CN219813349U

CN219813349U - Sole structure for an article of footwear and article of footwear

Info

Publication number: CN219813349U
Application number: CN202221330848.7U
Authority: CN
Inventors: C.埃尔登; Z.M.埃尔德; C.R.莱维; E.珀金斯; E.西蒙斯; P.伍德曼
Original assignee: Nike Innovate CV USA
Current assignee: Nike Innovate CV USA
Priority date: 2021-05-28
Filing date: 2022-05-30
Publication date: 2023-10-13
Anticipated expiration: 2032-05-30

Abstract

The present utility model relates to a sole structure for an article of footwear having an upper, the sole structure including a midsole. The midsole may include a cushioning member and a chassis. The cushioning member extends from a forefoot region to a heel region of the sole structure. The base is disposed between the top side of the cushioning member and the upper. An outsole is mounted to a bottom surface of the midsole. The outsole includes a first outsole portion, a second outsole portion, and a third outsole portion. The first outsole portion, the second outsole portion, and the third outsole portion are spaced apart from one another to provide flexibility to the sole structure. The first outsole portion, the second outsole portion, and the third outsole portion may be formed from a first material and a second material. The second material is more durable than the first material. The utility model also relates to an article of footwear.

Description

Sole structure for an article of footwear and article of footwear

Cross Reference to Related Applications

The present utility model claims priority from 35u.s.c. ≡119 (e) for applications: U.S. provisional patent application Ser. No. 63/300,259, U.S. provisional patent application Ser. No. 63/300,246, U.S. provisional patent application Ser. No. 63/300,252, U.S. provisional patent application Ser. No. 63/253,022, U.S. provisional patent application Ser. No. 63/194,327, U.S. provisional patent application Ser. No. 63/194,314, and U.S. provisional patent application Ser. No. 63/194,314, U.S. provisional patent application Ser. No. 63/327, and U.S. provisional patent application Ser. No. 63/194,314, U.S. No. 28, U.S. 5/28, and U.S. 5/28, of 2021, each of which is incorporated herein by reference in its entirety.

Technical Field

The present disclosure relates generally to sole structures for articles of footwear, and more particularly to sole structures incorporating an outsole.

Background

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

Articles of footwear generally include an upper and a sole structure. The upper may be formed of any suitable material(s) to receive, secure, and support the foot on the sole structure. The upper may be engaged 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 and enhance traction to the ground. The other 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 cushioning members to increase the durability of the sole structure and to cushion the foot by resiliently compressing under an applied load to attenuate ground reaction forces. The cushioning member may be a fluid-filled bladder or foam element. The sole structure may also include a comfort-enhancing insole or sockliner that is located within the void near the bottom portion of the upper, and the sole structure includes a lasting (strobel) that is attached to the upper and disposed between the midsole and the insole or sockliner.

The midsole, which uses a fluid-filled bladder, typically includes a bladder formed from two barrier layers of polymeric material that are sealed or bonded together. The fluid-filled bladder is pressurized with a fluid, such as air, and a tensile member may be incorporated within the bladder to maintain the shape of the bladder when elastically compressed under an applied load (e.g., during athletic activities). In general, bladder designs emphasize 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 aspects, the midsole may include a seat for engagement with the bladder to form a unitary structure.

The outsole generally covers the bottom surface of the midsole and provides both wear-resistance and ground traction. Such outsoles are typically formed as a single piece attached to a bottom surface of the midsole.

Disclosure of Invention

One aspect of the utility model provides a sole structure. The sole structure includes a cushioning member and a chassis. The cushioning member includes a first series of lobes disposed along a medial side and a lateral side of the sole structure from a forefoot region to a heel region. The outsole has a first side attached to the cushion element and a second side disposed on a side of the outsole opposite the first side. The second side defines a ground-contacting surface of the sole structure. The outsole includes a first outsole portion and a second outsole portion. The first outsole portion has a substantially U-shape and includes a first medial leg and a first lateral leg. The second outsole portion is spaced apart and separated from the first outsole portion and has a generally U-shape that includes a second medial leg and a second lateral leg, the first medial leg, the first lateral leg, the second medial leg, and the second lateral leg extending toward a front end of the sole structure.

In certain constructions, the buffer is a fluid-filled chamber. In another aspect, the cushioning member is a solid body. The cushioning element comprises or consists essentially of a cushioning element material comprising one or more polymers. In many examples, including when the buffer is a fluid-filled chamber, the buffer material comprises or consists essentially of a barrier film comprising a barrier material comprising one or more gas barrier compounds. The outsole comprises or consists essentially of an outsole material comprising one or more polymers. Articles of footwear incorporating the sole structures disclosed herein are also provided.

Implementations of the disclosure may include one or more of the following optional features. In some embodiments, the second outer bottom portion includes an inner leg extending in a direction away from the front end.

In some constructions, the inner leg extends between the first inner leg and the first outer leg.

In some constructions, the second outer bottom portion includes an arcuate portion extending between and connecting the second inner side leg and the second outer side leg, the inner leg extending from the arcuate portion.

The first outsole portion may include an arcuate portion extending between and connecting the first medial leg and the first lateral leg. The arcuate portion may extend along a rear end of the sole structure in a heel region.

In some constructions, the outsole further includes a third outsole portion that is spaced apart and separated from the first outsole portion and the second outsole portion. The third outsole portion may include a third medial leg and a third lateral leg that extend in a direction toward the front end of the sole structure. The third outsole portion may also include an arcuate portion extending between and connecting the third medial leg and the third lateral leg. The third outsole portion may also include a generally U-shape. In another aspect of the third outsole portion, the third outsole portion includes an inner leg extending from the arcuate portion in a direction away from the forward end. In such an aspect, the inner leg extends between the second inner leg and the second outer leg.

In some constructions, a portion of the cushion element is exposed in at least one of (i) between the first outsole portion and the second outsole portion, and (ii) between the second outsole portion and the third outsole portion.

In some constructions, the first outsole portion comprises or consists of a first outsole material and the second outsole portion comprises or consists of a second material. In one example, the first outsole material and the second outsole material have substantially the same appearance, physical properties, and composition. Alternatively, the first outsole material and the second outsole material may differ in one or more of appearance, physical properties, and composition.

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

Another aspect of the utility model provides an outsole for a sole structure. The sole structure includes a cushion including a first series of lobes disposed along a medial side and a lateral side of the sole structure from a forefoot region to a heel region. The sole structure also includes an outsole having a first side attached to the cushion element, a second side disposed on a side of the outsole opposite the first side and defining a ground-contacting surface of the sole structure. The outsole includes a first outsole portion and a second outsole portion. The first outsole portion has a substantially U-shape and includes a first medial leg and a first lateral leg. The second outer bottom portion is spaced apart and separated from the first outsole portion and has a generally U-shape including a second medial leg and a second lateral leg. The first medial leg, the first lateral leg, the second medial leg, and the second lateral leg each include a longitudinal axis that extends substantially parallel to a longitudinal axis of the sole structure.

Implementations of the disclosure may include one or more of the following optional features. In some embodiments, the second outer bottom portion includes an inner leg that extends in a direction away from the front end of the sole structure. The inner leg may extend between the first inner leg and the first outer leg.

In some constructions, the first outsole portion includes an arcuate portion extending between and connecting the first medial leg and the first lateral leg. In one aspect, the arcuate portion extends along the rear end of the sole structure in the heel region.

In some constructions, the outsole further includes a third outsole portion that is spaced apart and separated from the first outsole portion and the second outsole portion. In such an aspect, the third outsole portion includes a third medial leg and a third lateral leg that extend in a direction toward the front end of the sole structure. The third outsole portion may include an arcuate portion extending between and connecting the third medial leg and the third lateral leg. The third outsole portion may include a generally U-shape. In such an aspect, the third outsole portion includes an inner leg extending from the arcuate portion in a direction away from the forward end. The inner leg may extend between the second inner leg and the second outer leg. The third outsole portion may comprise or consist of a third outsole material, or may comprise or consist of a first outsole material or a second outsole material. As described above, the third outsole material may be different from the first outsole material, the second outsole material, or both, based on one or more of appearance, physical characteristics, and composition.

In some constructions, the cushion is a fluid-filled chamber including a cushion material. In another aspect, the bumper is a solid body comprising a bumper material. In yet another aspect, the buffer comprises a solid, fabric or foam element encapsulated in a barrier film. An article of footwear may incorporate an outsole.

Another aspect of the utility model provides an outsole for a sole structure. The sole structure includes a cushion including a first series of lobes disposed along a medial side and a lateral side of the sole structure from a forefoot region to a heel region. The sole structure also includes an outsole having a first side attached to the cushion element, a second side disposed on a side of the outsole opposite the first side and defining a ground-contacting surface of the sole structure. The outsole includes: a first outsole portion having a generally U-shape and including a first medial leg and a first lateral leg; and a first insert attached to the first outsole portion and formed of a different material than the first outsole portion. In one example, the first outsole portion includes a first outsole material and the first insert includes a second outsole material. The first outsole material and the second outsole material may have the same appearance, physical properties, and composition, or may differ in at least one of appearance, physical properties, and composition as described above.

In some constructions, the first insert is disposed within a pocket defined by the first outsole portion, and the first insert is attached to one of the first medial leg and the first lateral leg.

In some constructions, a second insert is attached to the first outsole portion and optionally includes a second outsole material, wherein the second insert is attached to the other of the first medial leg and the first lateral leg.

In some constructions, the first outsole portion includes an arcuate portion extending between and connecting the first medial leg and the first lateral leg.

In some constructions, the second outsole portion is spaced apart and separated from the first outsole portion, wherein the second outsole portion includes a generally U-shape having a second medial leg and a second lateral leg.

In certain constructions, the buffer is a fluid-filled chamber. In another aspect, the cushioning member is a solid body. In yet another aspect, the cushioning element comprises a solid, fabric or foam element encapsulated in a barrier element. An article of footwear may incorporate an outsole.

Drawings

The drawings described herein are for illustration 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 principles of the utility model;

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 for use in the sole structure of FIG. 1;

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

FIG. 5A is a top plan view of the bumper of FIG. 3;

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

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

FIG. 6A is a cross-sectional view of the bumper of FIG. 3 taken along line 6A-6A of FIG. 5A;

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

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

FIG. 7 is a cross-sectional view of the bumper of FIG. 3 taken along line 7-7 of FIG. 5A; and

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

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

FIG. 10 is a bottom plan 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;

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

FIG. 16 is a cross-sectional view of the sole structure of FIG. 1, taken along line 16-16 of FIG. 10.

Corresponding reference characters indicate corresponding parts throughout the several views of the drawings.

Detailed Description

Example constructions 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, in order to provide a thorough understanding of the construction of the present disclosure. It will be apparent to one of ordinary skill in the art that the example construction may be embodied in many different forms without the use of specific details, and that the specific details and example construction 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," "includes," "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 should not 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" or "engaged to," "connected to," "attached to" or "coupled to" another element or layer, it can 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" or "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 portions should not be limited by these terms. These terms are 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.

Referring to fig. 1-16, an article of footwear 10 is provided that includes a sole structure 100 and an upper 300 attached to sole structure 100. The article of footwear 10 may be divided into one or more zones. The areas may include a forefoot region 12, a midfoot region 14, and a heel region 16. The forefoot region 12 may be further described as including a toe portion 12T corresponding to the phalanges of the foot and a ball portion 12B corresponding to the Metatarsophalangeal (MTP) joint. Midfoot region 14 may correspond to the arch region of the foot and heel region 16 may correspond to the rear portion of the foot, including the calcaneus bone. Footwear 10 may also include a front end 18 associated with a forward-most point of forefoot region 12 and a rear end 20 corresponding with a rearward-most point of heel region 16. As shown in FIG. 1, a longitudinal axis A10 of footwear 10 extends along a length of footwear 10 from a front end 18 to a rear end 20 and generally divides footwear 10 into a medial side 22 and a lateral side 24. Thus, medial side 22 and lateral side 24 correspond to 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 described as the region between interior region 26 and the outer periphery of sole structure 100. In particular, peripheral region 28 extends from forefoot region 12 to heel region 16 along each of medial side 22 and lateral side 24, and surrounds each of forefoot region 12 and heel region 16. Accordingly, interior region 26 is circumscribed by peripheral region 28 and extends from forefoot region 12 to heel region 16 along a central portion of sole structure 100.

Referring to fig. 2A and 2B, sole structure 100 includes a midsole 102 configured to provide sole structure 100 with cushioning features and an outsole 104 configured to provide ground-engaging surface 30a of article of footwear 10. Unlike conventional sole structures, midsole 102 of sole structure 100 may be formed compositely and include a plurality of sub-components for providing the desired form of cushioning and support throughout sole structure 100. For example, midsole 102 includes cushioning member 106 and chassis 108, wherein chassis 108 is attached to upper 300 and provides an interface between upper 300 and cushioning member 106.

Referring to fig. 1-5C, a longitudinal axis a106 (shown in fig. 5A-5C) of bumper 106 extends from a first end 110 in forefoot region 12 to a second end 112 in heel region 16. Cushioning members 106 may be further described as including a top surface or side 114 and a bottom surface or side 116, bottom surface or side 116 being formed on a side of cushioning members 106 opposite top side 114. As discussed in more detail below with reference to fig. 6A, 7 and 8, the thickness T106 of the bumper 106 or the thickness T106 of the elements of the bumper 106 is defined by the distance from the top side 114 to the bottom side 116.

Cushioning members 106 are configured to cushion 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 the cushioning member 106 is a fluid-filled bladder 106A, fluid (air) is contained within the fluid-filled bladder 106A itself. Thus, the fluid within fluid-filled bladder 106A is displaced at the location(s) of the ground reaction and forced into other areas of fluid-filled bladder 106A in the form of reaction forces. However, in the case where the cushioning member 106 is a foam element 106B, the ground reaction force is 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 bladder 106A. This feature is preferred by users desiring a better cushioning response than the cushioning provided by fluid-filled bladder 106A.

As shown in the cross-sectional views of fig. 6A, 7 and 8, the cushioning element 106 is a flow-through filled bladder 106A that may be formed from a pair of opposing barrier layers 118 that may be interconnected at discrete locations to define the overall shape of the cushioning element 106. 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 single layer and multilayer films. In some constructions, one or both of the barrier layers 118 are made of a single layer film (monolayer) (e.g., thermoformed or blow molded). In other constructions, one or both of the barrier layers 118 are made of a multilayer film (multiple sublayers) (e.g., thermoformed or blow molded). 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 constructions, 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 configurations, 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 bladder means that the light passes through the barrier layer in a substantially straight line and the viewer can see through the barrier layer. In contrast, for an opaque barrier layer, light does not pass through the barrier layer and is not clearly visible through the barrier layer at all. A translucent barrier layer falls between a transparent barrier layer and an opaque barrier layer because light passes through the translucent layer, but some of the light is scattered so that the viewer cannot clearly see through the layer.

In one aspect, the balloons or balloons 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 permeability. The barrier film elastically retains fluid when used alone or in combination with the balloon or other materials in the balloon. Depending on the configuration and use of the balloon or bladder, the barrier film may hold the fluid at a pressure above, equal to, 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.

For films having a thickness of about 72 microns to about 320 microns, 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. 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 micrometers to about 320 micrometers, as 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 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 the alternating layers comprise two or more barrier layers, each of the two or more barrier layers individually comprising or consisting essentially of a barrier material comprising one or more gas barrier compounds. In a 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 based on the type or kind 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 vary 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 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 gas barrier compounds present in the second barrier material. In a first example, the first barrier component consists of only one or more gas barrier polymers and the second barrier component consists of only one or more inorganic gas barrier compounds. In a second example, the first barrier component is comprised of a first one or more gas barrier polymers and the second component is comprised of a second one or more gas barrier polymers, wherein the first one or more gas barrier polymers differ in polymer type, or concentration from the second one or more gas barrier polymers. In a third example, the first barrier component and the second barrier component both comprise the same type of gas barrier compound, but the concentration of the gas barrier compound is different, alternatively the concentration differs by at least 5% by weight 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.), wherein each of the first, second, third, and fourth barrier materials, etc. are different from each other as described above.

The barrier material (including the first barrier material, the second barrier material, etc.) has a low gas transmission rate. For example, when forming a monolayer film consisting essentially of a barrier material, the monolayer film has a gas permeability of less than 4 cubic centimeters per square meter per atmosphere per day for a film having a thickness of about 72 micrometers to about 320 micrometers, measured at 23 degrees celsius and 0% relative humidity, and may 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 include one or more gas barrier polymers, or may include one or more inorganic gas barrier compounds, or may include a combination of at least one gas barrier polymer and at least one inorganic gas barrier compound. The combination of the at least one gas barrier polymer and the at least one inorganic gas barrier compound may comprise a blend or mixture, or may comprise a composite in which fibers, 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 a combination thereof. Examples of inorganic barrier compounds include, for example, carbon fibers, glass flakes, silica, silicates, calcium carbonate, clays, 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 consists 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 where the barrier material comprises or consists essentially of one or more inorganic barrier compounds, the barrier material may be described as comprising an inorganic gas barrier component consisting of all 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 include thermoplastic polymers. 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, which means that all polymers present in the barrier material are thermoplastic gas barrier polymers. The barrier material may be described as including a polymer component consisting of all of the polymers present in the barrier material. For example, the polymer component of the barrier material may be composed of a single type of gas barrier polymer, such as one or more polyolefins, or may be composed 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 such as polyolefins of 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 may 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 polyethylenimine, polyacrylic acid, polyethylene oxide, polyacrylamide, polyamidoamine, or any combination thereof.

In another aspect, the multilayer film further includes one or more second layers that include a second material in addition to the one or more barrier layers (e.g., including a first barrier layer, a second barrier layer, etc.). In one such construction of the multilayer film, the one or more barrier layers comprise 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 is located on a first side of the barrier layer and the other second layer is 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 type 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 property 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 the overall material cost. The presence of the one or more second layers, particularly when the one or more second layers are located between one or more barrier layers, may help maintain the overall barrier properties of the film by increasing the distance between the cracks in the barrier layers, thereby increasing the distance that gas molecules must travel between the cracks in the barrier layers 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 layer of the 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 blurriness (hazing) of the multilayer film. The one or more second layers may include, but are not limited to, a tie layer that bonds two or more layers together, a structural layer that provides mechanical support to the multilayer film, a tie layer that provides an adhesive material, such as a hot melt adhesive material, to the multilayer film, and/or a cover layer that provides 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 therefore the barrier layer or layers may be prone to cracking 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 a second layer of elastomeric material results in a multilayer film that is better able to withstand repeated flexing and release while maintaining its gas barrier properties than a film without an elastomeric second layer.

The second material comprises or consists essentially of one or more polymers. As used herein, one or more polymers present in the second material are referred to herein as one or more "second polymers" or "second polymers" because these polymers are present in the second material. References to the second polymer(s) do 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 polymer component that consists 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 use in the second material are known in the art. Exemplary polymers that may be included in the second material (e.g., second polymer) include polyolefins, polyamides, polycarbonates, polyimides, 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 thermosettable elastomers, such as natural rubber and synthetic rubber, including butadiene rubber, isoprene rubber, silicone rubber, and the like.

Polyolefins are a class of polymers comprising monomer units derived from simple olefins such as ethylene, propylene and butene. 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 monomer units linked by amide linkages. Natural polyamides include proteins such as wool and silk, and synthetic amides such as nylon and aromatic polyamides. 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 functionality, typically formed by condensing 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 polyurethane.

Styrene polymers are a class of polymers comprising monomer 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 often 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 monomer units derived from the polyisocyanate are generally referred to as hard segments of the polyurethane, while the monomer units derived from the polyol are generally referred to as soft segments of the polyurethane. The hard segment may be derived from an aliphatic polyisocyanate, or an organic isocyanate, or a mixture of both. The soft segment may 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 segments comprising segments derived from one or more polydiene polyols can 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 polyurethane hard segments may be derived include: hexamethylene Diisocyanate (HDI), isophorone diisocyanate (IPDI), butylene Diisocyanate (BDI), diisocyanato cyclohexyl methane (HMDI), 2, 4-trimethylhexamethylene diisocyanate (TMDI), diisocyanato methylcyclohexane, diisocyanato methyltricyclodecane, norbornane Diisocyanate (NDI), cyclohexane diisocyanate (CHDI), 4 '-dicyclohexylmethane diisocyanate (H12 MDI), diisocyanato decane, lysine diisocyanate, toluene Diisocyanate (TDI), TDI and Trimethylolpropane (TMP), methylene diphenyl 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' -dimethyl diphenyl-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 may 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 monomer units derived from a C4-C12 polyol, or a C6-C10 polyol, or a C8 or lower polyol, meaning a polyol having 4 to 12 carbon molecules, or 6 to 10 carbon molecules, or 8 or less carbon molecules in its chemical structure. In another aspect, the polyurethane comprises or consists essentially of monomer 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 soft segments derived from polyols or diols having polyester functional units. The soft segments derived from polyols or diols having polyester functional units may comprise 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.

Multilayer films 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 alone or with one or more second layers, selecting materials (e.g., first and second barrier materials, or a single barrier material and second material) having similar processing characteristics such as melt temperature and melt flow index may reduce interlayer shear during extrusion and may allow alternating barrier layers and second layers to be coextruded while maintaining their structural integrity and desired layer thickness. In one example, the one or more barrier materials and optional second material (when used) can be extruded into separate individual films, which can then be laminated together to form a multilayer film.

Multilayer films can be produced using a layer-by-layer deposition process. The substrate optionally comprising the second material or barrier material may be constructed as 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.) alternatively, 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 one or more barrier layers may be applied using a charged solution or suspension, such as a cationic solution or suspension or an anionic solution or suspension, including a charged polymer solution or suspension. The one or more barrier layers may be applied sequentially using two or more solutions having opposite charges, 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 comprising 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 about 0.001 microns to about 10 microns. For example, the thickness of a single barrier layer may be about 0.001 microns to about 3 microns thick, or about 0.5 microns to about 2 microns thick, or about 0.5 microns to about 1 micron thick. The thickness of the single second layer may be about 2 microns to about 8 microns thick, or about 2 microns to about 4 microns thick.

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

In some aspects, barrier films, including multilayer films, have a shore hardness of from about 35A to about 95A, optionally from about 55A to about 90A. In these aspects, hardness may be measured using shore a ASTM D2240.

In one aspect, when a barrier film is formed from a plurality of alternating barrier layers and a second layer 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 from 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 may be measured using ASTM D1238. Alternatively or additionally, the barrier material or the second material, or both, have a melting temperature of 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, and the second material has a melting temperature from about 155 degrees celsius to about 165 degrees celsius. Further, in these aspects, the melting temperature may be measured using ASTM D3418.

In the illustrated embodiment, the barrier layer 118 includes a first upper barrier layer 118 forming the top side 114 of the bladder 106A and a second lower barrier layer 118 forming the bottom side 116 of the bladder 106A. In the illustrated example, the inner opposing surfaces (i.e., facing each other) of the barrier layer 118 are bonded together in discrete locations to form a web region 120 and a peripheral seam 122. Peripheral seam 122 extends around the outer periphery of bladder 106A and defines the peripheral contour of bladder 106A. As shown in fig. 3, 4, 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 chambers 124 including a plurality of peripheral chambers 126A-126c and a plurality of interior chambers 128a-128b, each forming a respective portion of the interior void 130 of the bladder 106A.

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

Referring now to fig. 5C and 6C, another aspect of cushioning member 106 is provided wherein cushioning member 106 includes foam elements 106B formed as solid bodies of resilient polymeric material that are received 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 the fluid-filled bladder 106A shown in fig. 5A and 6A; however, the ground reaction force is different due to the foam element 106B disposed therein. In essence, the combination of barrier layer 118 and encapsulated foam element 106B provides a hybrid cushion that shares the characteristics of fluid-filled bladder 106A and foam element 106B. That is, the applied load will (i) cause displacement of the fluid trapped between barrier layers 118 and (ii) be absorbed by the polymeric material of foam element 106B. Encapsulation of the polymeric material within the barrier layer 118 helps to keep the polymeric material of the foam element 106B clean and dry and helps the foam element 106B to maintain a desired shape. The thickness T106 of the cushioning member 106 shown in fig. 6C is the same as the thickness T106 of the cushioning member 106 shown in fig. 6A and 6B, regardless of whether the cushioning member 106 includes the barrier layer 118 and the polymeric material or is simply the polymeric material defining the cushioning member 106. Accordingly, discussion of the details of cushioning member 106 applies to the case where cushioning member 106 is a fluid-filled chamber, cushioning member 106 being formed entirely of one or more elastomeric polymeric materials, or being formed of one or more elastomeric polymeric materials encapsulated within barrier layer 118.

The bumper 106 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 herein by reference in its entirety. As discussed in more detail below, portions of these chambers 126a-126c extend along the medial and lateral sides 22, 24 in the peripheral region 28. Thus, 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, the peripheral chambers 126a-126c are arranged sequentially along the longitudinal axis A106 from the first end 110 of the bumper 106 to the second end 112 of the bumper 106. Thus, the chambers 126a-126c are aligned with each other along the length of the bumper 106.

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 cushion 106 also includes one or more interior chambers 128a, 128b disposed in the interior region 26 of the cushion 106. 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 intermediate 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. The intermediate sections 134a, 134b fluidly couple the inner side 22 of the bumper 106 to the outer side 24 of the bumper 106.

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 cushioning element 106. The series of lobes 138a-138i extend in a direction along the longitudinal axis A106 of the bumper 106. Each of the 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 the 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 the first end 140a-140i and the second end 142a-142i and having a third cross-sectional area that is greater than the first cross-sectional area and the second cross-sectional area. Accordingly, each of the lobes 138a-138i tapers from the intermediate portion 144a-144i toward the respective first and second ends 140a-140i, 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 the chamber 126a-126 c. In some examples, the width and thickness of each of the lobes 138a-138i taper from the intermediate portions 144a-144i.

In the illustrated example of cushioning element 106, the plurality of lobes 138a-138i are sequentially arranged end-to-end along peripheral region 28 such that the cross-sectional area of heel peripheral chamber 126a alternates between larger and smaller dimensions. As shown, the series of lobes 138a-138i includes a first pair of toe lobes 138a, 138b disposed on the toe peripheral chamber 126c, a pair of forefoot lobes 138c, 138d disposed on the forefoot peripheral chamber 126b, a pair of midfoot lobes 138e, 138f disposed in the midfoot region 14 at the forward end of the heel peripheral chamber 126a, a pair of heel lobes 138g, 138h disposed in the heel region 16 between the midfoot lobes 138e, 138f and the second end 112, and a rear lobe 138i disposed at the second end 112 of the bumper 106. The midfoot lobes 138e, 138f, the heel lobes 138g, 138h and the rear lobe 138i define a first series 148 of lobes 138e-138i that form the heel perimeter chamber 126 a. The pair of toe lobes 138a, 138b define a second series 150 of lobes 138a-138b, wherein 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 chassis 108.

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

With continued reference to fig. 3-5, a rear lobe 138i is disposed at the second end 112 of the bumper 106 with a medial portion 144i of the rear lobe 138i aligned with the longitudinal axis a106 of the bumper 106. In the illustrated example, the aft lobe 138i extends from a first end 140i on the inboard side 22 of the bumper 106 to a second end 142i on the outboard side 24 of the bumper 106. 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 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 rear lobe 138 i. Likewise, a second end 142f of lateral heel lobe 138h is connected to a second end 142i of rear lobe 138 i. Similar to midfoot lobes 138e, 138f and rear lobe 138i, heel lobes 138e-138h provide a ledge for heel peripheral chamber 126A along medial and lateral sides 22, 24 of bladder 106A.

With continued reference to fig. 3-5A, a rear lobe 138i is disposed at the second end 112 of the balloon 106A with a medial portion 144i of the rear lobe 138i aligned with the longitudinal axis a106 of the balloon 106A. In the illustrated example, the aft lobe 138i extends from a first end 140i on the inboard side 22 of the bumper 106 to a second end 142i on the outboard side 24 of the bumper 106. As described above, the middle portion 1441 has a larger cross-sectional area than each of the end portions 1401, 1421.

The heel lobes 138g, 138h of the heel perimeter chamber 126a include a medial heel lobe 138g disposed on the medial side 22 of the cushioning member 106 and a lateral heel lobe 138h disposed on the lateral side 24 of the cushioning member 106. 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 rear lobe 138 i. Likewise, a second end 142h of lateral heel lobe 138h is connected to a second end 142i of rear lobe 138 i. Similar to midfoot lobes 138e, 138f and rear lobe 138i, heel lobes 138g, 138h provide a ledge for heel peripheral chamber 126a along medial and lateral sides 22, 24 of cushioning element 106.

The intermediate sections 134a, 134b extend across the width of the bumper 106. Medial section 134b is adjacent midfoot region 14 and interconnects a pair of forefoot lobes 138c, 138d. As shown, the intermediate section 134b extends along an arcuate path from the inner side 22 to the outer side 24. The intermediate section 134a separates the toe portion 12T from the midfoot region 14 and interconnects the second ends 142a, 142b of the pair of toe lobes 138a, 138 b. As shown, the intermediate section 134a extends along an arcuate path from the medial side 22 to the lateral side 24, thereby helping to form a U-shaped recess between the pair of toe lobes 138a, 138 b.

Referring still to fig. 3-5B, forefoot peripheral chamber 126B includes a pair of forefoot lobes 138c, 138d extending through ball portion 12B of forefoot region 12 and disposed between heel peripheral chamber 126a and toe peripheral chamber 126 c. Specifically, the forefoot lobes 138c, 138d include a medial forefoot lobe 138c and a lateral forefoot lobe 138d. First recess 146a is formed where second end 142a of medial toe lobe 138a merges with first end 140c of medial forefoot lobe 138 c. Likewise, a second recess 146b is formed where the second end 142b of the lateral toe lobe 138b merges with the first end 140d of the lateral forefoot lobe 138d. Third recess 146c is formed where second end 142c of medial forefoot lobe 138c merges with first end 140e of medial midfoot lobe 138 e. Likewise, fourth recess 146d is formed where second end 142d of lateral forefoot lobe 138d merges with first end 140f of lateral midfoot lobe 138 f.

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 are greater in size (e.g., cross-section, width, thickness) than the first ends 140c, 140d and the second ends 142c, 142d. For example, in the illustrated configuration, the width of each of the first and second ends 140c, 140d, 142c, 142d increases from the respective intermediate portions 144c, 144d such that the first and second ends 140c, 140d, 142c, 142d converge inwardly toward the longitudinal axis a106 of the bumper 106. With continued reference to fig. 3-5, one or both toe lobes 138a, 138b of the toe peripheral chamber 126c may be spherical, whereby the intermediate portions 144a, 144b are sized (e.g., cross-section, width, thickness) greater than the first ends 140a, 140b and the second ends 142a, 142b.

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

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

Heel interior chamber 128b extends along longitudinal axis a106 from a first end 132b connected to medial section 134b of forefoot peripheral chamber 126b to a terminal second end 136b adjacent to rear lobe 138i of heel peripheral chamber 126 a. The outer periphery of heel interior chamber 128b 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 first generally U-shaped portion 154a surrounding heel interior chamber 128a, and a second generally U-shaped portion 154b surrounding forefoot interior chamber 128b, as shown, with first U-shaped portion 154a of web region 120 extending between and attaching the outer periphery of heel interior chamber 128a and the inner periphery of heel peripheral chamber 126 a. Likewise, the second U-shaped portion 154b extends between and attaches the outer perimeter of the forefoot interior chamber 128b and the inner perimeter of the forefoot peripheral chamber 126b, the outer perimeter of the forefoot interior chamber 128b and the inner perimeter of the forefoot peripheral chamber 126 b. As shown, with respect to the foregoing portion of web region 120, the term "U-shaped" is not strictly limited to a shape having two straight legs connected by a constant curvature, but rather refers to any shape that extends from a first end along a generally first direction line, then folds 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, bell, or 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 recesses or spaces 156A-156c, 158a-158c are formed on opposite sides 114, 116 of the bumper 106 between adjacent ones of the chambers 126A-126c, 128a-128b, as best shown in fig. 6A-8. In other words, the cushion 106 includes a series of upper pockets 156a-158c formed by the web region 120 and adjacent chambers 126a-126c, 128a-128b on the top side 114 of the cushion 106, and a series of lower pockets 158a-160c formed by the web region 120 and adjacent chambers 126a-126c, 128a-128b on the bottom side 116 of the bladder 106. As shown in fig. 5A-5C and 10, the respective pairs of pockets or spaces 158a, 158b of the first and second portions 154a, 154b of the web region 120 may flare outwardly from one another at their distal ends. For example, the distal ends of the first portions 154a located near the intermediate section 134b may extend in directions away from each other such that the distal ends are divergent. As such, one of the distal ends of the first portion 154a may extend in a direction toward the inner side 22, while the other of the distal ends of the first portion 154a may extend in a direction toward the outer side 24. Similarly, the distal end of the second portion 145b is divergent in the region proximate the intermediate section 134 a.

With continued reference to FIGS. 5A and 5B, the first and second ends 140a-140i, 142a-142i of the series of lobes 138a-138i and the first ends 132a, 132B of the interior chambers 128a, 128B form a plurality of conduits that fluidly couple adjacent ones of the peripheral chambers 126a-126c to one another. Accordingly, 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 each other such that fluid may be transferred between the peripheral chambers 126a-126 c.

With continued reference to fig. 2A and 2B, base 108 is configured to interface with cushioning members 106 to provide unitary midsole 102. Base 108 extends from a first end 160 at front end 18 of sole structure 100 to a second end 162 at rear end 20 of sole structure 100. Base 108 also includes a top surface 164 defining a portion of a footbed, and a bottom surface 166 formed on a side of base 108 opposite top surface 164 and configured to interface with top side 114 of cushioning member 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. The rear support 168i is disposed between a series of lateral supports 168a, 168c and 168e and a series of medial supports 168b, 168d and 168 f. A series of supports 168a-168i alternate with a series of recesses 170a-170f, the series of recesses 170a-170f also extending along the length of the base 108. In particular, the medial recesses 170a, 170c, and 170e of the second series of recesses 170a-170f extend along the medial side 22 of the base 108, and the lateral recesses 170b, 170d, and 170f of the second series of recesses 170a-170f extend along the lateral side 24 of the base 108.

The lateral midfoot recess 170c and the medial midfoot recess 170d cooperate to define a midfoot continuous recess 172 (fig. 11) extending the width of the base 108. Similarly, lateral forefoot recess 170a and medial forefoot recess 170b cooperate to define a forefoot continuous recess 174 (fig. 11) extending the width of base 108. Base 108 may also include a pair of internal supports 176a, 176b disposed in forefoot region 12. Each inner support 176a, 176b is schematically shown as having a generally triangular cross-section taken along the width of the inner support 176a, 176b. A forefoot inner support 176a is formed on the bottom surface 166 of the base 108 and is disposed in the forefoot continuous recess 174 so as to be disposed between the lateral forefoot recess 170a and the medial forefoot recess 170 b. Toe interior support 176b is disposed at front end 18 of sole 108. The bottom surface 166 of the forefoot inner support 176a is generally concave so as to be configured to engage the top surface of the intermediate section 134a of the bumper 106. Likewise, bottom surface 166 of toe interior support 176b is also generally concave so as to be configured to engage a top surface of intermediate section 134b of bumper 106.

The series of supports 168a-168i are aligned with and contact the series of lobes 138a-138 i. As such, the distal end of each of the supports 168a-168i is generally concave to receive the top surface of a respective one of the lobes 138a-138 i. The supports 168c-168i define a first series 178 of supports, the first series 178 of supports being configured to align with and contact the first series 148 of lobes 138e-138 i. The supports 168a-168b define a second series 180 of supports configured to align with the second series 150 of lobes disposed in the toe portion 12T of the forefoot region 12.

In aspects where base 108 is formed from multiple elements, base 108 may include cushioning member 182, plate 184, and insert 186, with insert 186 comprising an insert material comprising one or more polymers. In such an aspect, the first series 178 of supports 168c-168i are formed by assembling the plate 184 onto the bumper 182, and the second series 180 of supports 168a-168b are formed only by the plate 184. In such aspects, when assembled together, portions of the plate 184 and the bumper 182 collectively form the first series 178 of supports 168c-168i and cooperate to engage the top surfaces of the lobes 138a-138i of the respective first series 148.

With continued reference to fig. 2A and 2B, the base 108 may be configured to support the perimeter of a user's foot. In such an aspect, the base 108 may further include an upper portion 188a-188i disposed on at least one of the series of supports 168a-168 i. The upper portions 188a-188h are disposed along the perimeter of the base 108 and curve along the width and height of the base 108 to conform to the shape of the bottom of the foot. The upper portions 188a-188i include a series of inboard upper portions 188a, 188c, 188e, 188g and a series of outboard upper portions 188b, 188d, 188f, 188h that extend along the perimeter of the respective inboard 22 and outboard 24 sides of the base 108. The upper rear portion 188i is disposed on the rear end 20 of the base 108, and a series of inboard upper portions 188a, 188c, 188e, 188g and a series of upper outboard portions 188b, 188d, 188f, 188h are disposed sequentially from opposite ends of the upper rear portion 188i, respectively. The upper rear portion 188i forms a cup for helping support the rear of the heel. The height to the upper portions 188a-188i may be the same or different. In aspects where the base 108 is formed as a unitary piece, the upper portions 188a-188h are contiguous with a series of supports 168a-168 i. In aspects where base 108 is formed from multiple elements, such as bumper 182, plate 184, and insert 186, upper portions 188a-188h may be defined by plate 184.

As described above, the series 178 of first supports may be formed by a combination of cushioning supports 182 and plates 184. Plate 184 also includes an inboard support arm 190 and an outboard support arm 192 extending from the ends of an upper rear portion 1821. The distal ends of each of medial support arm 190 and lateral support arm 192 are spaced apart from one another to define an insertion foot well 194. The medial support arm 190 includes a series of inner medial flanges 196a-196d spaced apart from one another to form a series of inward medial depressions 198a-198c alternating with the respective inner medial flanges 196a-196 d. Each of the inner inboard flanges 196a-196d is disposed on an inner surface of the inboard support arm 190 and extends toward the center of the plate 184 so as to be generally orthogonal to the upper portion 188. The outboard support arm 192 includes a series of internal outboard flanges 200a-200d. The inner and outer flanges 200a-200d are spaced apart from one another to form a series of inward and outward depressions 202a-202d alternating with the corresponding inner and outer flanges 200a-200 c. Inner outboard flanges 200a-200d are provided on the inner surface of outboard support arm 192 and extend toward the center of plate 184. Insert pocket 194 has a shape defined by inner medial flanges 196a-196d, inward medial recesses 198a-198c, inner lateral flanges 200a-200d, and inward lateral recesses 200a-200c to properly receive insert 186 as shown in FIG. 9.

With continued reference to fig. 2A and 2B, the insert 186 has a peripheral edge configured to be positioned between the inboard support arm 190 and the outboard support arm 192 of the plate 184 for mounting within the insert pocket 194. The insert 186 is a unitary body having a series of wings 204a-204g extending along the periphery of the inner side 22 and outer side 24 of the insert 186. Wings 204a-204g are spaced apart from one another so as to define a peripheral edge configured to be placed within insert pocket 194. Rear wing 204h is disposed on second end 112 of base 108 and is configured to rest against a portion of upper rear portion 182i of plate 184. Plate 184 is mounted to the top surface of cushioning member 182 so as to be disposed between upper 300 and cushioning member 182. The plate 184 is longer than the buffer 182, and the outer and inner supports 168a, 168b are formed on the bottom surface of the plate 184.

The toe cap 206 is disposed on the first end 110 of the base 108. The toe cap 206 may include an insert material or may include a toe cap material comprising one or more polymers, wherein the toe cap material is different from the insert material as described above. The toe cap 206 is configured to protect the toes of the user. In one aspect, the toe cap 206 is formed as a separate piece and may be adhered to the insert 186 using any known or later developed attachment technique (including adhesives, stitching, etc.). The toe cap 206 is a generally arcuate member extending upwardly from the body of the insert 186.

Base 108 includes ridges 208a-208c, with ridges 208a-208c being configured to be disposed in one of upper pockets 156a-156c, respectively, of cushioning member 106 when base 108 is assembled to cushioning element 106. The front ridge 208a has a generally C-shaped configuration configured to receive the interior chamber 128b. The intermediate ridge 208b and the rear ridge 208c together form a generally U-shaped dimension so as to define recesses 210a-208c extending longitudinally between the elongated portions of the intermediate ridge 208b and the rear ridge 208c. Recesses 210a-210c are configured to receive heel interior chamber 128b. In the illustrated example, the ridges 208a-208c may be configured to extend entirely into the web regions 120 of the upper pockets 156a-156c in some areas and to be spaced apart from the web regions 120 of the upper pockets 156a-156c in other areas when the midsole 102 is assembled. Thus, portions of the bottom side 116 defining the ridges 208a-208c may contact the web region 120 at selected locations. In other examples, one or more of the ridges 208a-208c may be configured such that the distal end is spaced apart from the web region 120, or may be omitted from the chassis.

Referring now to fig. 9 and 10, one aspect of base 108 is provided wherein base 108 is comprised of bumper 182, plate 184, and insert 186. The bumper 182, plate 184, and insert 186 may be secured to one another using any technique, such as adhesives, welding, etc., to form a unitary piece. Alternatively, cushioning member 182, plate 184, and insert 186 may simply be mounted to one another and retained by attachment to outsole 104 and upper 300.

Referring now to FIG. 11, the base 108 and outsole 104 are shown assembled to the bumper 106. Ridges 208a-206c are shown contacting web region 120. Plate 184 is longer than cushioning member 182 with toe cap 206 extending beyond the rear end of cushioning member 182. Outsole 104 is mounted to a bottom surface of cushioning element 106 so as to protect cushioning element 106 during ground engagement. The ridges 208a-208c have an arcuate bottom surface 166, the arcuate bottom surface 166 being configured to engage a top surface of the respective interior chamber 128a, 128 b. The inner support 176a is placed against the top surface of the forefoot interior chamber 128a and the inner support 176b is placed against the top surface of the heel interior chamber 128 b. Midfoot continuous recess 172 and forefoot continuous recess 174 extend across the width of base 108. Midfoot continuous recess 172 and forefoot continuous recess 174 are positioned to facilitate bending of outsole 104.

Referring now to fig. 12, a cross-sectional view taken along line 12-12 of fig. 10 is provided. Fig. 12 illustrates engagement of toe lobes 138a, 138b with chassis 108. In such an aspect, the second series 180 of supports 168a-168b are formed entirely of the plate 184. The plate 184 and the insert 186 are assembled together to form a unitary piece. The top surface of plate 184 abuts and is generally seamless with the top surface of insert 186 to define the contours of the footbed. Cushioning member 182 does not extend to toe lobes 138a, 138b. A gap 212 is formed between the pair of toe lobes 138a, 138b. The gap 212 allows the toe lobes 138a, 138b to flex freely relative to the lobes 138c-138i, with the lobes 138c-138i being connected at respective first and second ends 140a-140i, 142a-142 i.

Referring now to fig. 13, a cross-sectional view taken along line 13-13 of fig. 10 is provided. The base 108 is placed entirely against the top surface of the bumper 106. Medial support 168c and lateral support 168d are engaged with a pair of forefoot lobes 138c, 138 d. Medial support 168c is formed from an assembly of bumper 182 and plate 184, wherein bumper 182 defines an inner portion of medial support 168c and plate 184 defines an outer portion of medial support 168 c. Likewise, bumper 182 defines an inner portion of lateral support 168d and plate 184 defines an outer portion of lateral support 168 d. The front ridge 208a is placed against the web region 120 defining the upper pocket 156 b. The area of cushioning 182 between medial side 22 and lateral side 24 of forefoot ridge 208a is arcuate to rest against the top surface of forefoot interior chamber 128 a.

Referring now to fig. 14, a cross-sectional view taken along line 14-14 of fig. 10 is provided. Medial support 168e and lateral support 168f are aligned with and contact the top surface of a respective one of a pair of midfoot lobes 138e, 138 f. Medial support 168e and lateral support 168f are sized to rest entirely against respective midfoot lobes 138e, 138 f. Medial support 168e is formed from an assembly of bumper 182 and plate 184, wherein bumper 182 defines an inner portion of medial support 168e and plate 184 defines an outer portion of medial support 168 e. Likewise, bumper 182 defines an inner portion of lateral support 168f and plate 184 defines an outer portion of lateral support 168 f. The region of the bumper 182 between the inner side 22 and the outer side 24 of the intermediate ridge 208b is arcuate to rest against the top surface of the interior chamber 128 a. Fig. 14 illustrates an aspect in which the bottom surface of the intermediate ridge 208b 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 cross-sectional view is taken along recesses 146e, 146f and recesses 170e, 170f of bumper 106, recesses 170e, 170f forming a forefoot continuous recess 174 formed on base 108. Thus, the base 108 is spaced apart from the bumper 106 so as to increase the flexibility of the surrounding wires 15-15.

Referring now to fig. 16, a cross-sectional view taken along line 16-16 of fig. 10 is provided. Medial support 168g and lateral support 168h are aligned with and contact the top surface of a respective one of a pair of heel lobes 138g, 138 h. Medial support 168g and lateral support 168h are sized to rest entirely against the respective heel lobes 138g, 138 h. The outer support 168h is formed from an assembly of a bumper 182 and a plate 184, wherein the bumper 182 defines an inner portion of the outer support 168h and the plate 184 defines an outer portion of the outer support 168 h. Likewise, bumper 182 defines an inner portion of medial support 168g and plate 184 defines an outer portion of medial support 168 g. Rear ridge 208c is positioned within upper pocket 156 a. The area of cushioning member 182 between medial side 22 and lateral side 24 of rear ridge 208c is arcuate to rest against the top surface of heel interior chamber 128 b. Fig. 16 illustrates an aspect in which the bottom surface of the back ridge 208c is spaced from the web region 120.

The components 182, 184, 186 of the chassis 108 may include 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, cushioning member 182 comprises a first foam material, deck 184 comprises a second foam material, and insert 186 comprises a third foam material that are substantially identical or differ from each other in one or more of appearance, physical characteristics, and composition as described above. For example, the cushioning material and the plate material may provide a greater cushioning and impact distribution than the insert material, while the insert material has a greater stiffness than the cushioning material and/or the plate material to provide increased lateral stiffness to the peripheral region 28 of the upper 300.

Referring again to fig. 2B and 11-16, in one aspect of the plate 184, each of the series of supports 168a-168g extends outwardly and downwardly from the periphery of the plate 184, and the upper portions 188a-188i extend upwardly and outwardly from the periphery of the plate 184. Each of the series of supports 168a-168g is aligned with a respective upper portion 188c-188i to define a generally V-shaped cross-section. The series of supports 168a-168g and the corresponding upper portions 188c-188i cooperate to provide compressive and reactive forces in response to a load. By way of example, the series of supports 168a-168g and corresponding upper portions 188c-188i act as springs in response to compressive loads.

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

The 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 thermosettable polymers (i.e., polymers that are 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 a homopolymer, copolymer (including terpolymer), or a mixture of both.

In some aspects, the one or more polymers may include olefin homopolymers, olefin copolymers, or blends thereof. Examples of olefin polymers include polyethylene, polypropylene, and combinations thereof. In other aspects, the one or more polymers may include one or more ethylene copolymers, such as ethylene-vinyl acetate (EVA) copolymers, EVOH copolymers, ethylene-ethyl acrylate copolymers, ethylene-unsaturated 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 acid esters, 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 may include one or more ionomer polymers. In these aspects, the ionomer polymer may include a polymer having carboxylic acid functionality, sulfonic acid functionality, 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 may 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 may include one or more polyamide copolymers (e.g., polyamide-polyether copolymers) and/or one or more polyurethanes (e.g., crosslinked polyurethanes and/or thermoplastic polyurethanes). Examples of suitable polyurethanes include those discussed 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 phase converts to a gas based on temperature and/or pressure changes 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 hexadicarboxamide, sodium bicarbonate, and/or isocyanate.

In some constructions, the foamed polymer material may be a crosslinked foam material. In these constructions, peroxide-based crosslinking agents, 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 chips, and the like.

The material may be formed using a molding process. In one example, when the material comprises a molded elastomer, the uncured material (e.g., uncured rubber) may be mixed in a Banbury mixer with optional fillers and curing packages (e.g., sulfur-based or peroxide-based curing packages), calendered, molded, placed in a mold, and vulcanized.

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 molded foam.

Alternatively, when the material is a foam, the foam may be a compression molded foam. Compression molding can be used to change the physical properties (e.g., density, stiffness, and/or hardness) of the foam, or to change 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 and foaming a material, forming foam particles or beads by foaming a material, cutting foam sheet stock, and the like. The compression molded foam may then be manufactured by placing 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 one or more foam preforms in the closed mold for a sufficient period of 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 foam remaining in the finished product, or any combination thereof. After heating and/or applying pressure, the mold is opened and the shaped foam article is removed from the mold.

In some examples, the outsole 104 extends over the midsole 102 to provide increased durability and resilience. In the illustrated example, the outsole 104 is provided as an outsole material that is overmolded onto the bottom side 116 of the bumper 106 to increase the durability of the exposed portions of the lower barrier layer 118 of the bumper 106. Thus, the outsole material is different from the cushioning material described above. For example, the outsole material may be different from the bumper material, including different from the lower barrier film, based on at least one of different thickness, different hardness, and different wear resistance. In some examples, the outsole 104 may be integrally formed with the lower barrier layer 118 of the bumper 106 using an over-molding process. In other examples, the outsole 104 may be formed separately from the lower barrier layer 118 of the bumper 106 and may be adhesively bonded to the lower barrier layer 118.

Referring again to fig. 2A, 2B and 10-16, the outsole 104 includes a ground-engaging surface 30a and a midsole-engaging surface 30B opposite the ground-engaging surface 30 a. Outsole 104 includes a first outsole portion 214, a second outsole portion 216, and a third outsole portion 218. The first outsole portion 214, the second outsole portion 216, and the third outsole portion 218 are spaced apart from one another, allowing for greater flexibility of the sole structure relative to conventional sole structures that utilize outsoles formed as a unitary piece. In particular, the peripheral edges of each of the first outsole portion 214, the second outsole portion 216, and the third outsole portion 218 are spaced apart from one another to allow the different components of the cushion 106 to move relative to one another. Further, as the plurality of chambers 124 are compressed under load due to running, walking, or jumping motion, the lower portions of the respective chambers 104 are allowed to expand (i.e., move outwardly as the chambers 104 deform). In other words, when the first outsole portion 214, the second outsole portion 216, and the third outsole portion 218 are spaced apart from one another, the chamber 104 is allowed to deform more freely in response to an applied load

Outsole 104 is comprised of a first material 220 and a second material 222. The second material 222 is more durable than the first material 220 and may be formed of a highly abrasion resistant rubber. Preferably, the second material 222 is disposed on an area of the outsole 104 in which portions of the foot engage the ground with greater force relative to other portions of the foot. As shown, the second material 222 is disposed along the rear end 20 in the heel region 16 and in the ball portion 12B and toe portion 12T of the forefoot region 12, consistent with areas that are more prone to engaging the ground.

First outsole portion 214 includes a heel portion 224, a first medial leg portion 226, and a first lateral leg portion 228. Heel portion 224 is generally arcuate along the length of heel portion 224, forming a "C" shape. First medial leg portion 226 and first lateral leg portion 228 extend along respective longitudinal axes that are substantially parallel to the longitudinal axis of sole structure 100 in a direction toward the front end of sole structure 100. As such, first medial leg portion 226 and first lateral leg portion 228 extend from opposite ends of heel portion 224 to define a generally U-shaped structure. Heel portion 224 is configured to be positioned along rear end 20 of the foot so as to support the rear end of the foot. Referring specifically to fig. 2A and 11, heel portion 224 is generally C-shaped when viewed along the width of heel portion 224. Heel portion 224 has a shape configured to receive bottom side 116 of rear lobe 138i of bumper 106. Heel portion 224 tapers from the center of heel portion 224 to the corresponding end of heel portion 224 to accommodate the spherical shape of rear lobe 1381.

The first inboard leg portion 226 and the first outboard leg portion 228 each include at least one pair of elongated pockets 230a-230d. Each pocket 230a-230d has a C-shaped cross-section when viewed along the width of the respective first inboard leg 226 and first outboard leg 228, as shown in fig. 2A and 14-16. Similar to heel portion 224, each pocket 230a-230d tapers from a center of the respective pocket 230a-230d to each end of the respective pocket 230a-230d to accommodate the shape of the bottom side 116 of the respective lobe 138e-138h of bumper 106.

As shown in fig. 2B, 10, 11, and 14-16, the first outsole portion 214 is formed from a first material 220 and a second material 222. In one aspect, the first outsole portion 214 includes a seat portion 232a configured to receive the second material 222. In particular, first outsole portion 214 may include a heel insert 234a formed from second material 222. Heel insert 234a is schematically shown as being generally bean-shaped. The base portion 232d is preferably shaped similar to the heel insert 234a, wherein the base portion 232d is a recess having a depth substantially the same as the height of the heel insert 234a and the perimeter of the base portion 232d is substantially the same as the perimeter of the heel insert 234a so as to properly receive the heel insert 234a and form a substantially continuous surface having a different durability. The first inner leg portion 226 and the first outer leg portion 228 may be formed entirely of the first material 220. In one aspect, the first material 220 is not only less durable than the second material 222, but may also be more flexible than the second material 222.

First outsole portion 214 may include a variable width measured in a direction extending between medial side 22 and lateral side 24 of sole structure 100 to accommodate lobes 138e-138i and recesses 146e-146h of cushioning element 106, as shown in fig. 10. Specifically, due to the shape of the bumper 106 to which the first outsole portion 214 is attached, the width of the first medial leg portion 226 and the first lateral leg portion 228 at the lobes 138e-138i may be greater than the width at the recesses 146e-146 h. Providing the first medial leg portion 226 and the first lateral leg portion 228 with a variable width causes the first medial leg portion 226 and the first lateral leg portion 228 to alternate between wider and narrower regions along the medial side 22 of the sole structure 100 and the lateral side of the sole structure 100 in a direction extending substantially parallel to the longitudinal axis a106 of the cushion 106. In one configuration, first medial leg portion 226 and first lateral leg portion 228 each include a maximum width at medial side 22 and lateral side 24 proximate rear end 20 of sole structure 100 and adjacent the junction of heel portion 224 with respective first medial leg portion 226 and first lateral leg portion 228.

The wider and narrower regions of the first medial leg portion 226 and the first lateral leg portion 228 provide the first outsole portion 214 with undulations that extend from the medial side 22 to the lateral side 24 and along the rear end 20. Specifically, the first outsole portion 214 alternates between wider portions (i.e., 230a, 230b, 230c, 230d, 234 a) and narrower portions (i.e., 230a, 230b, 230c, 230d, 234 a) disposed between adjacent wider portions. Accordingly, when first outsole portion 214 is viewed from the bottom of sole structure 100, first outsole portion 214 has a wave-like shape that extends from one end of medial side 22 to a second end of lateral side 24 along rear end 20, as shown in fig. 10.

First medial leg portion 226 and first lateral leg portion 228 may each include a distal end that is (I) arcuate, (ii) opposite second outsole portion 216, and (iii) spaced from second outer bottom portion 216. The distal ends of first medial leg portion 226 and first lateral leg portion 228 may be located in forefoot region 12 or midfoot region 14 such that first outsole portion 214 extends continuously from heel region 16 to midfoot region 14 or forefoot region 12 along medial side 22 of sole structure 100 and lateral side 24 of sole structure 100.

The second outer bottom portion 216 includes a first inner leg portion 236, a second inner leg portion 238, and a second outer leg portion 240. The first inner leg portion 236 is a generally elongated member having a generally spherical rear end. A second inner leg portion 238 and a second outer leg portion 240 are disposed on the front end of the first inner leg portion 236. Second medial leg portion 238 and second lateral leg portion 240 are generally C-shaped in cross-section, extend in a direction toward the front end of sole structure 100, and include a longitudinal axis that is substantially parallel to the longitudinal axis of sole structure 100. Although second medial leg portion 238 and second lateral leg portion 240 are described as including a longitudinal axis that extends substantially parallel to a longitudinal axis of sole structure 100, second medial leg portion 238 and second lateral leg portion 240 include a generally arcuate shape such that second medial leg portion 238 and second lateral leg portion 240 are curved. As shown in fig. 10, second medial leg portion 238 is curved such that a distal end of second medial leg portion 238 extends toward forward end 18, away from medial side 22, and in a direction toward a centerline of sole structure 100. Similarly, the second lateral leg portion 240 is curved such that the distal end of the second lateral leg portion 240 extends toward the front end 18, away from the lateral side 24, and in a direction toward the centerline of the sole structure 100. Based on the foregoing, the distal ends of the second medial leg portion 238 and the second lateral leg portion 240 converge toward each other in the forefoot region 12.

As shown in fig. 10, the arcuate shape of second medial leg portion 238 and second lateral leg portion 240 provides each of second medial leg portion 238 and second lateral leg portion 240 with a convex outer surface opposite medial side 22 of sole structure 100 and lateral side 24 of sole structure 100 and a concave inner surface opposite the centerline of sole structure 100, respectively. The concave inner surfaces of the second medial leg portion 238 and the second lateral leg portion 240 are spaced apart and opposite each other across the width of the sole structure 100.

The second medial leg portion 238 and the second lateral leg portion 240 cooperate with the base of the first inner leg portion 236 to provide the second outer bottom portion 216 in the forefoot region 12 with a generally U-shape. Although the second outer bottom portion 216 is described as including a generally U-shape in the forefoot region 12, the second outer bottom portion 216 may include a C-shape in the forefoot region 12, depending on the degree of curvature of the second medial leg portion 238 and the second lateral leg portion 240. Regardless of the shape of second outsole portion 216 (i.e., U-shaped or C-shaped), first inner leg portion 236 extends from the U-shaped or C-shaped portion of second outer bottom portion 216 in a direction toward heel region 16 of sole structure 100. As shown in fig. 10, the first inner leg portion 236 initially tapers from a wider region proximate the second inner leg portion 238 and the second outer leg portion 240 to a narrower region located between pockets 230a, 230b, and increases in width from the narrower region to a bulbous end located between pockets 230c, 230 d. The ball end includes an outer arcuate surface opposite heel insert 234 a.

As shown in fig. 10 and 13-16, second outsole portion 216 is configured to cover heel interior chamber 128b and medial section 134b and forefoot lobes 138c, 138d of cushioning element 106. As such, the first inner leg portion 236 is disposed between the first medial leg portion 226 and the first lateral leg portion 228 of the first outsole portion 214.

Referring now to fig. 10 and 13, the second inner leg portion 238 and the second outer leg portion 240 each have a C-shaped cross section when viewed in the width direction of the second inner leg portion 238 and the second outer leg portion 240. The second inner leg portion 238 and the second outer leg portion 240 taper from the center to each end to form an elongated bowl-shaped structure shaped to receive the bottom side 116 of the bumper 106.

The second inner leg portion 238 and the second outer leg portion 240 may be made of the first material 220 and may also include the second material 222. The first material 220 is attached to the bumper 106. In particular, second outsole portion 216 may include medial insert 234b and lateral insert 234c, both formed from second material 222. Medial insert 234b and lateral insert 234c are integrally bean-shaped members configured to conform to the bottom sides of forefoot lobes 138c, 138d. The second inner leg portion 238 and the second outer leg portion 240 include respective inner base portion 232b and outer base portion 232c, both formed from the first material 220. The inboard and outboard base portions 232b, 232c are preferably shaped similarly to the respective inboard and outboard inserts 234b, 234c, with the inboard and outboard base portions 232b, 232c being recesses having a depth that is substantially the same as the height of the respective inboard and outboard inserts 234b, 234 c. Further, the perimeter of the inboard and outboard base portions 232b, 232c is substantially the same as the perimeter of the respective inboard and outboard inserts 234b, 234c to properly accommodate the inboard and outboard inserts 234b, 234c and to form a substantially continuous surface having different durability.

Outsole 104 of the present application facilitates the manufacture of sole structure 100 relative to conventional outsoles that are formed as a unitary piece. That is, forming the outsole 104 as separate components allows for manufacturing tolerances and allows for easier assembly of each component to the midsole 106. It will be appreciated that if the outsole 104 is formed as a unitary component, small alignment errors in the forefoot region of the outsole 104 (i.e., due to manufacturing tolerances) can have a large impact on the alignment of the heel region of the outsole 104 relative to the midsole 106. When the components are formed separately, this error is less pronounced as the individual components are smaller.

Referring to fig. 10 and 14-16, the first inner leg portion 136 is entirely made of the first material 220. The third outsole portion 218 includes a second inner leg portion 242, a third medial leg portion 244, and a third lateral leg portion 246. The third inner leg portion 244 and the third outer leg portion 246 each have a C-shaped cross-section when viewed along the width of the third inner leg portion 244 and the third outer leg portion 246. The third inner leg portion 244 and the third outer leg portion 246 taper from the center to each end to form an elongated bowl-like structure shaped to receive the bottom side 116 of the bumper 106.

A third inner leg portion 246 and a third outer leg portion 248 are located on the front end of the second inner leg portion 242. Third medial leg portion 244 and third lateral leg portion 246 are generally C-shaped in cross-section, extend in a direction toward the front end of sole structure 100, and include a longitudinal axis that is substantially parallel to the longitudinal axis of sole structure 100. Although third medial leg portion 244 and third lateral leg portion 246 are depicted as including a longitudinal axis that extends substantially parallel to the longitudinal axis of sole structure 100, third medial leg portion 244 and third lateral leg portion 246 include a generally arcuate shape such that third medial leg portion 244 and third lateral leg portion 246 are curved. As shown in fig. 10, third medial leg portion 244 is curved such that a distal end of third medial leg portion 244 extends toward forward end 18, away from medial side 22, and in a direction toward a centerline of sole structure 100. Similarly, third lateral leg portion 246 is curved such that a distal end of third lateral leg portion 246 extends toward forward end 18, away from lateral side 24, and in a direction toward the centerline of sole structure 100. Based on the foregoing, the distal ends of third medial leg portion 244 and third lateral leg portion 246 converge toward each other near forward end 18 of sole structure 100.

As shown in fig. 10, the arcuate shape of third medial leg portion 244 and third lateral leg portion 246 provides each of third medial leg portion 244 and third lateral leg portion 246 with a convex outer surface opposite medial side 22 of sole structure 100 and lateral side 24 of sole structure 100 and a concave inner surface opposite the centerline of sole structure 100, respectively. The concave inner surfaces of third medial leg portion 244 and third lateral leg portion 246 are spaced apart and opposite each other across the width of sole structure 100.

Third medial leg portion 244 and third lateral leg portion 246 cooperate with the base of second interior leg portion 242 to provide third outsole portion 218 with a generally U-shape in forefoot region 12 near forward end 18 of sole structure 100. Although the third outsole portion 218 is described as including a generally U-shape in the forefoot region 12, the third outsole portion 218 may include a C-shape in the forefoot region 12, depending on the degree of curvature of the third medial leg portion 244 and the third lateral leg portion 246. Regardless of the shape of third outsole portion 218 (i.e., U-shaped or C-shaped), second interior leg portion 242 extends from the U-shaped or C-shaped portion of third outsole portion 218 in a direction toward heel region 16 of sole structure 100. Specifically, a second inner leg portion 242 extends from the U-shaped or C-shaped portion of the third outsole portion 218 away from the front end 18 of the sole structure 100 and between the second medial leg portion 238 and the second lateral leg portion 240.

As shown in fig. 10, the second inner leg portion 242 initially tapers from a wider region proximate the third inner leg portion 244 and the third outer leg portion 246 to a narrower region between the distal ends of the second inner leg portion 238 and the second outer leg portion 240 and increases in width from the narrower region to a bulbous end between the second inner leg portion 238 and the second outer leg portion 240. The bulbous end includes an outer arcuate surface opposite the base of the "U" or "C" formed by the second inner leg portion 238 and the second outer leg portion 240 of the second outer bottom portion 216. Finally, as shown in fig. 10, the distal ends of the second inner leg portion 238 and the second outer leg portion 240 are opposite the narrowed region of the second inner leg portion 242, while the concave surfaces of the second inner leg portion 238 and the second outer leg portion 240 are opposite the bulbous end of the second inner leg portion 242.

As shown in fig. 10, 12 and 13, the third outsole portion 218 is configured to cover the forefoot region 12 of the sole structure 100. In particular, the third outsole portion 218 is configured to cover the forefoot peripheral chamber 126b and the pair of toe lobes 138a, 138b with the second inner leg portion 242 disposed between the second medial leg portion 238 and the second lateral leg portion 240. The third outsole portion 218 may be entirely formed from the second material 222.

As shown in fig. 14-16, first outsole portion 214 is configured to cover lobes 138e-138i and preferably expose lower pocket 158 a. As shown in fig. 10, the distal ends of pockets 230a, 230b terminate at first ends 140e, 140f of respective medial and lateral midfoot lobes 138e, 138f, respectively, so as to be spaced apart from second medial and lateral leg portions of second outer bottom portion 216. Thus, third recess 146c and fourth recess 146d of cushioning member 106 are not limited, thereby providing greater flexibility to the sole structure about third recess 146c and fourth recess 146d relative to a sole structure that includes an integral outsole that covers the entire bottom side of cushioning member 106.

The rearward end of the second medial leg portion 238 terminates in a first end of the medial forefoot lobe 138c and is spaced apart from the forward end of the third medial leg portion 244. In this way, the first recess 146a is exposed between the second inner leg portion 238 and the third inner leg portion 244. The rearward end of second lateral leg portion 240 terminates in a first end of lateral forefoot lobe 138d and is spaced from the forward end of third lateral leg portion 246. In this way, the second recess 146b is exposed between the second outer leg portion 240 and the third outer leg portion 246. Accordingly, first recess 146a and second recess 146b of cushioning member 106 are not limited, thereby providing greater flexibility to the sole structure about first recess 146a and second recess 146b relative to a sole structure that includes a unitary outsole that covers the entire bottom side of cushioning member 106.

Referring again to fig. 11, the outsole 104 may be formed to have a constant thickness, or may have a variable thickness. The outsole 104 shown in the figures includes a variable thickness to allow the outsole 104 to be thicker in areas of high wear and thinner in areas that do not contact the ground frequently during use. For example, at section line 15-15 of FIG. 10, outsole 104 may have a reduced thickness when compared to the thickness at heel insert 234a, for example, because heel insert 234a may be in contact with the ground during each movement and the portion of outsole 104 located at section line 15-15 will be less in contact with the ground.

The outsole 104 is provided with localized areas of increased thickness to keep the overall weight of the outsole 104, and thus the overall weight of the sole structure 100, to a minimum. Further providing areas of reduced thickness provides sole structure 100 with the ability to flex and move more easily during use.

Upper 300 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 300 may be formed from one or more materials that are stitched or adhesively bonded together to form a 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, breathability, abrasion resistance, flexibility and comfort.

The following clauses provide the above-described cushioning, sole structure, and example configurations of the article of footwear.

Clause 1: a sole structure for an article of footwear, the sole structure comprising: a cushioning member comprising a first series of lobes disposed along a medial and lateral side of the sole structure from a forefoot region to a heel region; and an outsole having a first side attached to the cushion element, a second side disposed on a side of the outsole opposite the first side and defining a ground-contacting surface of the sole structure, a first outsole portion having a generally U-shape and including a first medial leg and a first lateral leg, and a second outsole portion spaced apart and separated from the first outsole portion and having a generally U-shape including a second medial leg and a second lateral leg, the first medial leg, the first lateral leg, the second medial leg, and the second lateral leg extending toward a front end of the sole structure.

Clause 2: the sole structure of clause 1, wherein the second outsole portion includes an inner leg extending in a direction away from the front end.

Clause 3: the sole structure of clause 2, wherein the inner leg extends between the first medial leg and the first lateral leg.

Clause 4: the sole structure according to clause 2, wherein the second outsole portion includes an arcuate portion extending between and connecting the second medial leg and the second lateral leg, the medial leg extending from the arcuate portion

Clause 5: the sole structure of any of the preceding clauses, wherein the first outsole portion includes an arcuate portion extending between and connecting the first medial leg and the first lateral leg.

Clause 6: the sole structure of clause 5, wherein the arcuate portion extends along the rear end of the sole structure in the heel region.

Clause 7: the sole structure of any of the preceding clauses, further comprising a third outsole portion that is spaced apart and separate from the first outsole portion and the second outsole portion.

Clause 8: the sole structure of clause 7, wherein the third outsole portion includes a third medial leg and a third lateral leg extending in a direction toward the front end of the sole structure.

Clause 9: the sole structure according to clause 8, wherein the third outsole portion includes an arcuate portion extending between and connecting the third medial leg and the third lateral leg.

Clause 10: the sole structure of clause 9, wherein the third outsole portion comprises a generally U-shape.

Clause 11: the sole structure according to clause 9, wherein the third outsole portion includes an inner leg extending from the arcuate portion in a direction away from the forward end.

Clause 12: the sole structure of clause 11, wherein the inner leg extends between the second medial leg and the second lateral leg.

Clause 13: the sole structure of clause 7, wherein a portion of the cushion element is exposed in at least one of (i) between the first outsole portion and the second outsole portion, and (ii) between the second outsole portion and the third outsole portion.

Clause 14: a sole structure according to any of the preceding clauses, wherein at least one of the first outsole portion and the second outsole portion is formed from at least two different materials.

Clause 15: the sole structure of any of the preceding clauses, wherein the cushion is a fluid-filled chamber.

Clause 16: the sole structure of any of clauses 1-14, wherein the cushion element is a solid body formed of an elastic polymeric material.

Clause 17: the sole structure of clause-14, wherein the cushion is a foam element encapsulated in a barrier element.

Clause 18: an article of footwear comprising a sole structure according to any of the preceding clauses.

Clause 19: a sole structure for an article of footwear, the sole structure comprising: a cushioning member comprising a first series of lobes disposed along a medial and lateral side of the sole structure from a forefoot region to a heel region; and an outsole having a first side attached to the cushion element, a second side disposed on a side of the outsole opposite the first side and defining a ground-contacting surface of the sole structure, a first outsole portion having a generally U-shape and including a first medial leg and a first lateral leg, and a second outsole portion spaced apart and separate from the first outsole portion and having a generally U-shape including a second medial leg and a second lateral leg, the first medial leg, the first lateral leg, the second medial leg, and the second lateral leg each including a longitudinal axis extending generally parallel to the longitudinal axis of the sole structure.

Clause 20: the sole structure of clause 19, wherein the second outsole portion includes an inner leg extending in a direction away from the front end of the sole structure.

Clause 21: the sole structure of clause 20, wherein the inner leg extends between the first medial leg and the first lateral leg.

Clause 22: the sole structure according to clause 20, wherein the second outsole portion includes an arcuate portion extending between and connecting the second medial leg and the second lateral leg, the medial leg extending from the arcuate portion

Clause 23: the sole structure of any of the preceding clauses, wherein the first outsole portion includes an arcuate portion extending between and connecting the first medial leg and the first lateral leg.

Clause 24: the sole structure of clause 23, wherein the arcuate portion extends along the rear end of the sole structure in the heel region.

Clause 25: the sole structure of any of the preceding clauses, further comprising a third outsole portion that is spaced apart and separate from the first outsole portion and the second outsole portion.

Clause 26: the sole structure of clause 25, wherein the third outsole portion includes a third medial leg and a third lateral leg extending in a direction toward the front end of the sole structure.

Clause 27: the sole structure according to clause 26, wherein the third outsole portion includes an arcuate portion extending between and connecting the third medial leg and the third lateral leg.

Clause 28: the sole structure of clause 27, wherein the third outsole portion includes a generally U-shape.

Clause 29: the sole structure of clause 27, wherein the third outsole portion includes an inner leg extending from the arcuate portion in a direction away from the forward end.

Clause 30: the sole structure of clause 29, wherein the inner leg extends between the second medial leg and the second lateral leg.

Clause 31: the sole structure of clause 25, wherein a portion of the cushion element is exposed in at least one of (i) between the first outsole portion and the second outsole portion, and (ii) between the second outsole portion and the third outsole portion.

Clause 32: a sole structure according to any of the preceding clauses, wherein at least one of the first outsole portion and the second outsole portion is formed from at least two different materials.

Clause 33: the sole structure of any of clauses 19-32, wherein the cushion is a fluid-filled chamber.

Clause 34: the sole structure of any of clauses 19-32, wherein the cushion is a solid body formed of an elastic polymeric material.

Clause 35: the sole structure of any of clauses 19-32, wherein the cushion is a foam element encapsulated in a barrier element.

Clause 36: an article of footwear comprising a sole structure according to any of the preceding clauses.

Clause 37: a sole structure for an article of footwear, the sole structure comprising: a cushioning member comprising a first series of lobes disposed along a medial and lateral side of the sole structure from a forefoot region to a heel region; and an outsole having a first side attached to the cushion element, a second side disposed on a side of the outsole opposite the first side and defining a ground-contacting surface of the sole structure, a first outsole portion having a generally U-shape and including a first medial leg and a first lateral leg, and a first insert attached to the first outsole portion and formed of a different material than the first outsole portion.

Clause 38: the sole structure of clause 37, wherein the first insert is disposed within a pocket defined by the first outsole portion.

Clause 39: the sole structure according to any of the preceding clauses, wherein,

the first insert is attached to one of the first medial leg and first lateral leg.

Clause 40: the sole structure of clause 39, further comprising a second insert attached to the first outsole portion and formed of a different material than the first outsole portion.

Clause 41: the sole structure of clause 38, wherein the second insert is attached to the other of the first medial leg and the first lateral leg.

Clause 42: the sole structure of any of the preceding clauses, further comprising a second insert attached to the first outsole portion and formed of a different material than the first outsole portion.

Clause 43: the sole structure of any of the preceding clauses, wherein the first outsole portion includes an arcuate portion extending between and connecting the first medial leg and the first lateral leg.

Clause 44: the sole structure according to clause 43, wherein the first insert is attached to the first outsole portion at an arcuate portion.

Clause 45: the sole structure of any of the preceding clauses, further comprising a second outsole portion that is spaced apart and separate from the first outsole portion.

Clause 46: the sole structure of clause 45, wherein the second outer bottom portion includes a generally U-shape with a second medial leg and a second lateral leg.

Clause 47: the sole structure according to clause 46,

a second insert is also included that is attached to the second outsole portion and is formed of a different material than the second outsole portion.

Clause 48: the sole structure of any of clauses 37-47, wherein the cushion is a fluid-filled chamber.

Clause 49: the sole structure of any of clauses 37-47, wherein the cushion is a solid body formed of an elastic polymeric material.

Clause 50: the sole structure of any of clauses 37-47, wherein the cushion is a foam element encapsulated in a barrier element.

Clause 51: an article of footwear comprising a sole structure according to any of the preceding clauses.

Clause 52: a sole structure for an article of footwear, the sole structure including a cushion and a first outsole attached to the cushion, the first outsole defining a ground-contacting surface of the sole structure and including a generally U-shape having a first leg extending along a lateral side of the sole structure, a second leg extending along a medial side of the sole structure, and an arcuate segment extending between and connecting the first leg and the second leg, at least one of the first leg and the second leg including a variable width along a length of the at least one of the first leg and the second leg.

Clause 53: the sole structure of clause 52, wherein the first outsole is disposed in a heel area of the sole structure.

Clause 54: the sole structure of clause 53, wherein the arcuate segment extends along a rear end of the sole structure.

Clause 55: the sole structure of clause 53, further comprising a second outsole spaced apart from the first outsole, the second outsole being disposed closer to a front end of the sole structure than the first outsole.

Clause 56: the sole structure of clause 55, wherein the second outer bottom includes a first portion disposed proximate a medial side of the sole structure and a second portion disposed proximate a lateral side of the sole structure.

Clause 57: the sole structure of clause 56, wherein the first portion is spaced apart from the second portion across a width of the sole structure.

Clause 58: the sole structure of clause 56, further comprising a third portion extending between and connecting the first and second portions, the first, second, and third portions cooperating to provide a second outsole having a generally U-shape.

Clause 59: the sole structure of clause 58, further comprising a third outsole disposed between the second outsole and the forward end of the sole structure, the third outsole being spaced apart from the second outsole.

Clause 60: the sole structure of clause 59, wherein the third outsole comprises a generally U-shape.

Clause 61: the sole structure of any of the preceding clauses, further comprising a second outsole having a generally U-shape and spaced apart from the first outsole, and a third outsole having a generally U-shape and spaced apart from the second outsole, each of the first outsole, the second outsole, and the third outsole including a longitudinal axis extending generally parallel to the longitudinal axis of the sole structure.

Clause 62: an article of footwear comprising a sole structure according to any of the preceding clauses.

Clause 63: a sole structure for an article of footwear, the sole structure comprising: a buffer member; and a first outsole attached to the cushion, the first outsole defining a ground-contacting surface of the sole structure and including a generally U-shape having a first section extending along a lateral side of the sole structure, a second section extending along a medial side of the sole structure, and an arcuate section extending between and connecting the first and second sections, the first section extending from the arcuate section to a first distal end in a first direction toward a centerline of the sole structure, and the second section extending from the arcuate section to a second distal end in a second direction toward the centerline of the sole structure.

Clause 64: the sole structure of clause 63, wherein the first direction converges with the second direction.

Clause 65: a sole structure according to any of the preceding clauses, wherein the first segment includes a first concave surface facing a centerline of the sole structure, and the second segment includes a second concave surface facing the centerline of the sole structure.

Clause 66: the sole structure of clause 65, wherein the first concave surface is opposite the second concave surface.

Clause 67: the sole structure of clause 65, wherein the first segment includes a first convex surface formed on a side of the first segment opposite the first concave surface, and the second segment includes a second convex surface formed on a side of the second segment opposite the second concave surface.

Clause 68: the sole structure of clause 67, wherein the first convex surface is opposite the medial side of the sole structure and the second convex surface is opposite the lateral side of the sole structure.

Clause 69: the sole structure of any of the preceding clauses, further comprising a second outsole having a substantially U-shape and being spaced apart from the first outsole.

Clause 70: the sole structure of clause 69, further comprising a third outsole having a substantially U-shape and being spaced apart from the second outsole.

Clause 71: the sole structure of clause 70, wherein the first outsole, the second outsole, and the third outsole each include a longitudinal axis that extends substantially parallel to a longitudinal axis of the sole structure.

Clause 72: an article of footwear comprising a sole structure according to any of the preceding clauses.

Clause 73: a sole structure for an article of footwear, the sole structure including a cushion and an outsole, the cushion including a first series of lobes and a first series of recesses alternating from a forefoot region to a heel region along a medial side and a lateral side of the sole structure; the outsole has: attached to a first side of the bumper; a second side disposed on a side of the outsole opposite the first side and defining a ground-contacting surface of the sole structure; a first outsole portion having a generally U-shape and including a first medial leg and a first lateral leg, wherein the first medial leg and the first lateral leg each include a variable width measured in a direction extending between a medial side and a lateral side of the sole structure to accommodate the lobes and recesses of the cushioning element.

Clause 74: the sole structure of clause 73, wherein the first medial leg and the first lateral leg alternate between wider and narrower regions along the medial and lateral sides of the sole structure in a direction extending substantially parallel to the longitudinal axis of the sole structure.

Clause 75: a sole structure according to clause 74, wherein the first outsole portion has a contoured shape that extends from one end of the medial side of the sole structure along the rear end of the sole structure to a second end of the lateral side of the sole structure.

Clause 76: the sole structure of any of the preceding clauses, further comprising a second outsole portion having a generally U-shape and being spaced apart from the first outsole portion.

Clause 77: the sole structure of clause 76, wherein the second outsole portion includes an inner leg that extends in a direction away from the front end of the sole structure.

Clause 78: the sole structure of clause 77, wherein the inner leg extends between the first medial leg and the first lateral leg.

Clause 79: the sole structure of clause 78, wherein the second outsole portion includes an arcuate portion extending between and connecting the second medial leg and the second lateral leg, the medial leg extending from the arcuate portion

Clause 80: the sole structure of clause 76, further comprising a third outsole portion having a generally U-shape and being spaced apart from the second outer bottom portion.

Clause 81: the sole structure of clause 80, wherein the third outsole portion includes an inner leg that extends in a direction away from the front end of the sole structure.

Clause 82: the sole structure of clause 81, wherein the inner leg extends between the second medial leg and the second lateral leg.

Clause 83: the sole structure of clause 82, wherein the third outsole portion includes an arcuate portion extending between and connecting the third medial leg and the third lateral leg, the inner leg extending from the arcuate portion

Clause 84: an article of footwear comprising a sole structure according to any of the preceding clauses.

The foregoing description has been provided for the 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 are interchangeable where applicable, and may be used in a selected configuration even if not specifically shown or described. It 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

1. A sole structure for an article of footwear, the sole structure comprising:

a cushioning member comprising a first series of lobes disposed along a medial and lateral side of the sole structure from a forefoot region to a heel region; and

an outsole, the outsole having: a first side attached to the bumper; a second side disposed on a side of the outsole opposite the first side and defining a ground-contacting surface of the sole structure; a first outsole portion having a generally U-shape and including a first medial leg and a first lateral leg; and a second outsole portion spaced apart and separated from the first outsole portion and having a generally U-shape including a second medial leg and a second lateral leg; the first medial leg, the first lateral leg, the second medial leg, and the second lateral leg extend toward a front end of the sole structure.

2. The sole structure according to claim 1, wherein the second outsole portion includes an inner leg that extends in a direction away from the forward end.

3. The sole structure according to claim 2, wherein the inner leg extends between the first medial leg and the first lateral leg.

4. The sole structure according to claim 2, wherein the second outer bottom portion includes an arcuate portion extending between and connecting the second medial leg and the second lateral leg, the inner leg extending from the arcuate portion.

5. The sole structure of claim 1, wherein the first outsole portion includes an arcuate portion extending between and connecting the first medial leg and the first lateral leg.

6. The sole structure according to claim 5, wherein the arcuate portion extends along a rear end of the sole structure in the heel region.

7. The sole structure of claim 1, further comprising a third outsole portion that is spaced apart and separated from the first outsole portion and the second outsole portion.

8. The sole structure according to claim 7, wherein the third outsole portion includes a third medial leg and a third lateral leg that extend in a direction toward a front end of the sole structure.

9. The sole structure of claim 8, wherein the third outsole portion includes an arcuate portion extending between and connecting the third medial leg and the third lateral leg.

10. The sole structure according to claim 9, wherein the third outsole portion includes a generally U-shape.

11. The sole structure according to claim 9, wherein the third outsole portion includes an inner leg extending from the arcuate portion in a direction away from the forward end.

12. The sole structure according to claim 11, wherein the inner leg extends between the second medial leg and the second lateral leg.

13. The sole structure of claim 7, wherein a portion of the cushioning member is exposed in at least one of the following positions: between the first outsole portion and the second outer bottom portion; between the second outsole portion and the third outsole portion.

14. The sole structure of claim 1, wherein the first outsole portion comprises a first outsole material and the second outsole portion comprises a second outsole material, the first outsole material and the second outsole material differing from each other in at least one of appearance, physical characteristics, and composition.

15. The sole structure according to claim 1, wherein the cushioning member is a fluid-filled chamber.

16. The sole structure according to claim 1, wherein the cushioning member is a solid body comprising a cushioning member material.

17. The sole structure according to claim 1, wherein the cushioning member comprises a foam element encapsulated in a barrier film.

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

19. A sole structure for an article of footwear, the sole structure comprising:

an outsole, the outsole having: a first side attached to the bumper; a second side disposed on a side of the outsole opposite the first side and defining a ground-contacting surface of the sole structure; a first outsole portion having a generally U-shape and including a first medial leg and a first lateral leg; and a second outsole portion spaced apart and separated from the first outsole portion and having a generally U-shape and including a second medial leg and a second lateral leg; the first medial leg, the first lateral leg, the second medial leg, and the second lateral leg each include a longitudinal axis that extends generally parallel to a longitudinal axis of the sole structure.

20. The sole structure of claim 19, wherein the second outsole portion includes an inner leg that extends in a direction away from a forward end of the sole structure.

21. The sole structure according to claim 20, wherein the inner leg extends between the first medial leg and the first lateral leg.

22. The sole structure according to claim 20, wherein the second outer bottom portion includes an arcuate portion extending between and connecting the second medial leg and the second lateral leg, the inner leg extending from the arcuate portion.

23. The sole structure of claim 19, wherein the first outsole portion includes an arcuate portion extending between and connecting the first medial leg and the first lateral leg.

24. The sole structure according to claim 23, wherein an arcuate portion extends along a rear end of the sole structure in the heel region.

25. The sole structure of claim 19, further comprising a third outsole portion that is spaced apart and separated from the first outsole portion and the second outsole portion.

26. The sole structure of claim 25, wherein the third outsole portion includes a third medial leg and a third lateral leg that extend in a direction toward a front end of the sole structure.

27. The sole structure of claim 26, wherein the third outsole portion includes an arcuate portion extending between and connecting the third medial leg and the third lateral leg.

28. The sole structure of claim 27, wherein the third outsole portion includes a generally U-shape.

29. The sole structure according to claim 27, wherein the third outsole portion includes an inner leg extending from the arcuate portion in a direction away from the forward end.

30. The sole structure according to claim 29, wherein the inner leg extends between the second medial leg and the second lateral leg.

31. The sole structure of claim 25, wherein a portion of the cushioning member is exposed in at least one of (i) between the first outsole portion and the second outsole portion, and (ii) between the second outsole portion and the third outsole portion.

32. The sole structure according to claim 19, wherein the cushioning member is a fluid-filled chamber.

33. The sole structure of claim 19, wherein the cushioning member is a solid body comprising a cushioning member material.

34. The sole structure according to claim 19, wherein the cushioning member comprises a foam element encapsulated in a barrier film.

35. An article of footwear comprising the sole structure of claim 19.

36. A sole structure for an article of footwear, the sole structure comprising:

an outsole, the outsole having: a first side attached to the bumper; a second side disposed on a side of the outsole opposite the first side and defining a ground-contacting surface of the sole structure; a first outsole portion having a generally U-shape and including a first medial leg and a first lateral leg; and a first insert attached to the first outsole portion; the first outsole portion includes a first outsole material and the first insert includes a first insert material, wherein the first outsole material and the first insert material differ from one another in at least one of appearance, physical properties, and composition.

37. The sole structure of claim 36, wherein the first insert is disposed within a pocket defined by the first outsole portion.

38. The sole structure according to claim 36, wherein the first insert is attached to one of the first medial leg and first lateral leg.

39. The sole structure of claim 38, further comprising a second insert attached to the first outsole portion, the first outsole portion comprising a first outsole material, the second insert comprising a second insert material, wherein the first outsole material and the second insert material differ from each other in at least one of appearance, physical properties, and composition.

40. The sole structure according to claim 39, wherein the second insert is attached to the other of the first medial leg and the first lateral leg.

41. The sole structure of claim 36, further comprising a second insert attached to the first outsole portion, the second insert comprising a second insert material, wherein the first outsole material and the second insert material differ from each other in at least one of appearance, physical properties, and composition.

42. The sole structure of claim 36, wherein the first outsole portion includes an arcuate portion extending between and connecting the first medial leg and the first lateral leg.

43. The sole structure according to claim 42, wherein the first insert is attached to the first outsole portion at the arcuate portion.

44. The sole structure of claim 36, further comprising a second outsole portion that is spaced apart and separate from the first outsole portion.

45. The sole structure according to claim 44, wherein the second outer bottom portion includes a generally U-shape with a second medial leg and a second lateral leg.

46. The sole structure of claim 45, further comprising a second insert attached to the second outsole portion and formed of a different material than the second outsole portion.

47. The sole structure according to claim 36, wherein the cushioning member is a fluid-filled chamber.

48. The sole structure according to claim 36, wherein the cushioning member is a solid body formed from an elastic polymeric material.

49. The sole structure according to claim 36, wherein the cushion is a foam element encapsulated in a barrier element.

50. An article of footwear comprising the sole structure of claim 36.

51. A sole structure for an article of footwear, the sole structure comprising:

a buffer member; and

a first outsole attached to the cushion, the first outsole defining a ground-contacting surface of the sole structure and including a generally U-shape having a first leg extending along a lateral side of the sole structure, a second leg extending along a medial side of the sole structure, and an arcuate segment extending between and connecting the first leg and the second leg, at least one of the first leg and the second leg including a variable width along a length of the at least one of the first leg and the second leg.

52. The sole structure according to claim 51, wherein the first outsole is disposed in a heel area of the sole structure.

53. The sole structure according to claim 52, wherein the arcuate segment extends along a rear end of the sole structure.

54. The sole structure of claim 51, further comprising a second outsole spaced apart from the first outsole, the second outsole disposed closer to a front end of the sole structure than the first outsole.

55. The sole structure of claim 54, wherein the second outer sole includes a first portion disposed proximate a medial side of the sole structure and a second portion disposed proximate a lateral side of the sole structure.

56. The sole structure of claim 55, wherein the first portion is spaced apart from the second portion across a width of the sole structure.

57. The sole structure of claim 55, further comprising a third portion extending between and connecting the first portion and the second portion, the first portion, the second portion, and the third portion cooperating to provide a second outsole having a generally U-shape.

58. The sole structure of claim 57, further comprising a third outsole disposed between the second outsole and the forward end of the sole structure, the third outsole being spaced apart from the second outsole.

59. The sole structure of claim 58, wherein the third outsole comprises a generally U-shape.

60. The sole structure of claim 51, further comprising a second outsole having a generally U-shape and spaced apart from the first outsole and a third outsole having a generally U-shape and spaced apart from the second outsole, wherein the first outsole, the second outsole, and the third outsole each include a longitudinal axis that extends generally parallel to a longitudinal axis of the sole structure.

61. An article of footwear comprising the sole structure of claim 51.

62. A sole structure for an article of footwear, the sole structure comprising:

a buffer member; and

a first outsole attached to the cushion element, defining a ground-contacting surface of the sole structure, and including a generally U-shape having a first segment extending along a lateral side of the sole structure, a second segment extending along a medial side of the sole structure, and an arcuate segment extending between and connecting the first segment and the second segment, the first segment extending from the arcuate segment to a first distal end in a first direction toward a centerline of the sole structure, and the second segment extending from the arcuate segment to a second distal end in a second direction toward the centerline of the sole structure.

63. The sole structure of claim 62, wherein the first direction converges with the second direction.

64. The sole structure of claim 62, wherein the first segment includes a first concave surface facing a centerline of the sole structure, and the second segment includes a second concave surface facing the centerline of the sole structure.

65. The sole structure according to claim 64, wherein the first concave surface is opposite the second concave surface.

66. The sole structure according to claim 64, wherein the first segment includes a first convex surface formed on a side of the first segment opposite the first concave surface, and the second segment includes a second convex surface formed on a side of the second segment opposite the second concave surface.

67. The sole structure according to claim 66, wherein the first convex surface is opposite a medial side of the sole structure and the second convex surface is opposite a lateral side of the sole structure.

68. The sole structure of claim 62, further comprising a second outsole having a substantially U-shape and spaced apart from the first outsole.

69. The sole structure of claim 68, further comprising a third outsole, the third outsole having a substantially U-shape and being spaced apart from the second outsole.

70. The sole structure of claim 69, wherein the first outsole, the second outsole, and the third outsole each include a longitudinal axis that extends substantially parallel to a longitudinal axis of the sole structure.

71. An article of footwear comprising a sole structure according to claim 62.

72. A sole structure for an article of footwear, the sole structure comprising:

a cushioning member comprising a first series of lobes and a first series of recesses alternating along a medial side and a lateral side of the sole structure from a forefoot region to a heel region; and

an outsole, comprising: attached to a first side of the bumper; a second side disposed on a side of the outsole opposite the first side and defining a ground-contacting surface of the sole structure; a first outsole portion having a generally U-shape and including a first medial leg and a first lateral leg,

the first medial leg and the first lateral leg each include a variable width measured in a direction extending between a medial side and a lateral side of the sole structure to accommodate the lobes and recesses of the cushioning member.

73. A sole structure according to claim 72, wherein the first medial leg and the first lateral leg alternate between a wider area and a narrower area along a medial side and a lateral side of the sole structure in a direction that extends substantially parallel to a longitudinal axis of the sole structure.

74. The sole structure of claim 73, wherein the first outsole portion has a contoured shape that extends from one end of the medial side of the sole structure along the rear end of the sole structure to a second end of the lateral side of the sole structure.

75. The sole structure of claim 72, further comprising a second outsole portion having a generally U-shape and spaced apart from the first outsole portion.

76. The sole structure of claim 75, wherein the second outsole portion includes an inner leg that extends in a direction away from a forward end of the sole structure.

77. The sole structure of claim 76, wherein the inner leg extends between the first medial leg and the first lateral leg.

78. The sole structure of claim 77, wherein the second outsole portion includes an arcuate portion extending between and connecting the second medial leg and the second lateral leg, the inner leg extending from the arcuate portion.

79. The sole structure of claim 78, further comprising a third outsole portion having a generally U-shape and spaced apart from the second outer bottom portion.

80. The sole structure of claim 79, wherein the third outsole portion includes an inner leg that extends in a direction away from the front end of the sole structure.

81. The sole structure of claim 80, wherein the inner leg extends between the second medial leg and the second lateral leg.

82. The sole structure of claim 81, wherein the third outsole portion includes an arcuate portion extending between and connecting a third medial leg and a third lateral leg, the medial leg extending from the arcuate portion.

83. An article of footwear comprising a sole structure according to claim 72.