrier material, the second barrier material, etc.) have a low gas transmission rate. For example, when forming a monolayer film consisting essentially of a barrier material, the monolayer film has a gas transmission rate of less than 4 cubic centimeters per square meter per atmosphere per day for a film having a thickness of about 72 microns to about 320 microns, as measured at 23 degrees celsius and 0% relative humidity, and as can be measured using ASTM D1434. The barrier material comprises or consists essentially of one or more gas barrier compounds. The one or more gas barrier compounds may comprise one or more gas barrier polymers, or may comprise one or more inorganic gas barrier compounds, or may comprise a combination of at least one gas barrier polymer and at least one inorganic gas barrier compound. The combination of at least one gas barrier polymer and at least one inorganic gas barrier compound may comprise a blend or mixture or may comprise a composite material in which fibres, particles or flakes of the inorganic gas barrier compound are surrounded by the gas barrier polymer.

In one aspect, the barrier material comprises or consists essentially of one or more inorganic gas barrier compounds. The one or more inorganic gas barrier compounds may take the form of fibers, particles, flakes, or a combination thereof. The fibers, particles, flakes may comprise or consist essentially of nanoscale fibers, particles, flakes, or combinations thereof. Examples of inorganic barrier compounds include, for example, carbon fibers, glass flakes, silica, silicates, calcium carbonate, clay, mica, talc, carbon black, particulate graphite, metal flakes, and combinations thereof. The inorganic gas barrier compound may comprise or consist essentially of one or more clays. Examples of suitable clays include bentonite, montmorillonite, kaolinite, and mixtures thereof. In one example, the inorganic gas barrier compound is comprised of clay. Optionally, the barrier material may further comprise one or more additional ingredients, such as polymers, processing aids, colorants, or any combination thereof. In aspects in which the barrier material comprises or consists essentially of one or more inorganic barrier compounds, the barrier material can be described as comprising an inorganic gas barrier component consisting of all of the inorganic barrier compounds present in the barrier material. When one or more inorganic gas barrier compounds are included in the barrier material, the total concentration of inorganic gas barrier components present in the barrier material may be less than 60 wt%, or less than 40 wt%, or less than 20 wt% of the total composition. Alternatively, in other examples, the barrier material consists essentially of one or more inorganic gas barrier materials.

In one aspect, the gas barrier compound comprises or consists essentially of one or more gas barrier polymers. The one or more gas barrier polymers may comprise a thermoplastic polymer. In one example, the barrier material may comprise or consist essentially of one or more thermoplastic polymers, meaning that the barrier material comprises or consists essentially of a plurality of thermoplastic polymers, including thermoplastic polymers that are not gas barrier polymers. In another example, the barrier material comprises or consists essentially of one or more thermoplastic gas barrier polymers, meaning that all polymers present in the barrier material are thermoplastic gas barrier polymers. The barrier material may be described as including a polymer component that is composed of all of the polymers present in the barrier material. For example, the polymer component of the barrier material may consist of a single type of gas barrier polymer, such as one or more polyolefins, or may consist of a single type of gas barrier polymer, such as one or more ethylene-vinyl alcohol copolymers. Optionally, the barrier material may further comprise one or more non-polymeric additives, such as one or more fillers, processing aids, colorants, or combinations thereof.

Many gas barrier polymers are known in the art. Examples of gas barrier polymers include: vinyl polymers such as vinylidene chloride polymers, acrylic polymers such as acrylonitrile polymers, polyamides, epoxy polymers, amine polymers, polyolefins such as polyethylene and polypropylene, copolymers thereof such as ethylene vinyl alcohol copolymers, and mixtures thereof. Examples of thermoplastic gas barrier polymers include thermoplastic vinyl homopolymers and copolymers, thermoplastic acrylic homopolymers and copolymers, thermoplastic amine homopolymers and copolymers, thermoplastic polyolefin homopolymers and copolymers, and mixtures thereof. In one example, the one or more gas barrier polymers comprise or consist essentially of one or more thermoplastic polyethylene copolymers, such as one or more thermoplastic ethylene-vinyl alcohol copolymers. The one or more ethylene-vinyl alcohol copolymers can include an ethylene content of about 28 mole% to about 44 mole%, or an ethylene content of about 32 mole% to about 44 mole%. In yet another example, the one or more gas barrier polymers may include or consist essentially of one or more polyethyleneimines, polyacrylic acids, polyethylene oxides, polyacrylamides, polyamidoamines, or any combination thereof.

In another aspect, in addition to the one or more barrier layers (e.g., including the first barrier layer, the second barrier layer, etc.), the multilayer film also includes one or more second layers that include the second material. In one such construction of the multilayer film, the one or more barrier layers comprises a plurality of barrier layers alternating with a plurality of second layers. For example, each of the one or more barrier layers may be located between two second layers (e.g., one second layer located on a first side of the barrier layer and another second layer located on a second side of the barrier layer, the second side being opposite the first side).

The second material of the one or more second layers may comprise one or more polymers. Depending on the kind of gas barrier compound used and the intended use of the multilayer film, the second material may have a higher gas transmission rate than the barrier material, which means that the second material has a poorer gas barrier than the barrier material. In some aspects, the one or more second layers serve as a substrate for the one or more barrier layers and may serve to increase the strength, elasticity, and/or durability of the multilayer film. Alternatively or additionally, the one or more second layers may be used to reduce the amount of gas barrier material(s) required, thereby reducing overall material costs. The presence of the one or more second layers, particularly when the one or more second layers are located between the one or more barrier layers, can help maintain the overall barrier properties of the film by increasing the distance between cracks in the barrier layer, and thus the distance gas molecules must travel between cracks in the barrier layer in order to pass through the multilayer film, even when the second material has a relatively high gas permeability. While small breaks or cracks in the barrier layers of a multilayer film may not significantly affect the overall barrier properties of the film, the use of a large number of thinner barrier layers may avoid or reduce visible cracking, crazing, or hazing (hazing) of the multilayer film. The one or more second layers may include, but are not limited to, tie layers that bond two or more layers together, structural layers that provide mechanical support to the multilayer film, tie layers that provide bonding materials, such as hot melt adhesive materials, to the multilayer film, and/or overlayers that provide protection to the outer surface of the multilayer film.

In certain aspects, the second material is an elastomeric material, comprising or consisting essentially of at least one elastomer. Many gas barrier compounds are brittle and/or relatively inflexible and thus the barrier layer or layers may be susceptible to rupture when subjected to repeated, excessive stress loads, such as those that may occur during flexing and release of the multilayer film. A multilayer film comprising one or more barrier layers alternating with second layers of elastomeric material results in a multilayer film that is better able to withstand repeated flexing and release while retaining its gas barrier properties compared to a film without the presence of an elastomeric second layer.

The second material comprises, or consists essentially of, one or more polymers. As used herein, the one or more polymers present in the second material are referred to herein as "second polymer(s)" or "second polymer(s)" because these polymers are present in the second material. Reference to "second polymer(s)" does not mean that the "first polymer" is present in the second material, or in the multilayer film as a whole, although in many aspects there are multiple classes or types of polymers. In one aspect, the second material comprises or consists essentially of one or more thermoplastic polymers. In another aspect, the second material comprises, or consists essentially of, one or more elastomeric polymers. In yet another aspect, the second material comprises or consists essentially of one or more thermoplastic elastomers. The second material may be described as including a polymeric component that is composed of all of the polymers present in the second material. In one example, the polymer component of the second material is comprised of one or more elastomers. Optionally, the second material may further comprise one or more non-polymeric additives, such as fillers, processing aids, and/or colorants.

Many polymers suitable for the second material are known in the art. Exemplary polymers that may be included in the second material (e.g., the second polymer) include polyolefins, polyamides, polycarbonates, polyimines, polyesters, polyacrylates, polyesters, polyethers, polystyrenes, polyureas, and polyurethanes, including homopolymers and copolymers thereof (e.g., polyolefin homopolymers, polyolefin copolymers, and the like), and combinations thereof. In one example, the second material comprises or consists essentially of one or more polymers selected from the group consisting of polyolefins, polyamides, polyesters, polystyrenes and polyurethanes, including homopolymers and copolymers thereof and combinations thereof. In another example, the polymer component of the second material is comprised of one or more thermoplastic polymers, or one or more elastomers, or one or more thermoplastic elastomers, including thermoplastic vulcanizates. Alternatively, the one or more second polymers may include one or more thermoset or thermally curable elastomers such as natural and synthetic rubbers, including butadiene rubbers, isoprene rubbers, silicone rubbers, and the like.

Polyolefins are a class of polymers that include monomer units derived from simple olefins such as ethylene, propylene, and butylene. Examples of thermoplastic polyolefins include polyethylene homopolymers, polypropylene copolymers (including polyethylene-polypropylene copolymers), polybutenes, ethylene-octene copolymers, olefin block copolymers; propylene-butane copolymers and combinations thereof, including blends of polyethylene homopolymers and polypropylene homopolymers. Examples of polyolefin elastomers include polyisobutylene elastomers, poly (alpha-olefin) elastomers, ethylene propylene diene monomer elastomers, and combinations thereof.

Polyamides are a class of polymers comprising monomeric units linked by amide bonds. Natural polyamides include proteins, such as wool and silk, and synthetic amides, such as nylon and aramid. The one or more second polymers may include thermoplastic polyamides, such as nylon 6, nylon 6-6, nylon-11, and thermoplastic polyamide copolymers.

Polyesters are a class of polymers comprising monomer units derived from ester functional groups, typically formed by the condensation of a dibasic acid such as terephthalic acid with one or more polyols. In one example, the second material may comprise or consist essentially of one or more thermoplastic polyester elastomers. Examples of polyester polymers include homopolymers such as polyethylene terephthalate, polybutylene terephthalate, poly (1, 4-cyclohexylene-dimethylene terephthalate), and copolymers such as polyester polyurethanes.

Styrene polymers are a class of polymers comprising monomeric units derived from styrene. The one or more second polymers may comprise or consist essentially of a styrene homopolymer, a styrene random copolymer, a styrene block copolymer, or a combination thereof. Examples of styrenic polymers include 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.

Polyurethanes are a class of polymers that include monomer units linked by urethane linkages. Polyurethanes are most commonly formed by reacting a polyisocyanate (e.g., a diisocyanate or triisocyanate) with a polyol (e.g., a diol or triol), optionally in the presence of a chain extender. The monomeric units derived from polyisocyanates are generally referred to as the hard segments of the polyurethane, while the monomeric units derived from polyols are generally referred to as the soft segments of the polyurethane. The hard segments may be derived from aliphatic polyisocyanates, or organic isocyanates, or mixtures of both. The soft segment can be derived from a saturated polyol, or an unsaturated polyol such as a polydiene polyol, or a mixture of both. When the multilayer film is to be bonded to a natural or synthetic rubber, the soft segment comprising a soft segment derived from one or more polydiene polyols may promote adhesion between the rubber and the film when the rubber and the film are crosslinked in contact with each other, for example during vulcanization.

Examples of suitable polyisocyanates from which the polyurethane hard segments can be derived include: hexamethylene Diisocyanate (HDI), isophorone diisocyanate (IPDI), tetramethylene diisocyanate (BDI), diisocyanatocyclohexylmethane (HMDI), 2, 4-trimethylhexamethylene diisocyanate (TMDI), diisocyanatomethylcyclohexane, diisocyanatomethyltricyclodecane, norbornane Diisocyanate (NDI), cyclohexane diisocyanate (CHDI), 4 '-dicyclohexylmethane diisocyanate (H12 MDI), diisocyanatodecane, lysine diisocyanate, toluene Diisocyanate (TDI), TDI and Trimethylolpropane (TMP), methylenediphenyl Diisocyanate (MDI), xylene Diisocyanate (XDI), tetramethylxylylene diisocyanate (TMXDI), hydrogenated Xylene Diisocyanate (HXDI), naphthalene 1, 5-diisocyanate (NDI), 1, 5-tetrahydronaphthalene diisocyanate, p-phenylene diisocyanate (PPDI), 3' -dimethyldiphenyl-4, 4 '-diisocyanate (DDDI), 4' -dibenzyl diisocyanate (DBDI), 4-chloro-1, 3-phenylene diisocyanate, and any combination thereof. In one aspect, the polyurethane comprises or consists essentially of hard segments derived from Toluene Diisocyanate (TDI) or methylene diphenyl diisocyanate (MDI) or both.

The soft segment of the polyurethane can be derived from a variety of polyols including polyester polyols, polyether polyols, polyester-ether polyols, polycarbonate polyols, polycaprolactone polyethers, and combinations thereof. In one aspect, the polyurethane comprises or consists essentially of monomeric units derived from a C4-C12 polyol, or a C6-C10 polyol, or a C8 or lower polyol, meaning a polyol having from 4 to 12 carbon molecules, or from 6 to 10 carbon molecules, or 8 or fewer carbon molecules in its chemical structure. In another aspect, the polyurethane comprises or consists essentially of monomeric units derived from polyester polyols, polyester-ether polyols, polyether polyols, and any combination thereof. In yet another aspect, the polyurethane comprises or consists essentially of a soft segment derived from a polyol or diol having polyester functional units. The soft segments derived from the polyol or diol having polyester functional units may constitute from about 10 to about 50, or from about 20 to about 40, or about 30 weight percent of the soft segments present in the polyurethane.

The multilayer film can be produced by various means, such as coextrusion, lamination, layer-by-layer deposition, and the like. When one or more barrier layers are coextruded, either alone or with one or more second layers, selecting materials (e.g., a first barrier material and a second barrier material, or a single barrier material and a second material) with similar processing characteristics, such as melt temperature and melt flow index, can reduce interlaminar shear during extrusion and can allow alternating barrier layers and second layers to be coextruded while maintaining their structural integrity and desired layer thicknesses. In one example, the one or more barrier materials and optional secondary material (when used) may be extruded as separate individual films, which may then be laminated together to form a multilayer film.

The multilayer film may be produced using a layer-by-layer deposition process. The substrate, optionally comprising a second material or barrier material, may be constructed into a multilayer film by depositing multiple layers on the substrate. The layers may include one or more barrier layers (e.g., a first barrier layer, a second barrier layer, etc.). Optionally, the layers may include one or more second layers. The one or more barrier layers and/or the second layer may be deposited by any means known in the art, such as dipping, spraying, coating, or other methods. The barrier layer or layers may be applied using charged solutions or suspensions, such as cationic or anionic solutions or suspensions, including charged polymer solutions or suspensions. The barrier layer or layers may be applied sequentially using two or more solutions of opposite charge, for example, by applying a cationic solution followed by an anionic solution followed by a cationic solution followed by an anionic solution, and so forth.

The total thickness of the barrier film, including the multilayer film, is from about 40 microns to about 500 microns, or from about 50 microns to about 400 microns, or from about 60 microns to about 350 microns. In one aspect, each individual layer of the plurality of layers of the multilayer film has a thickness of from about 0.001 microns to about 10 microns. For example, the thickness of the individual barrier layers may be from about 0.001 microns to about 3 microns thick, or from about 0.5 microns to about 2 microns thick, or from about 0.5 microns to about 1 micron thick. The thickness of the single second layer may be from about 2 microns to about 8 microns thick, or from about 2 microns to about 4 microns thick.

In another aspect, the thickness of the film and/or individual layers thereof can be measured by any method known in the art, such as ASTM E252, ASTM D6988, ASTM D8136, or using an optical microscope or an electron microscope.

In some aspects, the shore hardness of the barrier film, including the multilayer film, is from about 35A to about 95A, optionally from about 55A to about 90A. In these aspects, hardness can be measured using shore a ASTM D2240.

In one aspect, when the barrier film is formed from a plurality of alternating barrier layers and second layers using a coextrusion process, the barrier material has a melt flow index of about 5 to about 7 grams/10 minutes at 190 degrees celsius when a weight of 2.16 kilograms is used, and the second material has a melt flow index of about 20 to about 30 grams/10 minutes at 190 degrees celsius when a weight of 2.16 kilograms is used. In another aspect, the melt flow index of the barrier material is about 80% to about 120% of the melt flow index of the barrier material per 10 minutes when measured at 190 degrees celsius using a weight of 2.16 kilograms. In these aspects, the melt flow index can be measured using ASTM D1238. Alternatively or additionally, the barrier material or the second material or both have a melting temperature from about 165 degrees celsius to about 183 degrees celsius, or from about 155 degrees celsius to about 165 degrees celsius. In one such example, the barrier material has a melting temperature from about 165 degrees celsius to about 183 degrees celsius, while the second material has a melting temperature from about 155 degrees celsius to about 165 degrees celsius. Further, in these aspects, the melting temperature can be measured using ASTM D3418.

In the illustrated embodiment, the barrier layer 118 includes a first, upper barrier layer 118 that forms the top side 114 of the bladder 106A and a second, lower barrier layer 118 that forms the bottom side 116 of the bladder 106A. In the illustrated example, the inner facing surfaces of the barrier layer 118 (i.e., facing each other) are bonded together at discrete locations to form the web region 120 and the peripheral seam 122. Peripheral seam 122 extends around the outer periphery of bladder 106A and defines the peripheral outline of bladder 106A. As shown in FIGS. 3-5A, 6A, 7, and 8, the upper and lower barrier layers 118 are spaced apart from one another between the web region 120 and the peripheral seam 122 to define a plurality of compartments 126A-126c, 128a-128b, each of which forms a respective portion of an interior void 130 of the bladder 106A.

Bladder 106A may include a plurality of U-shaped or horseshoe-shaped chambers 126A-126c, as shown in U.S. patent application Ser. No. 17/133,732 to Chan et al, the disclosure of which is incorporated by reference herein in its entirety. Portions of these chambers 126a-126c extend along the medial and lateral sides 22, 24 in the peripheral region 28, as discussed in more detail below. Accordingly, these chambers 126a-126b may be referred to as peripheral chambers 126a-126c. Peripheral chambers 126a-126c include a heel peripheral chamber 126a, a forefoot peripheral chamber 126b, and a toe peripheral chamber 126c. In general, peripheral chambers 126A-126c are arranged sequentially along longitudinal axis A106 from first end 110 of bladder 106A to second end 112 of bladder 106A. Thus, the chambers 126A-126c are counter-rotating with respect to each other along the length of the bladder 106A.

Referring to fig. 3-5A, one or more of the peripheral chambers 126a-126c may have a variable cross-sectional area from one end to the other. In addition to the peripheral chambers 126A-126c, the bladder 106A includes one or more interior chambers 128a, 128b disposed in the interior region 26 of the bladder 106A. Here, each of the interior chambers 128a, 128b is at least partially surrounded by a respective one of the peripheral chambers 126a, 126 b. The peripheral chambers 126a-126c and the interior chambers 128a, 128b define an interior void 130. Generally, each of the interior chambers 128a, 128b extends from a first end 132a, 132b connected to the middle section 134a, 134b of an adjacent one of the peripheral chambers 126b, 126c to a terminal second end 136a, 136b adjacent the rear end 20 of the respective one of the peripheral chambers 126a, 126 b. Intermediate segments 134a, 134b fluidly couple medial side 22 of bladder 106A to lateral side 24 of bladder 106A.

As shown, heel peripheral chamber 126A, forefoot peripheral chamber 126b, and toe peripheral chamber 126c include a series of lobes 138a-138i interconnected and disposed along the periphery of bladder 106A. A series of lobes 138a-138i extend in a direction along longitudinal axis a106 of bladder 106A. Each of lobes 138a-138i has a variable cross-sectional area so as to taper from a midpoint of the respective lobe 138a-138i to an end of the respective lobe 138a-138i. For example, each of lobes 138a-138i includes a first end 140a-140i having a first cross-sectional area, a second end 142a-142i having a second cross-sectional area, and an intermediate portion 144a-144i disposed between first end 140a-140i and second end 142a-142i and having a third cross-sectional area that is greater than the first and second cross-sectional areas. Accordingly, each of lobes 138a-138i tapers from intermediate portions 144a-144i toward respective first and second ends 140a-140i and 142a-142i to define a first series of recesses 146a-146h, wherein each recess 146a-146h is disposed between a pair of adjacent lobes 138a-138i to alternate with the series of lobes 138a-138i along the length of chambers 126a-126c. In some examples, the width and thickness of each of lobes 138a-138i taper from intermediate portions 144a-144i.

In the illustrated example of bladder 106A, the plurality of lobes 138a-138i are arranged sequentially end-to-end along peripheral region 28 such that the cross-sectional area of heel peripheral chamber 126A alternates between larger and smaller sizes. As shown, the series of lobes 138a-138i includes a first pair of toe lobes 138a, 138b disposed on toe peripheral cavity 126c, a pair of forefoot lobes 138c, 138d disposed on forefoot peripheral cavity 126b, a pair of mid-foot lobes 138e, 138f disposed in mid-foot region 14 at a forward end of heel peripheral cavity 126A, a pair of heel lobes 138g, 138h disposed in heel region 16 between mid-foot lobes 18e, 138f and second end 112, and a back lobe 138i disposed at second end 112 of bladder 106A. Midfoot lobes 138e, 138f, heel lobes 138g, 138h and hind lobes 138i define a first series 148 of lobes forming heel peripheral chamber 126 a. A pair of toe lobes 138a, 138b and a pair of forefoot lobes 138c, 138d define a second series 150 of lobes. The pair of toe lobes 138a, 138b are spaced apart from one another to define a generally U-shaped recess when viewed along a plane defined by the width and length of the base 108.

Medial lobes 138e, 138f of heel peripheral chamber 126A include medial lobe 138e disposed at the forward end of heel region 16 on medial side 22 of bladder 106, and medial lobe 138f disposed at the forward end of heel region 16 on lateral side 24 of bladder 106A. Each of the medial midfoot lobe 138e and the lateral midfoot lobe 138f extends from a respective first end 140e, 140f to a respective second end 142e, 142f thereof along the peripheral region 28.

With continued reference to fig. 3-5A, trailing lobe 138i is disposed at second end 112 of bladder 106A, with intermediate portion 144i of trailing lobe 138i aligned with longitudinal axis a106 of bladder 106A. In the example shown, trailing lobes 138i extend from first ends 140i on medial side 22 of bladder 106A to second ends 142i on lateral side 24 of bladder 106A. As described above, the cross-sectional area of the intermediate portion 144i is greater than each of the first end 140i and the second end 142i.

Heel lobes 138g, 138h of heel peripheral chamber 126A include a medial heel lobe 138g disposed on medial side 22 of bladder 106A and a lateral heel lobe 138h disposed on lateral side 24 of bladder 106A. As shown, first ends 140g, 140h of heel lobes 138g, 138h are connected to second ends 142e, 142f of medial and lateral midfoot lobes 138e, 138f, respectively. The second end 142g of medial heel lobe 138g is connected to the first end 140i of the rear lobe 138i. Likewise, second ends 142f of lateral heel lobes 138h are connected to second ends 142i of heel lobes 138i. Similar to midfoot lobes 138e, 138f and hind lobes 138i, heel lobes 138e-138h provide a projection of heel peripheral chamber 126A along medial and lateral sides 22, 24 of bladder 106A.

With continued reference to fig. 3-5A, trailing lobe 138i is disposed at second end 112 of bladder 106A, with intermediate portion 144i of trailing lobe 138i aligned with longitudinal axis a106 of bladder 106A. In the example shown, trailing lobes 138i extend from first ends 140i on medial side 22 of bladder 106A to second ends 142i on lateral side 24 of bladder 106A. As described above, the intermediate portion 1441 has a larger cross-sectional area than each of the end portions 1401, 1421.

Heel lobes 138g, 138h of heel perimeter chamber 126A include medial heel lobe 138g disposed on medial side 22 of bladder 106A and lateral heel lobe 138h disposed on lateral side 24 of bladder 106A. As shown, first ends 140g, 140h of heel lobes 138g, 138h are connected to second ends 142e, 142f of medial and lateral midfoot lobes 138e, 138f, respectively. The second end 142g of the medial heel lobe 138g is connected to the first end 140i of the heel lobe 138i. Likewise, second end 142h of lateral heel lobe 138h is connected to second end 142i of heel lobe 138i. Similar to midfoot lobes 138e, 138f and hindfoot lobes 138i, heel lobes 138g, 138h provide a projection of heel peripheral chamber 126A along medial and lateral sides 22, 24 of bladder 106A.

Intermediate sections 134a, 134b extend across the width of bladder 106A. Intermediate segment 134b is adjacent midfoot region 14 and interconnects a pair of forefoot lobes 138c, 138d. As shown, the intermediate segment 134b extends along an arcuate path from the medial side 22 to the lateral side 24. Intermediate section 134a separates toe portion 12T from midfoot region 14 and interconnects second ends 142a, 142b of a pair of toe lobes 138a, 138 b. As shown, the middle section 134a extends along an arcuate path from the medial side 22 to the lateral side 24, thereby facilitating the formation of a U-shaped recess between the pair of toe lobes 138a, 138 b.

Referring still to fig. 3-5A, forefoot peripheral chamber 126B includes a pair of forefoot lobes 138c, 138d that extend through ball portion 12B of forefoot region 12 and are disposed between heel peripheral chamber 126a and toe peripheral chamber 126c. In particular, forefoot lobes 138c, 138d include medial forefoot lobe 138c and lateral forefoot lobe 138d. A first recess 146a is formed where second end 142a of medial toe lobe 138a meets first end 140c of medial forefoot lobe 138 c. Likewise, second recess 146b is formed where second end 142b of lateral toe lobe 138b merges with first end 140d of lateral forefoot lobe 138d. A third recess 146c is formed where the second end 142c of the medial forefoot lobe 138c merges with the first end 140e of the medial midfoot lobe 138 e. Likewise, a fourth concavity 146d is formed where the second end 142d of the outboard forefoot lobe 138d joins the first end 140f of the outboard midfoot lobe 138f.

In some examples, one or both of the forefoot lobes 138c, 138d of the forefoot peripheral chamber 126b may be spherical, such that the intermediate portions 144c, 144d have larger dimensions (e.g., cross-sections, widths, thicknesses) than the first and second ends 140c, 140d, 142c, 142d. For example, in the illustrated construction, the width of each of the first ends 140c, 140d and the second ends 142c, 142d increases from the respective intermediate portions 144c, 144d such that the first ends 140c, 140d and the second ends 142c, 142d converge inwardly toward the longitudinal axis a106 of the bladder 106A. With continued reference to fig. 3-5A, one or both toe lobes 138a, 138b of toe peripheral cavity 126c may be spherical, whereby medial portions 144a, 144b have greater dimensions (e.g., cross-section, width, thickness) than first ends 140a, 140b and second ends 142a, 142b.

Unlike heel and forefoot peripheral chambers 126a and 126b, which are fully attached to web region 120, toe peripheral chamber 126c may be only partially attached to web region 120. For example, toe lobes 138a, 138b of toe peripheral chamber 126c may protrude beyond web region 120 such that each distal end of toe lobes 138a, 138b hangs freely. Thus, each of toe lobes 138a, 138b may move independently of the other. In another configuration, toe lobes 138a, 138b of toe peripheral cavity 126c may be formed to have a substantially circular shape (not shown).

As shown in fig. 5A, the forefoot interior chamber 128a extends along the longitudinal axis a106 from a first end 132a connected to a middle segment 134a of the toe peripheral chamber 126c to a terminal second end 136a adjacent to a middle segment 134b of the forefoot peripheral chamber 126 b. As shown, the outer perimeter of the forefoot interior chamber 128b is offset inward from the inner perimeter of the forefoot perimeter chamber 126b by a substantially constant distance. In the illustrated example, the forefoot interior chamber 128b includes a necked-down portion 152 adjacent the first end 132b, the necked-down portion 152 extending between the recesses 146a, 146b of the forefoot peripheral chamber 126 b. The second end 136b of the forefoot interior chamber 128b may also be spherical and circumscribed by the forefoot lobes 138c, 138d of the forefoot peripheral chamber 126 b.

The heel interior chamber 128a extends along the longitudinal axis a106 from a first end 132a connected to a middle segment 134b of the forefoot peripheral chamber 126b to a terminal second end 136b adjacent a rear lobe 138i of the heel peripheral chamber 126 a. The outer periphery of heel interior chamber 128a is offset inwardly from the inner periphery of heel peripheral chamber 126a by a substantially constant distance. As such, the width of heel interior chamber 128b may increase in a direction from first end 132b to second end 136b.

The interior chambers 128a, 128b are attached to the respective peripheral chambers 126a, 126b by the web region 120 such that each interior chamber 128a, 128b is surrounded by a portion of the web region 120. Accordingly, web region 120 includes a generally U-shaped first portion 154a surrounding heel interior chamber 128a, and a generally U-shaped second portion 154b surrounding forefoot interior chamber 128b, as shown, U-shaped first portion 154a of web region 120 extending between and attaching an outer perimeter of heel interior chamber 128a and an inner perimeter of heel perimeter chamber 126 a. Likewise, the U-shaped second portion 154b extends between and attaches the outer periphery of the forefoot internal chamber 128b and the inner periphery of the forefoot peripheral chamber 126 b. As shown, with respect to the foregoing portions of the web region 120, the term "U-shaped" is not strictly limited to shapes having two straight legs connected by a constant curvature, but refers to any shape that extends from a first end along a generally first direction line, then turns back and extends along the first direction line to a second end adjacent to or facing the first end. Thus, the U-shaped portion of the web region may also be described as, for example, a horseshoe shape, a bell shape, or a hairpin shape.

Adjacent ones of the chambers 126A-126c, 128a-128b are separated from one another by portions of the web region 120 such that pockets or spaces 156A-158c, 160a-160c are formed on opposite sides 114, 116 of the bladder 106A between adjacent ones of the chambers 126A-126c, 128a-128b, as best shown in FIGS. 7 and 8. In other words, bladder 106A includes a series of upper pockets 156A-158c formed by web region 120 and adjacent chambers 126A-126c, 128a-128b on top side 114 of bladder 106A, and a series of lower pockets 158a-158c formed by web region 120 and adjacent chambers 126A-126c, 128a-128b on bottom side 116 of bladder 106A.

With continued reference to FIG. 5A, first and second ends 140a-140i and 142a-142i of the series of lobes 138a-138i and first ends 132a, 132b of interior chambers 128a, 128b form a plurality of conduits that fluidly couple adjacent ones of peripheral chambers 126a-126c to one another. Thus, the portions of the interior void 130 formed by each of the peripheral chambers 126a-126c and the interior chambers 128a, 128b are in fluid communication with one another such that fluid may be transferred between the peripheral chambers 126a-126c.

Referring now to fig. 5B and 6B, another aspect of cushioning member 106 is provided wherein cushioning member 106 is a foam element 106B. In one aspect, foam element 106B is a solid, unitary piece that extends the length, width, and height of cushioning member 106. In such an aspect, the top side 114 and the bottom side 116 of the foam element 106B define the shape of the foam element 106B. The foam element 106B comprises a foam material comprising one or more polymers, examples of which are provided below. As shown in fig. 5B and 6B, the shape of the foam element 106B is the same as the shape of the cushioning member 106 shown in all the drawings. In other words, the foam element 106B may be formed solely from a polymeric material having the same shape as defined by the barrier layer 118 shown in fig. 5A and 6A. It should be noted that the foam element 106B may have the same shape as the peripheral chambers 126A-126c and the interior chambers 128a, 128B described with respect to the fluid-filled bladder 106A, but does not enclose a space or define an interior void because the foam element 106B is formed as a unitary piece. When the bumper 106 is formed as a foam element 106B, features such as the web region 120 of the fluid-filled bladder 106A are also formed from the resilient polymeric material. The polymeric material may be formed to provide substantially the same cushioning and load bearing characteristics as fluid-filled bladder 106A shown in FIGS. 5A and 6A; however, as noted above, the ground reaction forces may be different. That is, ground reaction forces are primarily dissipated by foam elements 106B, as opposed to being distributed throughout fluid-filled bladder 106A. In this manner, the applied load is generally absorbed, rather than being dispersed or attenuated to other locations of cushioning member 106.

Referring to fig. 5C and 6C, another aspect of the cushioning component 106 is provided in which the cushioning component 106 includes a foam element 106B formed as a solid body including a foam material including one or more polymers contained within and between barrier layers 118 so as to be encapsulated. The polymeric material and associated barrier layer 118 may be formed to provide substantially the same cushioning and load-bearing characteristics as fluid-filled bladder 106A shown in fig. 5A and 6A; however, the ground reaction force differs due to the foam element 106B disposed therein. In essence, the combination of the barrier layer 118 and the encapsulated foam element 106B provides a hybrid cushion that shares the characteristics of the fluid-filled bladder 106A and the foam element 106B. That is, the applied load will (i) result in displacement of fluid trapped between the barrier layers 118 and (ii) be absorbed by the polymeric material of the foam element 106B. Encapsulating the polymeric material within the barrier layer 118 helps keep the polymeric material of the foam element 106B clean and dry and helps the foam element 106B maintain a desired shape. Regardless of whether cushioning member 106 includes a barrier layer 118 and a polymeric material or merely a polymeric material defining cushioning member 106, the thickness T106 of cushioning member 106 shown in fig. 6C is the same as the thickness T106 of cushioning member 106 shown in fig. 6A and 6B. Thus, the discussion of the details of cushioning member 106 applies where cushioning member 106 is a fluid-filled chamber, and cushioning member 106 includes or is formed from a foam material that includes one or more polymers encapsulated within barrier layer 118.

With continued reference to fig. 2A and 2B, base 108 is configured to interface with cushioning member 106 to provide unitary midsole 102. It should be appreciated that base 108 is configured to interface with any aspect of cushioning member 106 described herein. The base 108 extends from a first end 160 at the forward end 18 of the sole structure 100 to a second end 162 at the rearward end 20 of the sole structure 100. The base 108 also includes a top surface 164 that defines a portion of the footbed, and a bottom surface 166 formed on a side of the base 108 opposite the top surface 164 and configured to interface with the top side 114 of the bladder 106.

The base 108 may be formed as a unitary piece, or may be formed from multiple elements, as discussed in more detail below. The base 108 includes a series of supports 168a-168g that extend along the length of the base 108. In particular, a plurality of medial supports 168a, 168c, 168e, and 168g extend along the medial side 22 of the base 108, a plurality of lateral supports 168b, 168d, 168f, and 168h extend along the lateral side 24 of the base 108, and a rear support 168i is disposed at the rear end 20 of the base 108. A rear support 168i is disposed between the series of medial supports 168a, 168c, and 168e and the series of lateral supports 168b, 168d, and 168 f. The series of supports 168a-168i alternate with a series of recesses 170a-170f, which series of recesses 170a-170f also extend along the length of the base 108. In particular, the outboard recesses 170a, 170c, and 170e of the second series of recesses 170a-170f extend along the outboard side 24 of the base 108, and the inboard recesses 170b, 170d, and 170f of the second series of recesses 170a-170f extend along the inboard side 22 of the base 108.

Lateral concavity 170a and medial concavity 170b are disposed between midfoot region 14 and forefoot region 12. The outboard recess 170a and the inboard recess 70b each taper in width and height from the peripheral edge of the base 108 to the center of the base 108 and terminate in an outer surface that is coplanar with the bottom of the base 108 so as to form a shape that is a half cone as viewed in cross-section taken along the length of the cone. Lateral recess 170c and medial recess 70d form a midfoot continuous recess 172 that extends the width of base 108. A midfoot continuous concavity 172 separates heel region 16 from midfoot region 14. Midfoot continuous recess 172 is positioned to facilitate outsole 104 bending between heel region 16 and midfoot region 14.

Series of supports 168a-168i are aligned with and in contact with series of lobes 138a-138i. As such, the distal end of each of the supports 168a-168i is generally concave with a generally U-shaped cross-section taken along the width of the base 108 to receive the top surface of a respective lobe of the first series of lobes 138a-138i. The supports 168c-168i define a first series 174 of supports 168c-168i that are configured to align with and contact the first series 148 of lobes 138c-138 i. The supports 168a-168b define a second series 176 of supports configured to align with the second series 150 of lobes 38a-138b disposed in the toe portion 12T of the forefoot region 12.

In the case where the base 108 is constructed of multiple elements, the base 108 may include a cushion support 178 and a plate 180. In such an aspect, the plate 180 is wider than the cushion support 178, and the cushion support 178 is configured to be positioned below the plate 180 and above the cushion member 106. The plate 180 has a continuous surface defined by the peripheral edges of the plate 180. Further, in such an aspect, the first series 174 of supports 168c-168i are formed entirely on the bottom surface of the cushioning support 178 and the second series 176 of second supports 168a-168b are formed entirely on the bottom surface of the plate 180.

With continued reference to fig. 2A and 2B, the base 108 may be configured to support the periphery of a user's foot. In such an aspect, the base 108 can further include a series of upper portions 184a-184h disposed on the peripheral edge of the base 108. Where the base 108 is formed by the cushioning supports 178 and the plate 180, the series of upper portions 184a-184h are formed only on the plate 180.

The series of upper portions 184a-188h are disposed along the perimeter of the base 108 and are curved along the width and height of the chassis 108 so as to conform to the shape of the bottom of the foot. The series of upper portions 184a-184h includes a front upper portion 184a, a rear upper portion 184h, a series of inner upper portions 184b, 184d, 184f and a series of outer upper portions 184c, 184e, 184g that extend along the perimeter of the respective inner and outer sides 22, 24 of the base 108.

The rear upper portion 184h is disposed at the rear end 20 of the base 108 and the front upper portion 184a is disposed at the front end 18 of the base 108. The series of inboard upper portions 184b, 184d, 184f and the series of outboard upper portions 184c, 184e, 184g extend from opposite ends of the aft upper portion 184h to respective ends of the forward upper portion 184 a. The rear upper portion 184h is cupped to help support the rear of the heel. The front upper portion 184a curves along the perimeter of the rear end 20 of the base 108 and may have a substantially constant height. The heights to the upper portions 184a-184h may be the same or different. In aspects in which the base 108 is formed as a unitary piece, the upper portions 184a-188h abut the series of supports 168a-168 i. In aspects in which the base 108 is formed of multiple elements, such as the cushion support 178 and the plate 180, the series of upper portions 184a-184h may be formed entirely on the plate 180.

As described above, the base 108 may be formed by the assembly of the cushion support 178 to the plate 180. In such an aspect, plate 180 is mounted to a top surface of cushioning support 178 so as to be disposed between upper 200 and cushioning support 178. The plate 180 is longer than the cushion supports 178, and lateral and medial supports 168a, 168b (which are configured to align with and contact respective toe lobes 138a, 138 b) are formed on a bottom surface of the plate 180.

The bottom surface of the plate 180 includes an inner peripheral wall 186, the inner peripheral wall 186 bounding a space defining a relief pocket 188. The cushion pocket 188 is configured to receive the cushion support 178, wherein the cushion support 178 may be secured to the plate 180 so as to form a unitary piece. In one aspect, the cushion support 178 may be secured to the cushion pocket 188 using any securing device or technique, illustratively including adhesives, stitching, welding vibration fusing, or the like, alone or in combination.

In one aspect, wherein the base 108 is comprised of a cushioning support 178 and a plate 180, the cushioning support 178 includes a series of wings 190a-190h disposed along the perimeter of the base 108 so as to extend from the front end 18 to the rear end 20 along the medial and lateral sides 22, 24. The series of wings 190a-190h includes a front wing 190a disposed on the front end 18 of the base 108, a rear wing 190h disposed on the rear end 20 of the base 108, a series of inner side wings 190b, 190d, 190f disposed between the rear wing 190h and the front wing 190a along the inner side 22 of the base 108, and a series of outer side wings 190c, 190e, 190g disposed between the rear wing 190h and the front wing 190a along the outer side 24 of the base 108.

The inner perimeter wall 186 of the plate 180 may be sized to receive the cushioning support 178. The inner peripheral wall 186 includes a series of flanges 192a-192h that define the relief pocket 188. The height of inner peripheral wall 186 is substantially the same as the height of the series of wings 190a-190h, thereby forming a substantially seamless transition between the series of wings 190a-190h and the bottom surface of plate 180. Each flange in series 192a-192h is sized to be positioned between an adjacent pair of wings in series 190a-190 h.

The series of flanges 192a-192h includes a pair of front flanges 192a, 192b disposed on the front end 18 of the base 108 and spaced apart from one another to receive the front wing 190a. The series of flanges 192a-192h includes a pair of rear flanges 192g, 192h that are disposed on the rear end 20 of the base 108 and are spaced apart from one another to receive the rear wings 190h. A series of inner flanges 192c, 192e are disposed on inner side 22 of plate 180 between the pair of rear wings 190g, 190h and the pair of front wings 190a, 190 b. A series of outer flanges 192d, 192f are provided on the outer side 24 of the plate 180 between the pair of rear wings 190g, 190h and the pair of front wings 190a, 190 b. Series of inner wings 190b, 190d, 190f are disposed between respective ones of series of inner flanges 192c, 192 e. Likewise, series of outboard wings 190c, 190e, 190g are disposed between respective ones of series of outboard flanges 192d, 192 f.

Base 108 includes a series of ridges 194a-194c that may be configured to seat in one of upper pockets 156a-156c, respectively, when base 108 is assembled to cushioning member 106. A series of ridges 194a-194c are formed on the underside of the cushioning support 178 and include a front ridge 194a, a middle ridge 194b, and a rear ridge 194c. Anterior ridge 194a is disposed on forefoot region 12 and has a generally U-shaped configuration forming an anterior recess 198a, which anterior recess 198a is configured to engage interior chamber 128b. The intermediate ridge 194b is formed by a pair of spaced apart legs 196a, 196b, the pair of spaced apart legs 196a, 196b being disposed on the respective outer side 24 and inner side 22 of the base 108, thereby forming an elongated intermediate depression 198b, the intermediate depression 198b being configured to engage the interior chamber 128b. The rear ridge 194c is generally U-shaped in size so as to define a rear recess 198c configured to engage the interior chamber 128 a. In the illustrated example, ridges 194a-194c may be configured to extend completely into web regions 120 of upper pockets 158a-156c in some areas and to be spaced apart from web regions 120 of upper pockets 158a-156c in other areas when midsole 102 is assembled. Thus, the bottom surfaces of the ridges 194a-194c may contact the web region 120 at selected locations. In other embodiments, one or more of the ridges 194a-194c may be configured such that the distal end is spaced from the web region 120, or may be omitted from the base 108.

Referring now to fig. 9 and 10, one aspect of the base 108 is provided wherein the base 108 is comprised of a cushioning support 178 and a plate 180. The cushion support 178 and the plate 180 may be secured to each other to form a unitary piece using any technique, such as adhesives, welding, and the like. Alternatively, cushioning support 178 and plate 180 may simply be mounted to each other and retained by attachment to outsole 104 and upper 200. The plate 180 has a top surface that is continuous between the peripheral edges of the plate 180.

Referring now to FIG. 11, base 108 and outsole 104 are shown assembled on cushioning member 106. Ridge 194c is shown contacting web region 120, while ridge 194a is spaced from web region 120. The plate 180 is longer than the cushion support 178 and the second series 150 of lobes 138a-138b extend beyond the forward end of the cushion support 178. Outsole 104 is mounted to a bottom surface of cushioning member 106 so as to protect cushioning member 106 during engagement with the ground. The top surface of the respective interior chamber 128a, 128b is located within the respective depression 198a-198c of the corresponding ridge 194a-194 c. The rear support 1681 has a generally hemispherical cross-section that corresponds to a top surface of the rear lobe 1381. The rear end of the rear ridge 194c is spaced from the web region 120. The rear end of the front ridge 194a rests against the web region 120. The midfoot continuous recess 172 separates the rear ridge 194a from the middle ridge 194 b.

Referring now to FIG. 12, a cross-sectional view taken along line 12-12 of FIG. 10 is provided. Fig. 12 shows the engagement of toe lobes 138a, 138b with base 108. In such an aspect, the second series 176 of second supports 168a-168b are formed entirely from the plate 180. Cushioning support 178 does not extend to toe lobes 138a, 138b and a gap 202 is formed between the pair of toe lobes 138a, 138 b. Gap 202 allows toe lobes 138a, 138b to flex freely with respect to lobes 138c-138i, which are connected at respective first and second ends 140a-140i and 142a-142 i.

Referring now to FIG. 13, a cross-sectional view taken along line 13-13 of FIG. 10 is provided. Base 108 is placed fully against top side 114 of cushioning members 106. The medial support 168c and the lateral support 168d engage the pair of forefoot lobes 138c, 138d. The outboard support 168c is formed entirely on the cushion support 178, and the plate 180 rests on the top surface of the cushion support 178. The rear recess 198c of the cushion support 178 defined by the rear ridge 194c is arcuate so as to rest against the top surface of the forefoot interior chamber 128 a. The bottom surface of the front ridge 194a engages the web region 120.

Referring now to FIG. 14, a cross-sectional view taken along line 14-14 of FIG. 10 is provided. The medial support 168e and the lateral support 168f are aligned with and contact a top surface of a respective one of the pair of midfoot lobes 138e, 138f. The medial support 168f and the lateral support 168e are sized to be placed completely against the respective midfoot lobes 138e, 138f. The intermediate depression 198b between the legs 196a, 196b of the intermediate ridge 194b is arcuate so as to rest against the top surface of the inner chamber 128b. Fig. 14 illustrates an aspect in which the bottom surface of the intermediate ridge 194b is spaced from the web region 120.

Referring now to FIG. 15, a cross-sectional view taken along line 15-15 of FIG. 10 is provided. The medial support 168h and the lateral support 168g are aligned with and contact a top surface of a respective one of the pair of heel lobes 138h, 138 g. The medial support 168h and the lateral support 168g are sized to lie entirely against the respective heel lobes 138h, 138 g. The rear recess 198c defined by the rear ridge 194c is arcuate so as to rest against the top surface of the interior chamber 128b. Fig. 14 illustrates an aspect in which the bottom surface of the intermediate ridge 194b is spaced from the web region 120.

The components 178, 180 of the chassis 108 may comprise a chassis material comprising one or more polymers (e.g., foam or rubber) to impart cushioning, response, and energy distribution characteristics to the wearer's foot. In the illustrated example, the cushion support 178 includes a first foam material and the plate 180 includes a second foam material. For example, cushioning supports 178 may include a foam material that provides greater cushioning and impact distribution, while plate 180 includes a foam material with a greater stiffness to provide increased lateral and medial stiffness to perimeter region 28 of upper 200. The upper portions 184b-184h are positioned within the respective wings 190b-190 h. The wings 184b-184h and upper portions 184b-184h extend outwardly and upwardly from the perimeter of the plate 180. The wing portions 184b-184h and the upper portions 184b-184h are aligned with the respective supports 168c-168 i.

Referring again to fig. 2A and 11-15, in one aspect, the cushion support 178 has a generally v-shaped cross-section along the height of the cushion support 178. In particular, the center of cushioning supports 178 defining wings 190b-190h from supports 168c-168i is recessed inwardly relative to wings 190b-190h and corresponding supports 168c-168 i. The series of supports 168c-168i cooperate with the respective wings 184b-184h to provide a compressive force and a reaction force in response to a load. By way of example, the series of supports 168c-168i and the corresponding wings 184b-184h act as springs in response to a compressive load.

The base material comprises one or more polymers. Example base materials include foams or solid materials, including molded foams and molded solid materials.

Various materials described herein (e.g., outsole material, bumper material, base material, etc.) include, or consist essentially of, one or more polymers. The one or more polymers may include one or more thermoplastic polymers, one or more thermoset or thermally curable polymers (i.e., polymers capable of being crosslinked but not yet crosslinked), or one or more thermoset polymers. The one or more polymers may include one or more elastomers, including thermoplastic elastomers (TPEs) or thermoset elastomers, or both. The one or more polymers may include aliphatic polymers, aromatic polymers, or a mixture of both; or may comprise homopolymers, copolymers (including terpolymers), or mixtures of the two.

In some aspects, the one or more polymers may include an olefin homopolymer, an olefin copolymer, or a blend thereof. Examples of olefin polymers include polyethylene, polypropylene, and combinations thereof. In other aspects, the one or more polymers can 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 yet another aspect, the one or more polymers may include one or more polyacrylates, such as polyacrylic acid, esters of polyacrylic acid, polyacrylonitrile, polyacrylic acrylates, polymethyl acrylate, polyethyl acrylate, polybutyl acrylate, polymethyl methacrylate, and polyvinyl acetate; including derivatives thereof, copolymers thereof, and any combination thereof.

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

In other aspects, the one or more polymers can include one or more styrene 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 other aspects, the one or more polymers can 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 above with respect to barrier layer 118. Alternatively, the one or more polymers may include one or more natural and/or synthetic rubbers, such as polybutadiene and polyisoprene.

When the material is a foam, the foam may be foamed using a physical blowing agent that changes phase to a gas upon change in temperature and/or pressure or a chemical blowing agent that forms a gas when heated above its activation temperature. For example, the chemical blowing agent may be an azo compound, such as hexamethylene dicarbonamide, sodium bicarbonate and/or an isocyanate.

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

The material may be formed using a molding process. In one example, when the material comprises a shaped elastomer, the uncured material (e.g., uncured rubber) can be mixed with optional fillers and a curing package (such as a sulfur-based or peroxide-based curing package) in a banbury mixer, calendered, shaped, placed in a mold, and cured.

In another example, when the material is a foam material, the material may be foamed during a molding process, such as an injection molding process. The thermoplastic polymer material may be melted in the barrel of an injection molding system and mixed with a physical or chemical blowing agent and optionally a crosslinking agent and then injected into a mold under conditions that activate the blowing agent to form a shaped foam.

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

Compression molding supplies desirably begin by forming one or more foam preforms, such as by injection molding of the material and foaming it, by foaming the material to form foam particles or beads, by cutting foam sheet stock, and the like. A compression-molded foam may then be produced by placing the one or more foam preforms in a compression mold and applying sufficient pressure to the one or more foam preforms to compress the one or more foam preforms in the closed mold. Once the mold is closed, sufficient heat and/or pressure is applied to the one or more foam preforms in the closed mold for a sufficient time to alter the foam preform(s) by forming a skin on the outer surface of the compression molded foam, or fusing individual foam particles to one another, or increasing the density of the foam remaining in the finished product, or any combination thereof. After heating and/or application of pressure, the mold is opened and the shaped foam article is removed from the mold.

In some examples, outsole 104 extends over midsole 102 to provide increased durability and resiliency. In the illustrated example, outsole 104 is provided as a polymer layer that is overmolded onto cushioning member 106 to provide increased durability to the exposed portions of lower barrier layer 118 of cushioning member 106. Outsole 104 is, therefore, formed of a different material than cushioning member 106 and includes at least one of a different thickness, a different hardness, and a different wear-resistance than lower barrier layer 118. In some examples, outsole 104 may be integrally formed with lower barrier layer 118 of cushioning member 106 using an overmolding process. In other examples, outsole 104 may be formed separately from lower barrier layer 118 of cushioning member 106, and may be bonded to lower barrier layer 118.

Upper 200 is attached to sole structure 100 and includes an interior surface that defines an interior cavity configured to receive and secure a foot for support on sole structure 100. Upper 200 may be formed from one or more materials that are stitched or adhesively bonded together to form an interior chamber. Suitable materials for the upper may include, but are not limited to, mesh, textiles, foam, leather, and synthetic leather. The materials may be selected and positioned to impart durability, air permeability, abrasion resistance, flexibility, and comfort.

The following clauses provide exemplary configurations of the bladder, sole structure, and article of footwear described above.

Clause 1: a sole structure for an article of footwear having an upper includes a cushioning member and a base. The cushioning member extends from a forefoot region to a heel region of the sole structure and includes a first series of lobes alternating with a first series of recesses along a length of the cushioning member. The first series of lobes and the first series of recesses extend along one of a medial side of the sole structure and a lateral side of the sole structure. The cushioning member also includes a second series of lobes in the toe portion. This base includes: a first series of supports, each support aligned with and in contact with a respective lobe of the first series of lobes; and a second series of supports, each support being aligned with and in contact with a respective lobe of the second series of lobes; each of the first series of supports comprises a first material and each of the second series of supports comprises a second material different from the first series of supports.

Clause 2: the sole structure of clause 1, wherein at least one support of the first series of supports and the second series of supports includes an upper portion extending in an outward direction from a body of the at least one support.

Clause 3: the sole structure of clause 2, wherein the base includes a cushioning support.

Clause 4: the sole structure of clause 3, wherein the cushioning support includes a continuous recess extending across a width of the cushioning support between the heel region and the midfoot region.

Clause 5: the sole structure of clause 3, wherein the base further comprises a plate attached on a side of the cushioning support opposite the cushioning member.

Clause 6: the sole structure of clause 5, wherein the plate is longer than the cushioning support.

Clause 7: the sole structure of clause 5, wherein the cushioning support comprises a first material having a first hardness and the plate comprises a second material having a second hardness greater than the first hardness.

Clause 8: the sole structure of any of the preceding clauses wherein the first material comprises a foam material.

Clause 9: the sole structure of any of the preceding clauses, wherein the second series of supports includes a pair of supports configured to align with and contact a pair of toe lobes of the second series of lobes, the toe lobes disposed in the forefoot region.

Clause 10: the sole structure of any of the preceding clauses, wherein the first series of supports includes a plurality of forefoot supports and a plurality of heel supports, the plurality of forefoot supports and the plurality of heel supports being integrally formed of the first material.

Clause 11: the sole structure of any of the preceding clauses wherein the cushioning member is one of a foam element and a fluid-filled bladder, the foam element being a solid, unitary piece that extends the length, width, and height of the cushioning member.

Clause 12: the sole structure of clause 11, wherein the fluid-filled bladder is formed from an opposing pair of barrier layers.

Clause 13: the sole structure of any of the preceding clauses wherein the cushioning member includes a foam element encapsulated in a pair of opposing barrier layers.

Clause 14: an article of footwear comprising a sole structure according to any of the preceding clauses.

Clause 15: a sole structure comprising a cushioning member including (i) a peripheral chamber including a first series of lobes arranged along a peripheral region of the sole structure from a forefoot region to a heel region of a bladder, and (ii) an interior chamber at least partially surrounded by and spaced apart from the peripheral chamber by a web region; and a base including a cushioning support defining a first series of supports disposed along a perimeter region of the sole structure, each support of the first series of supports being separated from an adjacent one of the supports by a recess and contacting a respective one of the lobes.

Clause 16: the sole structure of clause 15, wherein the base further comprises a plate attached on a side of the cushioning support opposite the cushioning member.

Clause 17: the sole structure of clause 16, wherein the plate is longer than the cushioning support.

Clause 18: the sole structure of clause 16, wherein the cushioning support includes a series of wings extending along a perimeter of the cushioning support, the series of wings configured to be positioned against the bottom surface of the plate.

Clause 19: the sole structure of any of the preceding clauses, wherein at least one support of the first series of supports includes an upper portion extending upwardly and outwardly from a body of the at least one support of the first series of supports.

Clause 20: the sole structure of any of the preceding clauses wherein a recess extends across a width of the cushioning support.

Clause 21: the sole structure of any of the preceding clauses, wherein the recess is disposed between the midfoot region and the heel region.

Clause 22: the sole structure of any of the preceding clauses wherein the cushioning support includes a series of ridges configured to be located within a respective one of a series of pockets formed on the top side of the bladder.

Clause 23: the sole structure of any of the preceding clauses wherein the cushioning support comprises an internal support configured to align with a medial chamber disposed between a medial side and a lateral side of the sole structure.

Clause 24: the sole structure of any of the preceding clauses, wherein the first series of supports includes a plurality of forefoot supports and a plurality of heel supports, the plurality of forefoot supports and the plurality of heel supports being integrally formed from the cushioning support.

Clause 25: the sole structure of any of the preceding clauses, wherein the cushioning member is one of a foam element and a fluid-filled bladder, the foam element being a solid, unitary piece that extends a length, a width, and a height of the cushioning member.

Clause 26: the sole structure of clause 25, wherein the fluid-filled bladder is formed from an opposing pair of barrier layers.

Clause 27: the sole structure of any of the preceding clauses wherein the cushioning member includes a foam element encapsulated in a pair of opposing barrier layers.

Clause 28: an article of footwear comprising a sole structure according to any of the preceding clauses.

The foregoing description has been presented 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. Which can likewise be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.

Claims (28)

1. A sole structure, comprising:

a cushioning member including a first series of lobes disposed along one of a medial side and a lateral side of the sole structure from a forefoot region to a heel region and a second series of lobes located in a toe portion; and

a base, comprising: a first series of supports, each of the first series of supports aligned with and in contact with a respective lobe of the first series of lobes; and a second series of supports, each of the second series of supports being aligned with and in contact with a respective lobe of the second series of lobes; each of the first series of supports comprises a first material and each of the second series of supports comprises a second material different from the first series of supports.

2. The sole structure of claim 1, wherein at least one support of the first series of supports and the second series of supports includes an upper portion extending in an outward direction from a body of the at least one support.

3. The sole structure of claim 1, wherein the base includes a cushioning support.

4. The sole structure of claim 3, wherein the cushioning support includes a continuous recess extending across a width of the cushioning support between the heel and midfoot regions.

5. The sole structure of claim 3, wherein the base further includes a plate attached on a side of the cushioning support opposite the cushioning member.

6. The sole structure of claim 5, wherein the plate is longer than the cushioning support.

7. The sole structure of claim 5, wherein the cushioning support comprises a first material having a first hardness and the plate comprises a second material having a second hardness greater than the first hardness.

8. The sole structure of claim 1, wherein the first material comprises a foam material.

9. The sole structure of claim 1, wherein the second series of supports includes a pair of supports configured to align with and contact a pair of toe lobes of the second series of lobes, the toe lobes disposed in the forefoot region.

10. The sole structure of claim 1, wherein the first series of supports includes a plurality of forefoot supports and a plurality of heel supports, the plurality of forefoot supports and the plurality of heel supports being integrally formed of a first material.

11. The sole structure of claim 1, wherein the cushioning member is one of a foam element and a fluid-filled bladder, the foam element being a solid, unitary piece that extends a length, a width, and a height of the cushioning member.

12. The sole structure of claim 11, wherein the fluid-filled bladder is formed from an opposing pair of barrier layers.

13. The sole structure according to claim 1, wherein the cushioning member includes a foam element encapsulated in a pair of opposing barrier layers.

14. An article of footwear comprising the sole structure of claim 1.

15. A sole structure, comprising:

a cushioning member including (i) a peripheral chamber including a first series of lobes arranged along a peripheral region of the sole structure from a forefoot region to a heel region of the cushioning member, and (ii) an interior chamber at least partially surrounded by the peripheral chamber and spaced apart from the peripheral chamber by a web region; and

a base including a cushioning support defining a first series of supports arranged along a peripheral region of the sole structure, each support of the first series of supports being separated from an adjacent one of the supports by a recess and contacting a respective one of the lobes.

16. The sole structure of claim 15, wherein the base further includes a plate attached on a side of the cushioning support opposite the cushioning member.

17. The sole structure of claim 16, wherein the plate is longer than the cushioning support.

18. The sole structure of claim 16, wherein the cushioning support includes a series of wings extending along a perimeter of the cushioning support, the series of wings configured to be positioned against a bottom surface of the plate.

19. The sole structure of claim 15, wherein at least one support of the first series of supports includes an upper portion extending upwardly and outwardly from a body of the at least one support of the first series of supports.

20. The sole structure of claim 15, wherein the recess extends across a width of the cushioning support.

21. The sole structure according to claim 15, wherein the recess is disposed between the midfoot region and the heel region.

22. The sole structure of claim 15, wherein the cushioning support includes a series of ridges configured to be located within a respective one of a series of pockets formed on the top side of the cushioning member.

23. The sole structure of claim 15, wherein the cushioning support includes an interior support configured to align with a medial chamber disposed between a medial side and a lateral side of the sole structure.

24. The sole structure of claim 15, wherein the first series of supports includes a plurality of forefoot supports and a plurality of heel supports, the plurality of forefoot supports and the plurality of heel supports being integrally formed from the cushioning support.

25. The sole structure of claim 15, wherein the cushioning member is one of a foam element and a fluid-filled bladder, the foam element being a solid, unitary piece that extends a length, a width, and a height of the cushioning member.

26. The sole structure of claim 25, wherein the fluid-filled bladder is formed from an opposing pair of barrier layers.

27. The sole structure according to claim 15, wherein the cushioning member includes a foam element encapsulated in a pair of opposing barrier layers.

28. An article of footwear comprising the sole structure of claim 15.

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