CN116234472A

CN116234472A - Article of footwear with zone cushion system

Info

Publication number: CN116234472A
Application number: CN202180064805.0A
Authority: CN
Inventors: N·特鲁法诺夫
Original assignee: Nike Innovate CV USA
Current assignee: Nike Innovate CV USA
Priority date: 2020-10-02
Filing date: 2021-10-01
Publication date: 2023-06-06
Also published as: EP4221534A1; WO2022072832A1

Abstract

An article of footwear includes an upper and a sole structure secured to an underside of the upper. The sole structure includes a midsole; an outsole surface for contacting the ground; and a cushioning system disposed between the midsole and an outsole surface that contacts the ground. The cushioning system includes a deck including an upper deck and a lower deck provided in a spaced apart relationship. The upper and lower plates are integrally connected at a rear portion of the sole structure. A midfoot fluid filling chamber is disposed between the upper and lower plates in the midfoot region and a forefoot fluid filling chamber is disposed between the upper and lower plates in the forefoot region.

Description

Article of footwear with zone cushion system

Cross Reference to Related Applications

The present application claims priority from U.S. provisional patent application No.63/086,716, filed on day 2 of 10 in 2020.

Technical Field

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

Background

Conventional articles of athletic footwear include two primary elements, an upper and a sole structure. The upper provides a covering for the foot that securely receives and positions the foot with respect to the sole structure. In addition, the upper may have a configuration that protects the foot and provides ventilation, thereby cooling the foot and removing perspiration. The sole structure is secured to a lower surface of the upper and is generally positioned between the foot and the ground. In addition to attenuating ground reaction forces and absorbing energy (i.e., imparting cushioning), the sole structure may provide traction and control potentially harmful foot motions, such as over pronation. Accordingly, the upper and the sole structure operate cooperatively to provide a comfortable structure that is suited for a variety of ambulatory activities, such as walking and running.

The sole structure generally includes multiple layers that are generally referred to as an insole, a midsole, and an outsole. The insole is a thin cushioning member located within the upper and adjacent to the plantar (lower) surface to enhance footwear comfort. The midsole, which is traditionally attached to the upper along the entire length of the upper, forms the middle layer of the sole structure and serves a variety of purposes that include controlling foot motions and providing cushioning. The outsole forms the ground-contacting element of footwear and is typically fashioned from a durable, wear-resistant material that includes texturing to improve traction.

The primary element of a conventional midsole is a resilient polymer foam material, such as polyurethane or ethyl acetate, that extends the entire length of the footwear. The properties of the polymer foam material in the midsole are primarily dependent upon factors that include the dimensional configuration of the midsole and the specific characteristics of the material selected for the polymer foam (including the density of the polymer foam material). By varying these factors throughout the midsole, the relative stiffness, ground reaction force attenuation, and energy absorption characteristics may be altered to meet the specific needs of the activity for which the footwear is intended.

Disclosure of Invention

A sole structure for an article of footwear includes a midsole formed from a foamed polymer, a ground-contacting outsole surface, and a cushioning system disposed between the midsole and the ground-contacting outsole surface. The cushioning system includes a polymeric plate defining an upper plate and a lower plate provided in a spaced relationship. The upper and lower plates are integrally connected at a rear portion of the sole structure. At least two vertically stacked fluid-filled chambers are provided between the upper and lower plates in the midfoot region of the cushioning system. The at least two vertically stacked fluid-filled chambers include a first midfoot fluid-filled chamber coupled to the upper plate and a second midfoot fluid-filled chamber coupled to and located between the first midfoot fluid-filled chamber and the lower plate.

The cushioning system also includes at least two laterally disposed fluid-filled chambers disposed between the upper and lower plates in the midfoot region of the cushioning system. The at least two laterally disposed fluid-filled chambers include a lateral forefoot fluid-filled chamber and a medial forefoot fluid-filled chamber. A lateral forefoot fluid-filled chamber is located between a lateral edge of the sole structure and a medial forefoot fluid-filled chamber, and a medial forefoot fluid-filled chamber is located between a medial edge of the sole structure and the lateral forefoot fluid-filled chamber.

Drawings

FIG. 1 is a side view of a lateral side of an article of footwear.

Fig. 2 is a side view of a medial side of the article of footwear.

Fig. 3 is a side perspective view of the medial heel area of the article of footwear.

Fig. 4 is a schematic partial cross-sectional view of a stacked fluid-filled chamber with internal tensile elements.

Fig. 5 is a bottom view of a sole structure for an article of footwear.

Fig. 6 is a top perspective view of a forefoot region of the article of footwear.

Fig. 7A is a schematic side view of an embodiment of an article of footwear having a cushioning structure with an intermediate crash stop in the heel region.

Fig. 7B is a schematic side view of an embodiment of an article of footwear having a cushioning structure with an intermediate crash stop in the heel region.

Fig. 7C is a schematic side view of an embodiment of an article of footwear having a cushioning structure with an intermediate crash stop in the heel region.

Fig. 7D is a schematic side view of an embodiment of an article of footwear having a cushioning structure with an intermediate crash stop in the heel region.

Fig. 7E is a schematic side view of an embodiment of an article of footwear having a cushioning structure with an intermediate crash stop in the heel region.

Fig. 7F is a schematic side view of an embodiment of an article of footwear having a cushioning structure with an intermediate crash stop in the heel region.

Fig. 8A is a schematic side view of an embodiment of an article of footwear having a cushioning structure with a fluid-filled chamber in the heel region.

Fig. 8B is a schematic side view of an embodiment of an article of footwear having a cushioning structure with a fluid-filled chamber in the heel region.

Fig. 8C is a schematic side view of an embodiment of an article of footwear having a cushioning structure with a fluid-filled chamber in the heel region.

Fig. 8D is a schematic side view of an embodiment of an article of footwear having a cushioning structure with a fluid-filled chamber in the heel region.

Fig. 9A is a schematic side view of an embodiment of an article of footwear having a cushioning structure with a mechanical cushioning element in the heel region.

Fig. 9B is a schematic side view of an embodiment of an article of footwear having a cushioning structure with a mechanical cushioning element in the heel region.

Fig. 9C is a schematic side view of an embodiment of an article of footwear having a cushioning structure with a mechanical cushioning element in the heel region.

Fig. 9D is a schematic side view of an embodiment of an article of footwear having a cushioning structure with a mechanical cushioning element in the heel region.

Fig. 10A is a schematic side view of an embodiment of an article of footwear having a cushioning structure with foam cushioning elements in the heel region.

Fig. 10B is a schematic side view of an embodiment of an article of footwear having a cushioning structure with foam cushioning elements in the heel region.

Fig. 10C is a schematic side view of an embodiment of an article of footwear having a cushioning structure with foam cushioning elements in the heel region.

Fig. 10D is a schematic side view of an embodiment of an article of footwear having a cushioning structure with foam cushioning elements in the heel region.

Fig. 10E is a schematic side view of an embodiment of an article of footwear having a cushioning structure with foam cushioning elements in the heel region.

Fig. 10F is a schematic side view of an embodiment of an article of footwear having a cushioning structure with foam cushioning elements in the heel region.

Fig. 10G is a schematic side view of an embodiment of an article of footwear having a cushioning structure with foam cushioning elements in the heel region.

Fig. 11A is a schematic side view of an embodiment of an article of footwear having a cushioning structure with foam elements in the heel region.

Fig. 11B is a schematic side view of an embodiment of an article of footwear having a cushioning structure with foam elements in the heel region.

Fig. 11C is a schematic side view of an embodiment of an article of footwear having a cushioning structure with foam elements in the heel region.

Fig. 11D is a schematic side view of an embodiment of an article of footwear having a cushioning structure with foam elements in the heel region.

Fig. 12A is a schematic side view of an embodiment of an article of footwear having a cushioning structure with foam cushioning elements and mechanical cushioning elements in the heel region.

Fig. 12B is a schematic side view of an embodiment of an article of footwear having a cushioning structure with foam cushioning elements and mechanical cushioning elements in the heel region.

Fig. 12C is a schematic side view of an embodiment of an article of footwear having a cushioning structure with foam cushioning elements and mechanical cushioning elements in the heel region.

FIG. 13 is a top side view of an article of footwear including a dual cinching closure system.

FIG. 14 is a top lateral perspective view of a throat portion of an article of footwear.

Detailed Description

The following discussion and accompanying figures disclose an article of footwear 10 (also referred to as article 10) according to the present disclosure. In general, the present article 10 incorporates a novel cushioning system in which the upper substantially rests on a cantilevered panel (cantilevered plate) that is supported in part via one or more cushioning features disposed on an underside of the cantilevered panel (i.e., between the cantilevered panel and a connected ground plate). The article 10 is depicted in the figures and discussed below as having a configuration suitable for athletic activities, particularly running. However, the concepts disclosed with respect to article 10 may be applied to footwear styles that are specifically designed for a wide range of other athletic activities, including basketball, baseball, football, soccer, walking, and hiking, for example, and may also be applied to a variety of non-athletic footwear styles. Accordingly, those skilled in the relevant art will recognize that the concepts disclosed herein may be applied to a wide variety of footwear styles and are not limited to the specific embodiments discussed below and depicted in the accompanying figures.

Referring to fig. 1 and 2, an article of footwear 10 is shown that includes an upper 12 and a sole structure 14 attached to upper 12. The article of footwear 10 may be divided into one or more zones. These areas may include forefoot region 16, midfoot region 18, and heel region 20. The forefoot region 16 may correspond with the toes and the joints connecting the metatarsals with the phalanges of the foot. Midfoot region 18 may correspond to the arch region of the foot, while heel region 18 may correspond to the rear of the foot, including the calcaneus bone. The article of footwear 10 may additionally include a medial side 22 (shown in fig. 2) and a lateral side 24 (shown in fig. 1) corresponding with opposite sides of the article of footwear 10 and extending through the

regions

16, 18, 20.

Upper 12 includes an interior surface that defines an interior void 26, and interior void 26 receives and secures a foot for support on sole structure 14. An ankle opening 28 in heel region 20 may provide access to interior void 26. For example, ankle opening 28 may receive a foot to secure the foot within void 26 and facilitate entry and removal of the foot from interior void 26.

In some examples, one or more fasteners or other closure systems 30 extend through upper 12 to adjust the fit of interior void 26 around the foot while accommodating the entry and removal of the foot therefrom. The fasteners or other closure systems 30 may include laces, straps, ropes, latching mechanisms, clasps, snaps, shackles, or any other suitable type of fastener.

Upper 12 may be formed from one or more materials that are stitched or adhesively bonded together to form an interior void 26. Suitable materials for upper 12 may include textiles, foam, leather, and synthetic leather. The materials may be selected and positioned to impart durability, air permeability, wear resistance, flexibility, and comfort to the foot when disposed within interior void 26.

Sole structure 14 is attached to an underside of upper 12 and provides support and cushioning for article of footwear 10 during use. That is, sole structure 14 attenuates ground reaction forces that are caused by footwear 10 hitting the ground during use. Accordingly, as described below, sole structure 14 may incorporate one or more materials having energy-absorbing properties to allow sole structure 14 to minimize the impact experienced by a user while wearing article of footwear 10.

Sole structure 14 may include a midsole 36, an outsole 38, and one or more cushioning systems 40 generally disposed between midsole 36 and outsole 38. Cushioning system 40 may cooperate with midsole 36 to attenuate ground reaction forces during use, while providing a stable and responsive platform for supporting the foot of a wearer. Cushioning system 40 may include a plate 42 that generally extends between a front end 44 of article of footwear 10 and a rear end 46 of article of footwear 10. Cushioning system 40 may also include one or more fluid-filled chambers 48, with fluid-filled chambers 48 being operable to compress under the weight of the wearer.

With continued reference to fig. 1-2, midsole 36 is shown extending generally from a front end 44 of article of footwear 10 to a rear end 46 of article of footwear 10. As further shown, in some embodiments, midsole 36 may extend beyond the forward-most and rearward-most ends of upper 12. Midsole 36 is secured to a lower portion of upper 12 and is positioned to extend under the foot during use. Midsole 36 attenuates ground reaction forces and absorbs energy (i.e., provides cushioning) during walking or running, among other purposes. Midsole 36 may be formed from an energy-absorbing material, such as a polymer foam. Forming midsole 36 from an energy-absorbing material, such as ethyl acetate foam, allows midsole 36 to attenuate ground reaction forces that are caused by movement of article of footwear 10 over the ground during use.

Outsole 38 or outsole surface is disposed on a ground-facing lower surface of cushioning system 40 and is disposed on a side of cushioning system 40 opposite midsole 36 and upper 12. Outsole 38 may define a ground-engaging surface 50, with ground-engaging surface 50 being operable to provide wear resistance and enhance traction between article of footwear 12 and the ground. Outsole 38 may be formed of a resilient material, such as rubber or softer thermoplastic polyurethane, which may improve traction and durability. Ground-engaging surface 50 may include one or more outwardly extending traction elements to provide increased traction for article of footwear 10 during use.

Midsole 36 may be used to attach cushioning system 40 to upper 12, as best shown in fig. 3. In one embodiment, cushioning system 40 may be coupled to midsole 36, for example, by adhering a portion of plate 42 to a lower surface of midsole 36 (i.e., via a suitable adhesive-not shown). Alternatively, cushioning system 40 may be attached to midsole 36 by molding the material of midsole 36 directly onto plate 42 (e.g., insert injection molding). For example, plate 42 may be disposed within a cavity of a mold (not shown) used to form midsole 36. When midsole 36 is formed (i.e., by foaming the polymeric material), the material of midsole 36 engages the material of plate 42, thereby forming a unitary structure having both midsole 36 and plate 42.

Although cushioning system 40 is depicted and described as being attached to the underside of midsole 36 (i.e., on the side of the midsole opposite upper 12), a portion of cushioning system 40 may alternatively be embedded within the material of midsole 36. For example, a portion of plate 42 may be encapsulated by midsole 36 such that a portion of midsole 36 extends through a portion of plate 42 or to an opposite side of a portion of plate 42. In addition, the plate 42 may be disposed within the midsole 36, but not fully encapsulated. For example, the plate 42 may be visible around the perimeter of the midsole 36 as a portion of the midsole 36 extends between the plate 42 and the upper 12 and another portion of the midsole 36 extends between the plate 42 and the outsole 38.

As shown, the plate 42 may include an upper cantilever plate 60, with the upper cantilever plate 60 integrally coupled with a lower ground plate 62 (i.e., at a joint/joint region 64) to form a spring-like damper. In a general sense, the upper plate 60 and the lower plate 62 are configured to deflect toward one another in response to static or dynamic loads applied by the wearer. In some configurations, the joint region 64 may include a rounded bend that smoothly couples the spaced apart upper and

lower plates

60, 62. Cushioning system 40 may also include one or more fluid-filled chambers 48 disposed between upper plate 60 and lower plate 62 to help control the magnitude (and/or rate) of deflection between

plates

60, 62 away from joint 64.

In one configuration, upper plate 60 and lower plate 62 may each extend along a longitudinal dimension of sole structure 14, and in some embodiments, one or both of upper plate 60 and lower plate 62 may extend entirely from forward end 44 of sole structure 14 to rearward end 46 of sole structure 14. In some configurations, the upper plate 60 can extend along at least a portion of the heel region 20 and midfoot region 18. In other cases, the upper plate 60 may extend through at least a portion of the heel region 20, midfoot region 18, and forefoot region 16. Additionally, in some configurations, the lower plate 62 may extend through at least a portion of the heel region 20, midfoot region 18, and forefoot region 16.

In one embodiment, the plate 42 may comprise a single sheet of relatively rigid material that is folded/wrapped upon itself. For example, the plate 42 may be formed from a non-foamed polymeric material, or alternatively, from a composite material comprising fibers such as carbon fibers. Suitable materials may include Thermoplastic Polyurethane (TPU), polyamide (e.g., PA6 or PA 66), or other engineering polymers. The material may comprise fibrous fillers such as short or long glass fibers, aramid, bamboo or carbon fibers, or may comprise similar continuous fabrics. Forming plate 42 from a relatively rigid material allows plate 42 to distribute forces associated with the use of article 10 while maintaining upper plate 60 and lower plate 62 in a spaced relationship. In some embodiments, the spaced relationship is desirably greater than about 5mm, or greater than about 8mm, or even greater than about 10mm. In other embodiments, the plate 62 is not thermoformed from a single piece, but may be injection molded into a substantially final shape.

In one configuration, the joint region 64 of the plate 42 may be disposed within or behind the heel region 20 of the sole structure 14, and may be formed with a thickness and stiffness suitable to withstand the expected static and impact loads without allowing the upper and

lower plates

60, 62 to excessively deflect and/or contact each other. In such embodiments, a medial concavity/void 66 may exist between the upper plate 60 and the lower plate 62 within the heel region 20. In the unloaded/relaxed state, the recess/void 66 may have a first height 68 measured perpendicular to the ground. Static and impact loads from the wearer may urge the upper and

lower plates

60, 62 into a more closely spaced relationship when worn. In other words, the recess/void 66 may be compressed to have a second height that is less than the first height 68.

The degree to which the

plates

60, 62 flex toward one another in the heel region 20 may be controlled in large part by the stiffness of the plate 42 within the joint region 64. While some elastic bending/movement of upper plate 60 and lower plate 62 is desirable to provide cushioning/force attenuation, if joint region 64 is not sufficiently stiff, deflection may be greater than desired, which may result in the shoe feeling unstable.

In some embodiments, to subject the entire heel region 20 to similar reaction forces from the cushioning system, the joint region 64 of the plate 42 may be disposed rearward of the rear end 70 of the upper 12 and/or rearward of the rear end 72 of the midsole 36.

While the cushioning response in heel region 20 may be primarily due to the elasticity/stiffness of joint region 64 of plate 42, cushioning system 40 may rely on one or more fluid-filled chambers 48 to provide the cushioning response in midfoot region 18 and/or in forefoot region 16. In the embodiment shown in fig. 1-3, cushioning system 40 includes first and second fluid-filled

chambers

80, 82 disposed within midfoot region 18, and a fluid-filled chamber 84 disposed within forefoot region 16.

As shown in fig. 1-4, a first fluid-filled chamber 80 is generally disposed between the upper plate 60 and a second fluid-filled chamber 82, and the second fluid-filled chamber 82 is disposed between the lower plate 62 and the first fluid-filled chamber 80. Specifically, a first fluid-filled chamber 80 is attached to the lower surface of upper plate 60 on a first side and to a second fluid-filled chamber 82 on a second side. The second fluid-filled chamber 82 is attached to the upper surface of the lower plate 62 on a first side and to the first fluid-filled chamber 80 on a second side. Additionally or alternatively, the first fluid-filled chamber 80 may be attached to the second fluid-filled chamber 82 by thermally joining (e.g., melting/welding) the material of the first fluid-filled chamber 80 and the material of the second fluid-filled chamber 82 at the junction of the first fluid-filled chamber 80 and the second fluid-filled chamber 82.

Similar to the first and second fluid-filled

chambers

80, 82, the forefoot fluid-filled chamber 84 may be disposed between the upper and

lower plates

60, 62. In one embodiment, the forefoot fluid-filled chamber 84 is attached to the lower surface of the upper plate 60 on a first side and to the upper surface of the lower plate 62 on a second side. The fluid-filled

chambers

80, 82, 84 may be attached to each other and/or to the upper and

lower plates

60, 62, respectively, via a suitable adhesive.

In one configuration, such as best shown in fig. 5, the forefoot fluid chamber 84 may actually include two separate fluid-filled chambers: medial forefoot fluid-filled chamber 86 and lateral forefoot fluid-filled chamber 88. In this embodiment, the midfoot region 18 may include two stacked fluid-filled

chambers

80, 82, while the forefoot region 16 may include two laterally adjacent fluid-filled

chambers

86, 88.

Referring again to fig. 4, each of the fluid-filled

chambers

80, 82, 84, 86, 88 may include a first blocking element 90 and a second blocking element 92. The first barrier element 90 and the second barrier element 92 may be formed from Thermoplastic Polyurethane (TPU) sheets. In particular, the first blocking element 90 may be formed from a sheet of TPU material and may comprise a substantially flat shape. The second barrier element 92 may likewise be formed from a sheet of TPU material and may be formed in the configuration shown in fig. 4 to define an interior void 94. The first barrier element 90 may be joined to the second barrier element 92 by applying heat and pressure at the perimeter of the first barrier element 90 and the second barrier element 92 to define a peripheral seam 96. Peripheral seam 96 seals interior void 94, thereby defining the volume of each

chamber

80, 82, 84, 86, 88.

The interior void 94 of the fluid-filled

chambers

80, 82, 84, 86, 88 may receive a tensile element 98 therein. Each stretch element 98 may include a series of stretch strands (100) extending between an upper stretch panel 102 and a lower stretch panel 104. The upper stretch-panel 102 may be attached to the first barrier element 90 and the lower stretch-panel 104 may be attached to the second barrier element 92. In this manner, as each

chamber

80, 82, 84, 86, 88 receives pressurized fluid, the tensile strand 100 of the tensile element 98 is in tension. Because the upper stretch-panel 102 is attached to the first barrier element 90 and the lower stretch-panel 104 is attached to the second barrier element 92, the stretch strands 100 maintain the desired shape of the

respective chambers

80, 82, 84, 86, 88 when pressurized fluid is injected into the interior void 94.

During operation, when the ground engaging surface 50 of the outsole 38 contacts the ground, forces are transferred to the fluid-filled

chambers

80, 82, 84, 86, 88 via the lower plate 62. The applied force compresses each fluid-filled

chamber

80, 82, 84, 86, 88, thereby absorbing the forces associated with the outsole 38 contacting the ground. This force is transferred to upper plate 60 and midsole 36, but is not felt by the user in the form of a point or localized load. Instead, the force applied by outsole 38 is distributed across

plates

60, 62 and is damped via the cantilever geometry of plate 42, the dynamic response of fluid-filled chamber 48, and the compressibility of midsole 36.

Referring to fig. 6, in one configuration, forefoot region 16 of sole structure 14 may have a lateral width 120, which lateral width 120 is greater than a corresponding lateral width 122 of upper 12 measured at the same location along longitudinal axis 124. Lateral width 120 of sole structure 14 may be measured between lateral edge 126 and medial edge 128 of sole structure 14 and orthogonal to major longitudinal axis 124 (best shown in fig. 5). Similarly, lateral width 122 of upper 12 may be measured between lateral edge 130 and medial edge 132 of upper 12 and orthogonal to major longitudinal axis 124.

As generally shown in fig. 6, in one configuration, medial forefoot fluid-filled chamber 86 may extend at least partially beyond medial edge 132 of upper 12, and lateral forefoot fluid-filled chamber 88 may extend at least partially beyond lateral edge 130 of upper 12 (when viewed from a top view). This may provide additional lateral stability to the footwear and a more uniform pressure distribution between outsole 38 and the ground.

In some configurations, the lower plate 62 may include one or more upturned sole portions 140, such as extending on one or both of the medial side of the medial forefoot fluid-filled chamber 86, the lateral side of the lateral forefoot fluid-filled chamber 88, and the medial or lateral side of the second midfoot fluid-filled chamber 82. This arrangement may provide some degree of shock protection to the fluid-filled chamber. Likewise, if outsole 38 extends upwardly onto the outer surface of the upturned sole portion 140, this feature may further provide traction to the sidewalls of sole structure 14.

While lower plate 62 may extend from the forward-most end to the rearward-most end of the sole structure, in one configuration upper plate 60 may terminate just anterior/anteriorly of forefoot fluid-filled chamber 84. In this embodiment, midsole 36 may be secured to the upper surface of upper plate 60 and the upper surface of lower plate 62.

Referring to fig. 5-6, in one configuration, forefoot region 16 may include a vertical split 150 through sole structure 14 and/or upper 12, with vertical split 150 extending from a forward end of article 10. In so doing, some or all of the forefoot region 16 may be divided into a medial forefoot region 152 and a lateral forefoot region 154. When worn, the split 150 may extend between two immediately adjacent toes of the wearer. Because the medial and

lateral forefoot regions

152, 154 are physically separated, this design utilizes separate medial and lateral fluid-filled

chambers

86, 88. To provide further independence, the split 150 may extend through and divide the upper 12, midsole 36, and lower plate 62. In some embodiments, upper plate 60 may be further separated such that the split extends at least partially between medial and lateral fluid-filled

chambers

86, 88. Referring to fig. 5, in one configuration, the split 150 in the lower plate 62 may include two sections, a front section 160 disposed generally along a first split axis 162, and a second rear section 164 disposed along a second split axis 166. In one configuration, the first split axis 162 may intersect the medial fluid-filled chamber 86 and the second split axis 166 may intersect the lateral fluid-filled chamber 88. Furthermore, the two

axes

162, 166 may be disposed at an angle relative to the longitudinal axis 124 of the sole 14. For example, the first axis of segmentation 162 may extend from the front end 44 of the sole structure 14 generally toward the medial edge 128. Conversely, second axis of separation 166 may extend from first axis of separation 162 toward lateral edge 126 of sole structure 14. This may provide a further degree of independent movement between the medial and lateral sides of the forefoot, particularly to the medial and

lateral forefoot regions

152, 154.

Looking at the arrangement of the forefoot fluid-filled

chambers

86, 88 themselves, in one configuration, the medial fluid-filled chamber 86 may be located slightly forward of the lateral fluid-filled chamber 88 such that the line 168 drawn between their respective centers is disposed at an oblique angle (i.e., neither parallel nor perpendicular) relative to the longitudinal axis 124.

Referring again to fig. 1, in one configuration, the lower plate 62 may be a generally smooth and continuous plate (when viewed from a side view) having upturned arcuate front and rear ends. Conversely, the upper plate 60 may include a stepped geometry defined by a first forefoot portion 170, a second midfoot portion 172, and a third heel portion 174, each substantially parallel to the lower plate 62. Forefoot portion 170 may be closest to lower plate 62, heel portion 174 may be located a furthest distance from lower plate 62, and midfoot portion 172 may be located an intermediate distance between forefoot portion 170 and heel portion 174. An angled transition region 176 may exist between adjacent forefoot and

midfoot portions

170, 172 and between adjacent midfoot and

heel portions

172, 174. The use of a stepped approach may allow cushioning system 40 to accommodate a stack of fluid-filled cushioning chambers in midfoot region 18.

In some embodiments, the heel region 20 may also include a bumper 178 disposed between the upper plate 60 and the lower plate 62. In one configuration, the bumper 178 may be adhered to the lower surface of the upper plate 60 and may have a height that allows for a spaced relationship between the bumper 178 and the lower plate 62. In another embodiment, bumper 178 may be a portion of midsole 36 that extends through an aperture in upper plate 60. In yet another embodiment, the bumper 178 may be a molded contour of the upper plate 60. The purpose of the bumper 178 may be to limit the allowable deflection response of the heel region 20 while also preventing larger objects from becoming trapped within the bumper system 40.

Figures 7A-7F schematically illustrate six alternative embodiments, each utilizing a bumper 178 to constrain the force response of cushioning system 40 as a function of vertical compression within heel region 20. Fig. 7A-7D provide designs incorporating only a single bumper 178 protruding from either upper plate 60 or lower plate 62. In fig. 7E-7F, the design shown includes bumpers 178 protruding from both the upper plate 60 and the lower plate 62. By configuring these bumpers to ultimately contact and engage each other, the bumpers may serve to stabilize the upper against relative movement or rolling in the anterior/posterior direction or in the lateral/medial direction. For example, in the embodiment shown in fig. 7E, if the user is running, when the shoe strikes the ground, the heel will compress through the front/anterior surface 200 of the upper bumper and that surface may contact the rear/posterior surface 202 of the lower bumper to help stabilize the shoe and/or prevent excessive forward translation of the foot relative to the ground contacting lower plate 62 (e.g., during normal running steps after an initial strike/impact, and prior to pedaling).

In another embodiment, instead of using a bumper, the heel region 20 may include one or more fluid-filled chambers 210 between the upper plate 60 and the lower plate 62, such as generally shown in fig. 8A-8D. In some embodiments, these fluid-filled chambers 210 may be air-filled bladders, and may be similar in design and structure to bladders in midfoot. In other embodiments, such as shown in fig. 8D, the fluid-filled chamber may be a single-level chamber extending entirely between the upper plate 60 and the lower plate 62.

Fig. 9A-9D schematically illustrate alternative designs for incorporating different mechanical cushioning structures 220 between upper plate 60 and lower plate 62. As shown in fig. 9A-9C, these mechanical cushioning structures 220 may include one or more intermediate structures, such as plates, struts, and/or springs extending between the lower plate 62 and the upper plate 60. In one configuration, each of these structures may be formed from the same plate-like material as upper plate 60 and lower plate 62, and in some embodiments, they may be formed by the same manufacturing process used to form upper plate 60 and lower plate 62. When cushioning system 40 is compressed, mechanical cushioning structure 220 may flex, hinge, or compress in a spring-like manner to elastically absorb and store energy from an impact. As the wearer begins to remove the compressive load, mechanical cushioning structure 220 may rebound and the stored energy may help restore cushioning system 40 to its original state. The embodiment shown in fig. 9D completely repositions joint area 64 under heel area 20 of upper 12. In so doing, the joint region 64 is subjected to a more vertical load than the hinging moment experienced when it is located substantially behind/behind the heel region 20.

Much like the embodiment shown in fig. 9A-9D, wherein the mechanical shock absorbing/cushioning structure 220 is used to absorb shock loads, fig. 10A-10G schematically illustrate seven different embodiments wherein the intermediate foam structure 230 is located between and in contact with both the upper and

lower plates

60, 62. When cushioning structure 40 undergoes vertical compression, foam structure 230 will compress elastically as upper plate 60 approaches lower plate 62. In one configuration, each foam structure 230 may be substantially continuous from a macroscopic perspective, and may not have any holes or apertures that are larger than the holes or apertures inherent in the foam itself. In other embodiments, the foam structure 230 may have one or more in-mold or molded/laser cut apertures that may extend through a portion or the entire foam structure. In one embodiment, the foam may have at least one continuous columnar portion extending from the upper plate 60 to the lower plate 62 and be completely devoid of apertures (i.e., apertures that are larger than the cell size of the foam itself). This design may provide more continuous force response based on compression. In some embodiments, less than 25% of the foam structure 230 may extend continuously between the upper and

lower plates

60, 62 when viewed perpendicular to one or both of the upper or

lower plates

60, 62. In another embodiment, the amount of foam that extends continuously between the upper and lower plates (when viewed two-dimensionally in a direction perpendicular to one or both of the upper or lower plates 60, 62) may be between 0%, or between 5% and 25%, or between 20% and 40%, or between 30% and 50%, or between 40% and 70%, or between 60% and 80%, or between 80% and 100%. The inclusion of a greater number of apertures in the foam will alter the force response so that a greater initial deflection is allowed and a greater amount/volume of foam is engaged with a greater amount of deflection.

In other embodiments, such as shown in fig. 11A-11D, cushioning system 40 may include an intermediate foam structure 230, however, instead of being designed for compression, it may be more designed as a hinge that primarily blocks debris out of the interior volume between

plates

60, 62, while functioning much like the cushioning in fig. 7A-7F. In this design, the voids or apertures 232 in the foam may create a cantilevered design that is closer to a living hinge than the foam pad. In other embodiments, such as shown in fig. 12A-12C, the intermediate foam structure 230 may be paired with the mechanical cushioning structure 220 to provide a composite response.

Although the various intermediate cushioning configurations shown in fig. 7A-12C are all shown in heel region 20, it is expressly contemplated that different ones of these configurations may be used in combination or may be located elsewhere in cushioning system 40, such as, but not limited to, in midfoot region 18 and/or forefoot region 16. In addition, any of these intermediate buffer designs may be used with or in place of the fluid-filled chambers 48 shown in FIGS. 1-6.

In one configuration, closure system 30 of upper 12 may include one or more over-arches 180, which over-arches 180 extend from medial side 22 of the shoe onto upper 12, as shown in fig. 2, and span to lateral side 24, as shown in fig. 13. On the outboard end 182 of the strap 180, the closure system may include a dual fastening system 184. Such dual fastening systems 184 can include a first fastener 186, the first fastener 186 securing and pulling the strap 180 toward the forefoot region 16 of the sole structure 14. In addition, dual fastening system 184 may include a second fastener 188, where second fastener 188 secures and pulls strap 180 toward heel region 20 of sole structure 14.

Closure system 30 may also include a coating tongue 190, as shown in fig. 14, that extends from medial side 22 of upper 12 toward lateral side 24 of upper 12. When the over-arch strap 180 is pulled closed and secured, it may maintain the tongue 190 in close overlapping contact with the lateral side 192 of the upper 12.

To make the cushioning system, in one configuration, the plate 42 may begin as a die cut or injection molded sheet. If the base resin of plate 42 is a thermoplastic polymer, the sheet may be heated and bent around a mold having the contours of upper plate 60, lower plate 62, and joint 64. Once the plate 42 is formed around the tool, the upturned sole portion 140 may be formed via localized heating and shaping. In alternative embodiments, the plate may be injection molded into its finished form. In some embodiments, outsole 38 may be integral with lower plate 62, such as by insert molding or co-molding with plate 42. In another embodiment, the outsole 38 may be adhered to the lower plate 62, for example, via a suitable adhesive.

The above features and advantages and other features and advantages of the present teachings are readily apparent from the following detailed description of the best modes and other embodiments for carrying out the present teachings when taken in connection with the accompanying drawings.

"a," "an," "the," "at least one," and "one or more" are used interchangeably to indicate at least one of the items is present; a plurality of such items may be present unless the context clearly indicates otherwise. All numerical values of parameters (e.g., amounts or conditions) in this specification (including the appended claims) are to be understood as being modified in all instances by the term "about", whether or not "about" actually appears before the numerical value. "about" means that the recited value allows some slight imprecision (with near precision in value; approximately or reasonably near to the value). If the imprecision provided by "about" is not otherwise understood in the art with this ordinary meaning, then "about" as used herein at least refers to variations that may be caused by ordinary methods of measuring and using such parameters. Moreover, the disclosure of a range includes disclosure of all values and further divided ranges throughout the range. Each value within a range and the endpoints of the range are disclosed herein as separate embodiments. The terms "comprising," "including," "containing," and "having" are inclusive and therefore specify the presence of the stated items but do not preclude the presence of other items. As used in this specification, the term "or" includes any and all combinations of one or more of the listed items. When the terms first, second, third, etc. are used to distinguish between different items, these designations are for convenience only and do not limit the items.

Any directional references used herein assume that the article of footwear is positioned in an upright position on a flat horizontal ground plane such that the outsole is in contact with the ground plane (i.e., as if worn by a user standing in an upright manner).

Claims

1. An article of footwear having a heel region, a midfoot region, and a forefoot region, the article of footwear comprising:

an upper having an interior volume adapted to receive a foot of a wearer;

a sole structure secured to an underside of the upper, the sole structure comprising:

a foam midsole;

an outsole surface for contacting the ground; and

a cushioning system disposed between the foam midsole and an outsole surface that contacts the ground, the cushioning system comprising:

a unitary plate structure extending through the heel region, the midfoot region, and the forefoot region, the unitary plate structure comprising an upper plate, a lower plate, and a joint portion coupling the upper plate with the lower plate, wherein the joint portion is located in a rear portion of the heel region, and wherein the upper plate and lower plate are disposed in spaced relation in each of the heel region, midfoot region, and forefoot region;

a forefoot fluid-filled chamber disposed between the upper plate and the lower plate within the forefoot region, wherein the forefoot fluid-filled chamber comprises a plurality of bonded thermoplastic sheets defining an interior void therebetween, and wherein at least one of the plurality of bonded thermoplastic sheets is bonded to one of the upper plate and the lower plate;

a midfoot fluid filling chamber disposed between an upper plate and a lower plate within the midfoot region, wherein the midfoot fluid filling chamber comprises a plurality of bonded thermoplastic sheets defining an interior void therebetween, and wherein at least one of the plurality of bonded thermoplastic sheets of the midfoot fluid filling chamber is bonded to one of the upper plate and the lower plate; and

at least one of a fluid-filled chamber, an elastically deformable mechanical cushioning structure, or a compressible foam cushioning structure is disposed between the upper plate and the lower plate in the heel region.

2. The article of footwear of claim 1, wherein the midsole has a first hardness and the plate has a second hardness, and wherein the second hardness is greater than the first hardness.

3. The article of footwear of claim 1, wherein the midfoot fluid filling chamber comprises a first midfoot fluid filling chamber and a second midfoot fluid filling chamber;

the first midfoot fluid filling chamber is in contact with the upper plate and disposed between the upper plate and the second midfoot fluid filling chamber; and is also provided with

The second midfoot fluid filling chamber is in contact with the lower plate and is disposed between the lower plate and the first midfoot fluid filling chamber.

4. The article of footwear of claim 3, wherein at least one of the first midfoot fluid filled chamber or the second midfoot fluid filled chamber includes a plurality of tensile elements extending through an interior void of the chamber.

5. The article of footwear of claim 1, wherein the forefoot fluid-filled chamber includes a lateral forefoot fluid-filled chamber and a medial forefoot fluid-filled chamber;

the lateral forefoot fluid-filled chamber is located between a lateral edge of the sole structure and the medial forefoot fluid-filled chamber; and is also provided with

The medial forefoot fluid-filled chamber is located between a medial edge of the sole structure and the lateral forefoot fluid-filled chamber.

6. The article of footwear of claim 5, wherein at least one of the lateral forefoot fluid-filled chamber or the medial forefoot fluid-filled chamber includes a plurality of tensile elements extending through an interior void of the chamber.

7. The article of footwear of claim 1, further comprising a split extending from a front edge of the forefoot region and separating a portion of each of the upper, the midsole, and the lower plate into a medial forefoot portion and a lateral forefoot portion.

8. A sole structure for an article of footwear, the sole structure having a heel region, a midfoot region, and a forefoot region, the sole structure comprising:

a midsole;

an outsole surface for contacting the ground; and

a cushioning system disposed between the midsole and the ground-contacting outsole surface, the cushioning system comprising:

a plate defining upper and lower plates disposed in spaced relation, the upper and lower plates integrally connected at a rear portion of the sole structure;

9. The sole structure of claim 8, wherein the midsole has a first hardness and the plate has a second hardness, and wherein the second hardness is greater than the first hardness.

10. The sole structure of claim 8, wherein the midfoot fluid filling chamber comprises a first midfoot fluid filling chamber and a second midfoot fluid filling chamber;

11. The sole structure of claim 10, wherein at least one of the first midfoot fluid filled chamber or the second midfoot fluid filled chamber includes a plurality of tensile elements extending through an interior void of the chamber.

12. The sole structure of claim 8, wherein the forefoot fluid-filled chamber includes a lateral forefoot fluid-filled chamber and a medial forefoot fluid-filled chamber;

13. The sole structure of claim 12, wherein at least one of the lateral forefoot fluid-filled chamber or the medial forefoot fluid-filled chamber includes a plurality of tensile elements extending through an interior void of the chamber.