Classifications

• • A—HUMAN NECESSITIES
  • A43—FOOTWEAR
  • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
  • A43B13/00—Soles; Sole-and-heel integral units
  • A43B13/14—Soles; Sole-and-heel integral units characterised by the constructive form
  • A43B13/18—Resilient soles
  • A43B13/187—Resiliency achieved by the features of the material, e.g. foam, non liquid materials
  • A43B13/188—Differential cushioning regions
• • A—HUMAN NECESSITIES
  • A43—FOOTWEAR
  • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
  • A43B13/00—Soles; Sole-and-heel integral units
  • A43B13/14—Soles; Sole-and-heel integral units characterised by the constructive form
  • A43B13/18—Resilient soles
  • A43B13/181—Resiliency achieved by the structure of the sole
• • A—HUMAN NECESSITIES
  • A43—FOOTWEAR
  • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
  • A43B13/00—Soles; Sole-and-heel integral units
  • A43B13/02—Soles; Sole-and-heel integral units characterised by the material
  • A43B13/12—Soles with several layers of different materials
  • A43B13/125—Soles with several layers of different materials characterised by the midsole or middle layer
  • A43B13/127—Soles with several layers of different materials characterised by the midsole or middle layer the midsole being multilayer
• • A—HUMAN NECESSITIES
  • A43—FOOTWEAR
  • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
  • A43B13/00—Soles; Sole-and-heel integral units
  • A43B13/14—Soles; Sole-and-heel integral units characterised by the constructive form
• • A—HUMAN NECESSITIES
  • A43—FOOTWEAR
  • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
  • A43B13/00—Soles; Sole-and-heel integral units
  • A43B13/14—Soles; Sole-and-heel integral units characterised by the constructive form
  • A43B13/18—Resilient soles
  • A43B13/187—Resiliency achieved by the features of the material, e.g. foam, non liquid materials
• • A—HUMAN NECESSITIES
  • A43—FOOTWEAR
  • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
  • A43B13/00—Soles; Sole-and-heel integral units
  • A43B13/14—Soles; Sole-and-heel integral units characterised by the constructive form
  • A43B13/18—Resilient soles
  • A43B13/189—Resilient soles filled with a non-compressible fluid, e.g. gel, water
• • A—HUMAN NECESSITIES
  • A43—FOOTWEAR
  • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
  • A43B13/00—Soles; Sole-and-heel integral units
  • A43B13/14—Soles; Sole-and-heel integral units characterised by the constructive form
  • A43B13/18—Resilient soles
  • A43B13/20—Pneumatic soles filled with a compressible fluid, e.g. air, gas
• • A—HUMAN NECESSITIES
  • A43—FOOTWEAR
  • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
  • A43B13/00—Soles; Sole-and-heel integral units
  • A43B13/14—Soles; Sole-and-heel integral units characterised by the constructive form
  • A43B13/18—Resilient soles
  • A43B13/20—Pneumatic soles filled with a compressible fluid, e.g. air, gas
  • A43B13/206—Pneumatic soles filled with a compressible fluid, e.g. air, gas provided with tubes or pipes or tubular shaped cushioning members

Definitions

• the present disclosure relates generally to sole structures for articles of footwear, and more particularly, to sole structures incorporating a chassis for accommodating a fluid-filled bladder.
• Articles of footwear conventionally include an upper and a sole structure.
• the upper may be formed from any suitable material(s) to receive, secure, and support a foot on the sole structure.
• the upper may cooperate with laces, straps, or other fasteners to adjust the fit of the upper around the foot.
• Sole structures generally include a layered arrangement extending between a ground surface and the upper.
• One layer of the sole structure includes an outsole that provides abrasion- resistance and traction with the ground surface.
• the outsole may be formed from rubber or other materials that impart durability and wear-resistance, as well as enhance traction with the ground surface.
• Another layer of the sole structure includes a midsole disposed between the outsole and the upper.
• the midsole provides cushioning for the foot and may be partially formed from a polymer foam material that compresses resiliently under an applied load to cushion the foot by attenuating ground-reaction forces.
• the midsole may additionally or alternatively incorporate a cushion member to increase durability of the sole structure, as well as to provide cushioning to the foot by compressing resiliently under an applied load to attenuate ground-reaction forces.
• the cushion member may be a fluid-filled bladder or a foam element.
• Sole structures may also include a comfort-enhancing insole or a sockliner located within a void proximate to the bottom portion of the upper and a strobel attached to the upper and disposed between the midsole and the insole or sockliner.
• Midsoles employing fluid-filled bladders typically include a bladder formed from two barrier layers of polymer material that are sealed or bonded together.
• the fluid-filled bladders are pressurized with a fluid such as air, and may incorporate tensile members within the bladder to retain the shape of the bladder when compressed resiliently under applied loads, such as during athletic movements.
• bladders are designed with an emphasis on balancing support for the foot and cushioning characteristics that relate to responsiveness as the bladder resiliently compresses under an applied load.
• the midsole may include a chassis for interfacing with the bladder so as to form a unitary structure.
• FIG. 1 is a perspective view of an article of footwear including a sole structure in accordance with principles of the present disclosure
• 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 cushion member for use in the sole structure of FIG. 1;
• FIG. 4 is a bottom perspective view of the cushion member of FIG. 3;
• FIG. 5 A is a top plan view of the cushion member of FIG. 3;
• FIG. 5B is a top plan view of another aspect of a cushion member for use in the sole structure of FIG. 1;
• FIG. 5C is a top plan view of yet another aspect of a cushion member for use in the sole structure of FIG. 1;
• FIG. 6A is a cross-sectional view of the cushion member shown in FIG. 5A taken along Line 6A-6A;
• FIG. 6B is a cross-sectional view of the cushion member of FIG. 5B, taken along Line 6B-6B of FIG. 5B;
• FIG. 6C is a cross-sectional view of the cushion member of FIG. 5C, taken along Line 6C-6C of FIG. 5C;
• FIG. 7 is a cross-sectional view of the cushion member of FIG. 3, taken along Line 7-7 of FIG. 5 A;
• FIG. 8 is a cross-sectional view of the cushion member of FIG. 3, taken along Line 8-8 of FIG. 5 A.
• 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.
• Example configurations will now be described more fully with reference to the accompanying drawings.
• Example configurations are provided so that this disclosure will be thorough, and will fully convey the scope of the disclosure to those of ordinary skill in the art. Specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of configurations of the present disclosure. It will be apparent to those of ordinary skill in the art that specific details need not be employed, that example configurations may be embodied in many different forms, and that the specific details and the example configurations should not be construed to limit the scope of the disclosure.
• the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections. These elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example configurations. [0033]
• the sole structure includes a cushion member and a chassis.
• the cushion is a fluid-filled chamber comprising a cushion material.
• the cushion is a solid body comprising a cushion material.
• the cushion comprises a solid, textile or foam element encapsulated in a barrier membrane.
• the cushion comprises or consists essentially of a cushion material including one or more polymers.
• the cushion material comprises or consists essentially of a barrier membrane, the barrier membrane comprising a barrier material including one or more gas barrier compounds.
• the cushion member extends from a forefoot region of the sole structure to a heel region of the sole structure.
• the cushion member may include a first series of lobes alternating with a first series of recesses along a length of the cushion member. The first series of lobes and the first series of recesses extend along one of a medial side of the sole structure and a lateral side of the sole structure.
• the chassis is disposed between the cushion member and the upper.
• the chassis includes a series of first supports alternating with a second series of recesses along a length of the chassis, supports of the series of first supports are aligned and in contact with respective lobes of the first series of lobes and the second series of recesses are aligned with the first series of recesses.
• Implementations of the disclosure may include one or more of the following optional features.
• the chassis includes a cushion support.
• the chassis may further include a plate mounted to a top surface of the cushion support between the upper and the cushion support. The plate may be longer than the cushion support.
• At least one support of the series of first supports may include an upper portion extending in a direction toward the upper and outwardly from a body of the at least one support.
• the plate may be formed from a material having a higher rigidity than a material forming the cushion support, and the cushion support may be formed from foam.
• the series of first supports may include a pair of posterior supports that are configured to be aligned with and contact a pair of toe lobes of the first series of lobes. The toe lobes are disposed in the forefoot region and formed solely on the plate.
• the series of first supports includes a plurality of forefoot supports and a plurality of heel supports, the plurality of forefoot supports and the plurality of heel supports may be wholly formed from the cushion support.
• the cushion support includes a continuous recesses extending a width of the cushion support and separating the heel region from a mid-foot region.
• An article of footwear may incorporate the sole structure.
• a chassis may be incorporated as part of a sole structure of an article of footwear.
• the article of footwear includes an upper.
• the sole structure includes a cushion member extending from a forefoot region of the sole structure to a heel region of the sole structure.
• the cushion member includes a first series of lobes alternating with a first series of recesses along a length of the cushion member.
• the first series of lobes and the first series of recesses extend along one of a medial side of the sole structure and a lateral side of the sole structure.
• the chassis comprises a cushion support disposed between the cushion member and the upper and includes a series of first supports alternating with a second series of recesses along a length of the cushion support. Supports of the series of first supports are aligned and in contact with respective lobes of the first series of lobes and the second series of recesses are aligned with the first series of recesses.
• Implementations of the disclosure may include one or more of the following optional features.
• the chassis may further include a plate mounted to a top surface of the cushion support between the upper and the cushion support. The plate may be longer than the cushion support.
• At least one support of the series of first supports includes an upper portion extending in a direction toward the upper and outwardly from a body of the at least one support.
• One of the recesses of the first series of recesses may be configured to extend across a width of the cushion support, separating the heel region from a mid-foot region.
• the cushion support includes a series of ridges configured to be seated within a corresponding one of a series of pockets formed on a top side of the cushion member.
• the cushion support may include a series of wings extending along a periphery of the cushion support, the series of wings are configured to be seated to a bottom surface of the plate.
• the series of first supports includes a plurality of forefoot supports and a plurality of heel supports, the plurality of forefoot supports and the plurality of heel supports may be wholly formed from the cushion.
• An article of footwear may incorporate the chassis.
• the materials may differ in appearance in terms of color (including in hue or lightness or both), or in terms of level of transparency or translucency, or in both color and level of transparency or translucency.
• the materials may differ in one or more physical properties, such as in hardness or in elongation or in both hardness and elongation.
• the one or more physical properties may differ by at least 5 percent or at least 10 percent or at least 20 percent.
• the materials may differ in composition.
• the materials may differ based on the classes or types of polymers present, may differ based on a concentration of the classes or types of polymers, or based on both.
• the materials may differ in composition based the additives present, or based on a concentration of the additives present, or based on both.
• the concentrations of the one or more polymers and/or one or more additives can differ by at least 5 weight percent or at least 10 weight percent or at least 20 weight percent of the material.
• an article of footwear 10 includes a sole structure 100 and an upper 200 attached to the sole structure 100.
• the article of footwear 10 may be divided into one or more regions.
• the regions may include a forefoot region 12, a mid-foot region 14, and a heel region 16 (shown in FIGS. 5A-5C).
• the forefoot region 12 may be further described as including a toe portion 12 T corresponding to the phalanges of the foot, and a ball portion 12 B corresponding to a metatarsophalangeal (MTP) joint.
• the mid-foot region 14 may correspond with an arch area of the foot
• the heel region 16 may correspond with rear portions of the foot, including a calcaneus bone.
• the footwear 10 may further include an anterior end 18 associated with a forward- most point of the forefoot region 12, and a posterior end 20 corresponding to a rearward-most point of the heel region 16.
• a longitudinal axis Aio of the footwear 10 extends along a length of the footwear 10 from the anterior end 18 to the posterior end 20, and generally divides the footwear 10 into a medial side 22 and a lateral side 24, as shown in FIG. 10. Accordingly, the medial side 22 and the lateral side 24 respectively correspond with opposite sides of the footwear 10 and extend through the regions 12, 14, 16.
• the article of footwear 10, and more particularly, the sole structure 100 may be further described as including an interior region 26 and a peripheral region 28, as indicated in FIG. 1.
• the peripheral region 28 is generally described as being a region between the interior region 26 and an outer perimeter of the sole structure 100.
• the peripheral region 28 extends from the forefoot region 12 to the heel region 16 along each of the medial side 22 and the lateral side 24, and wraps around each of the forefoot region 12 and the heel region 16.
• the interior region 26 is circumscribed by the peripheral region 28, and extends from the forefoot region 12 to the heel region 16 along a central portion of the sole structure 100.
• the sole structure 100 includes a midsole 102 configured to provide cushioning characteristics to the sole structure 100, and an outsole 104 configured to provide a ground-engaging surface 30 of the article of footwear 10.
• the midsole 102 of the sole structure 100 may be formed compositely and include a plurality of subcomponents for providing desired forms of cushioning and support throughout the sole structure 100.
• the midsole 102 includes a cushion member 106 and a chassis 108, where the chassis 108 is attached to the upper 200 and provides an interface between the upper 200 and the cushion member 106.
• a longitudinal axis A IO6 (shown in FIGS. 5A-5C) of the cushion member 106 extends from a first end 110 in the forefoot region 12 to a second end 112 in the heel region 16.
• the cushion member 106 may be further described as including a top surface or side 114 and a bottom surface or side 116 formed on an opposite side of the cushion member 106 from the top side 114.
• a thicknesses Tio 6 of the cushion member 106, or of elements of the cushion member 106 are defined by a distance from the top side 114 to the bottom side 116.
• the cushion member 106 is configured to provide cushioning for the foot by attenuating ground-reaction forces.
• the cushion member 106 is a fluid-filled bladder 106A and in another aspect the cushion member 106 is a foam element 106B.
• the difference between the fluid-filled bladder 106 A and the foam element 106B being the attenuation of ground-reaction forces.
• the cushion member 106 is a fluid-filled bladder 106A
• the fluid (air) is contained within the fluid-filled bladder 106A itself.
• the fluid within the fluid-filled bladder 106A is displaced at the location(s) of a ground-reaction and is forced into other areas of the fluid-filled bladder 106A in the form of a reaction force.
• the cushion member 106 is a foam element 106B
• the ground-reaction forces are absorbed by the foam element at the point of impact.
• the remaining portions of the foam element 106B do not experience the reaction force in the same way as the fluid-filled bladder 106 A.
• Such a feature may be preferable for users who desire a more cushioned response in comparison to the cushioning provided by the fluid-filled bladder 106 A.
• a depiction of the cushion member 106 is shown as a fluid-filled bladder 106 A.
• the fluid-filled bladder 106A may be formed by an opposing pair of barrier layers 118, which can be joined to each other at discrete locations to define an overall shape of the bladder 106 A.
• the bladder 106 A may be produced from any suitable combination of one or more barrier layers.
• the term “barrier layer” e.g., barrier layers 118
• the barrier layers 118 encompasses both monolayer and multilayer films.
• one or both of the barrier layers 118 are each produced (e.g., thermoformed or blow molded) from a monolayer film (a single layer).
• one or both of the barrier layers 118 are each produced (e.g., thermoformed or blow molded) from a multilayer film (multiple sublayers).
• each layer or sublayer can have a film thickness ranging from about 0.2 micrometers to about 1 millimeter. In further embodiments, the film thickness for each layer or sublayer can range from about 0.5 micrometers to about 500 micrometers. In yet further embodiments, the film thickness for each layer or sublayer can range from about 1 micrometer to about 100 micrometers.
• One or both of the barrier layers 118 can independently be transparent, translucent, and/or opaque.
• transparent for a barrier layer and/or a bladder means that light passes through the barrier layer in substantially straight lines and a viewer can see through the barrier layer. In comparison, for an opaque barrier layer, light does not pass through the barrier layer and one cannot see clearly through the barrier layer at all.
• a translucent barrier layer falls between a transparent barrier layer and an opaque barrier layer, in that light passes through a translucent layer but some of the light is scattered so that a viewer cannot see clearly through the layer.
• the airbags or bladders disclosed herein comprise or consist of a barrier membrane.
• a barrier membrane is understood to be a membrane having a relatively low rate of transmittance of a fluid. When used alone or in combination with other materials in an airbag or bladder, the barrier membrane resiliently retains the fluid. Depending upon the structure and use of the airbag or bladder, the barrier membrane may retain the fluid at a pressure which is above, at, or below atmospheric pressure.
• the fluid is a liquid or a gas. Examples of gasses include air, oxygen gas (O2), and nitrogen gas (N2), as well as inert gasses.
• the barrier membrane is a nitrogen gas barrier material.
• the gas transmission rate of the barrier membrane can be less than 4 or less than 3 or less than 2 cubic centimeters per square meter per atmosphere per day per day for a membrane having a thickness of from about 72 micrometers to about 320 micrometers, as measured at 23 degrees Celsius and 0 percent relative humidity.
• the gas transmission rate of the barrier membrane is from about 0.1 to about 3, or from about 0.5 to about 3, or from about 0.5 to about 3 cubic centimeters per square meter per atmosphere per day per day for a membrane having a thickness of from about 72 micrometers to about 320 micrometers, as measured at 23 degrees Celsius and 0 percent relative humidity.
• the gas transmission rate such as the oxygen gas or nitrogen gas transmission rate, can be measured using ASTM D1434.
• the barrier membrane comprise a multi-layered film comprising a plurality of layers, the plurality of layers comprising one or more barrier layers, the one or more barrier layers comprising a barrier material, the barrier material comprising or consisting essentially of one or more gas barrier compounds.
• the multi-layered film comprises at least 5 layers or at least 10 layers.
• the multi-layered 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.
• the plurality of layers includes a series of alternating layers, in which the alternating layers include two or more barrier layers, each of the two or more barrier layers individually comprising a barrier material, the barrier material comprising or consisting essentially of one or more gas barrier compounds.
• adjacent layers are individually formed of materials which differ from each other at least in their chemical compositions based on the individual components present (e.g., the materials of adjacent layers may differ based on whether or not a gas barrier compound is present, or differ based on class or type of gas barrier compound present), the concentration of the individual components present (e.g., the materials of adjacent layers may differ based on the concentration of a specific type of gas barrier compound present), or may differ based on both the components present and their concentrations.
• the plurality of layers of the multi-layered film can include first barrier layers comprising a first barrier material and second barrier layers comprising a second barrier material, wherein the first and second barrier materials differ from each other based as described above.
• the first barrier material can be described as comprising a first gas barrier component consisting of all the gas barrier compounds present in the first barrier material
• the second barrier material can be described as comprising a second barrier material component consisting of all the gas barrier compounds present in the second barrier material hi a first example, the first barrier component consists only of one or more gas barrier polymers, and the second barrier component consists only of one or more inorganic gas barrier compounds.
• the first barrier component consists of a first one or more gas barrier polymers
• the second component consists of a second one or more gas barrier polymers, wherein the first one or more gas barrier polymers differ from the second one or more gas barrier polymers in polymer class, type, or concentration.
• the first barrier component and the second barrier component both include the same type of gas barrier compound, but the concentration of the gas barrier compound differ, optionally the concentrations differ by at least 5 weight percent based on the weight of the barrier material.
• the first barrier layers and the second barrier layers can alternate with each other, or can alternate with additional barrier layers (e.g., third barrier layers comprising a third barrier material, fourth barrier layers comprising a fourth barrier material, etc., wherein each of the first, second, third and fourth, etc., barrier materials differ from each other as described above.
• additional barrier layers e.g., third barrier layers comprising a third barrier material, fourth barrier layers comprising a fourth barrier material, etc., wherein each of the first, second, third and fourth, etc., barrier materials differ from each other as described above.
• the barrier material (including a first barrier material, a second barrier material, etc.) has a low gas transmittance rate.
• the single-layer film when formed into a single-layer film consisting essentially of the barrier material, the single-layer film has a gas transmittance rate of less than 4 cubic centimeters per square meter per atmosphere per day per day for a membrane having a thickness of from about 72 micrometers to about 320 micrometers, as measured at 23 degrees Celsius and 0 percent relative humidity, and can be measured using ASTM D1434.
• the barrier material comprises or consists essentially of one or more gas barrier compounds.
• the one or more gas barrier compounds can comprise one or more gas barrier polymers, or can comprise one or more inorganic gas barrier compound, or can comprise a combination of at least one gas barrier polymer and at least one inorganic gas barrier compound.
• the combination of at least one gas barrier polymer and at least one inorganic gas barrier compound can comprise a blend or mixture, or can comprise a composite in which fibers, particles or platelets of the inorganic gas barrier compound are surrounded by the gas barrier polymer.
• the barrier material comprises or consists essentially of one or more inorganic gas barrier compounds.
• the one or more inorganic gas barrier compounds can take the form of fibers, particulates, platelets, or combinations thereof.
• the fibers, particulates, platelets can comprise or consist essentially of nanoscale fibers, particulates, platelets, or combinations thereof.
• examples of inorganic barrier compounds includes, for example, carbon fibers, glass fibers, glass flakes, silicas, silicates, calcium carbonate, clay, mica, talc, carbon black, particulate graphite, metallic flakes, and combinations thereof.
• the inorganic gas barrier component can comprise or consist essentially of one or more clays.
• the inorganic gas barrier component consists of clay.
• the barrier material can further comprise one or more additional ingredients, such as a polymer, processing aid, colorant, or any combination thereof.
• the barrier material can be described as comprising an inorganic gas barrier component consisting of all inorganic barrier compounds present in the barrier material.
• the total concentration of the inorganic gas barrier component present in the barrier material can be less than 60 weight percent, or less than 40 weight percent, or less than 20 weight percent of the total composition.
• the barrier material consists essentially of the one or more inorganic gas barrier materials.
• the gas barrier compound comprises or consists essentially of one or more gas barrier polymers.
• the one or more gas barrier polymers can include thermoplastic polymers.
• the barrier material can 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 which are not gas barrier polymers.
• the barrier material comprises or consists essentially of one or more thermoplastic gas barrier polymers, meaning that all the polymers present in the barrier material are thermoplastic gas barrier polymers.
• the barrier material can be described as comprising a polymeric component consisting of all polymers present in the barrier material.
• the polymeric component of the barrier material can consist of a single class of gas barrier polymer, such as, for example, one or more polyolefin, or can consist of a single type of gas barrier polymer, such as one or more ethylene-vinyl alcohol copolymers.
• the barrier material can further comprise one or more non-polymeric additives, such as one or more filler, processing aid, colorant, or combination thereof.
• gas barrier polymers examples include vinyl polymers such as vinylidene chloride polymers, acrylic polymers such as acrylonitrile polymers, polyamides, epoxy polymers, amine polymers, polyolefins such as polyethylenes and polypropylenes, copolymers thereof, such as ethylene-vinyl alcohol copolymers, and mixtures thereof.
• 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.
• the one or more gas barrier polymers comprise or consist essentially of one or more thermoplastic polyethylene copolymers, such as, for example, one or more thermoplastic ethylene-vinyl alcohol copolymers.
• the one or more ethylene-vinyl alcohol copolymers can include from about 28 mole percent to about 44 mole percent ethylene content, or from about 32 mole percent to about 44 mole percent ethylene content.
• the one or more gas barrier polymers can comprise or consist essentially of one or more one or more polyethyleneimine, polyacrylic acid, polyethyleneoxide, polyacrylamide, polyamidoamine, or any combination thereof.
• the multi-layered film further comprises one or more second layers, the one or more second layers comprising a second material.
• the one or more barrier layers include a plurality of barrier layers alternating with a plurality of second layers.
• each of the one or more barrier layers may be positioned between two second layers (e.g., with one second layer positioned on a first side of the barrier layer, and another second layer on a second side of the barrier layer, the second side opposing the first side).
• the second material of the one or more second layers can comprise one or more polymers. Depending upon the class of gas barrier compounds used and the intended use of the multi-layered film, the second material may have a higher gas transmittance rate than the barrier material, meaning that the second material is a poorer gas barrier than the barrier material.
• the one or more second layers act as substrates for the one or more barrier layers, and may serve to increase the strength, elasticity, and/or durability of the multi-layered film. Alternatively or additionally, the one or more second layers may serve to decrease the amount of gas barrier material(s) needed, thereby reducing the overall material cost.
• the presence of the one or more second layers may help maintain the overall barrier properties of the film by increasing the distance between cracks in the barrier layers, thereby increasing the distance gas molecules must travel between cracks in the barrier layers in order to pass through the multi-layered film. While small fractures or cracks in the barrier layers of a multi-layered film may not significantly impact the overall barrier properties of the film, using a larger number of thinner barrier layers can avoid or reduce visible cracking, crazing or hazing of the multi-layered film.
• the one or more second layers can include, but are not limited to, tie layers adhering two or more layers together, structural layers providing mechanical support to the multi-layered films, bonding layers providing a bonding material such as a hot melt adhesive material to the multi-layered film, and/or cap layers providing protection to an exterior surface of the multi-layered film.
• 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 so the one or more barrier layers may be susceptible to cracking when subjected to repeated, excessive stress loads, such as those potentially generated during flexing and release of a multi-layered film.
• a multi-layered film which includes one or more barrier layers alternating with second layers of an elastomeric material results in a multi-layered film that is better able to withstand repeated flexing and release while maintaining its gas barrier properties, as compared to a film without the elastomeric second layers present.
• the second material comprises or consists essentially of one or more polymers.
• the one or more polymers present in the second material are referred to herein as one or more “second polymers” or a “second polymer”, as these polymers are present in the second material.
• References to “second polymer(s)” are not intended to indicate that a “first polymer” is present, either in the second material, or in the multi-layered film as a whole, although, in many aspects, multiple classes or types of polymers are present.
• the second material comprises or consists essentially of one or more thermoplastic polymers.
• the second material comprises or consists essentially of one or more elastomeric polymers.
• the second material comprises or consists essentially of one or more thermoplastic elastomers.
• the second material can be described as comprising a polymeric component consisting of all polymers present in the second material.
• the polymeric component of the second material consists of one or more elastomers.
• the second material can further comprise one or more non-polymeric additives, such as fillers, processing aids, and/or colorants. [0063] Many polymers which are suitable for use in the second material are known in the art.
• Exemplary polymers which can be included in the second material include polyolefins, polyamides, polycarbonates, polyimines, polyesters, polyacrylates, polyesters, polyethers, polystyrenes, polyureas, and polyurethanes, including homopolymers and copolymers thereof (e.g., polyolefin homopolymers, polyolefin copolymers, etc.), and combinations thereof.
• the second material comprises or consists essentially of one or more polymers chosen from polyolefins, polyamides, polyesters, polystyrenes, and polyurethanes, including homopolymers and copolymers thereof, and combinations thereof.
• the polymeric component of the second material consists of one or more thermoplastic polymers, or one or more elastomers or one or more thermoplastic elastomers, including thermoplastic vulcanizates.
• the one or more second polymers can include one or more thermoset or thermosettable elastomers, such as, for example, natural rubbers and synthetic rubbers, including butadiene rubber, isoprene rubber, silicone rubber, and the like.
• Polyolefins are a class of polymers which include monomeric units derived from simple alkenes, such as ethylene, propylene and butene.
• thermoplastic polyolefins include polyethylene homopolymers, polypropylene homopolymers polypropylene copolymers (including polyethylene-polypropylene copolymers), polybutene, ethylene-octene copolymers, olefin block copolymers; propylene-butane copolymers, and combinations thereof, including blends of polyethylene homopolymers and polypropylene homopolymers.
• polyolefin elastomers examples include polyisobutylene elastomers, poly(alpha-olefm) elastomers, ethylene propylene elastomers, ethylene propylene diene monomer elastomers, and combinations thereof.
• Polyamides are a class of polymers which include monomeric units linked by amide bonds. Naturally-occurring polyamides include proteins such as wool and silk, and synthetic amides such as nylons and aramids.
• the one or more second polymers can include thermoplastic polyamides such as nylon 6, nylon 6-6, nylon-11, as well as thermoplastic polyamide copolymers.
• Polyesters are a class of polymers which include monomeric units derived from an ester functional group, and are commonly made by condensing dibasic acids such as, for example, terephthalic acid, with one or more polyols.
• the second material can comprise or consist essentially of one or more thermoplastic polyester elastomers.
• polyester polymers include homopolymers such as polyethylene terephthalate, polybutylene terephthalate, poly- 1,4-cyclohexylene-dimethylene terephthalate, as well as copolymers such as polyester polyurethanes.
• Styrenic polymers are a class of polymers which include monomeric units derived from styrene.
• the one or more second polymers can comprise or consist eseentially of styrenic homopolymers, styrenic random copolymers, styrenic block copolymers, or combinations thereof.
• 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.
• 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 copo
• Polyurethanes are a class of polymers which include monomeric units joined by carbamate linkages. Polyurethanes are most commonly formed by reacting a polyisocyanate (e.g., a diisocyanate or a triisocyanate) with a polyol (e.g., a diol or triol), optionally in the presence of a chain extender.
• a polyisocyanate e.g., a diisocyanate or a triisocyanate
• a polyol e.g., a diol or triol
• the monomeric units derived from the polyisocyanate are often referred to as the hard segments of the polyurethane, while the monomeric units derived from the polyols are often referred to as the soft segments of the polyurethane.
• the hard segments can be derived from aliphatic polyisocyanates, or from organic isocyanates, or from a mixture of both.
• the soft segments can be derived from saturated polyols, or from unsaturated polyols such as polydiene polyols, or from a mixture of both.
• including soft segments derived from one or more polydiene polyols can facilitate bonding between the rubber and the film when the rubber and the film are crosslinked in contact with each other, such as in a vulcanization process.
• suitable polyisocyanates from which the hard segments of the polyurethane can be derived include hexamethylene diisocyanate (HDI), isophorone diisocyanate (IPDI), butylenediisocyanate (BDI), bisisocyanatocyclohexylmethane (HMDI), 2,2,4- trimethylhexam ethylene diisocyanate (TMDI), bisisocyanatomethylcyclohexane, bisisochanatomethyltricyclodecane, norbornane diisocyanate (NDI), cyclohexane diisocyanate (CHDI), 4,4'-dicyclohexhylmethane diisocyanate (H12MDI), diisocyanatododecane, lysine diisocyanate, toluene diisocyanate (TDI), TDI adducts with trimethylolpropane (TMP), methylene diphen
• the soft segments of the polyurethane can be derived from a wide variety of polyols, including polyester polyols, polyether polyols, polyester-ether polyols, polycarbonate polyols, polycaprolactone polyethers, and combinations thereof.
• the polyurethane comprises or consist essentially of monmeric units derived from C4-C12 polyols, or C6-C10 polyols, or Cx or lower polyols, meaning polyols with 4 to 12 carbon molecules, or with 6 to 10 carbon molecules, or with 8 or fewer carbon molecules in their chemical structures.
• the polyurethane comprises or consists essentially of monomeric units derived from polyester polyols, polyester-ether polyols, polyether polyols, and any combination thereof.
• 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 can comprise about 10 to about 50, or about 20 to about 40, or about 30 weight percent of the soft segments present in the polyurethane.
• the multi-layered films can be produced by various means such as co-extrusion, lamination, layer-by-layer deposition, and the like.
• selecting materials e.g., a first barrier material and a second barrier material, or a single barrier material and a second material
• melt temperature and melt flow index can reduce interlayer shear during the extrusion process, and can allow the alternating barrier layers and second layers to be co-extruded while retaining their structural integrities and desired layer thicknesses.
• the one or more barrier materials and optionally the second material when used can be extruded into separate individual films, which can then be laminated together to form the multi layered films.
• the multi-layered films can be produced using a layer-by-layer deposition process.
• a substrate which optionally can comprise a second material or a barrier material, can be built into a multi-layered film by depositing a plurality of layers onto the substrate.
• the layers can include one or more barrier layers (e,g., first barrier layers, second barrier layers, etc.).
• the layers can include one or more second layers.
• the one or more barrier layers and/or second layers can be deposited by any means known in the art such as, for example, dipping, spraying, coating, or another method.
• the one or more barrier layers can be applied using charged solutions or suspensions, e.g., cationic solutions or suspensions or anionic solutions or suspensions, including a charged polymer solution or suspension.
• the one or more barrier layers can be applied using a series of two or more solutions having opposite charges, e.g., by applying a cationic solution, followed by an anionic solution, followed by a cationic solution, followed by an anionic solution
• the barrier membranes including the multi-layered films, have an overall thickness of from about 40 micrometers to about 500 micrometers, or about 50 micrometers to about 400 micrometers, or about 60 micrometers to about 350 micrometers.
• each individual layer of the plurality of layers of the multi-layered film has a thickness of from about 0.001 micrometers to about 10 micrometers.
• the thickness of an individual barrier layer can range from about 0.001 micrometers to about 3 micrometers thick, or from about 0.5 micrometers to about 2 micrometers thick, or from about 0.5 micrometers to about 1 micrometer thick.
• the thickness of an individual second layer can range from about 2 micrometers to about 8 micrometers thick, or from about 2 micrometers to about 4 micrometers thick.
• thickness of the films and/or their individual layers can be measured by any method known in the art such as, for example, ASTM E252, ASTM D6988, ASTM D8136, or using light microscopy or electron microscopy.
• the barrier membranes including the multi-layered films, have a Shore hardness of from about 35 A to about 95 A, optionally from about 55 A to about 90 A.
• hardness can be measured using ASTM D2240 using the Shore A scale.
• the barrier material when a co-extrusion process is used to form the barrier membrane from a plurality of alternating barrier layers and second layers, has a melt flow index of from about 5 to about 7 grams per 10 minutes at 190 degrees Celsius when using a weight of 2.16 kilograms, while the second material has a melt flow index of from about 20 to about 30 grams per 10 minutes at 190 degrees Celsius when using a weight of 2.16 kilograms.
• the melt flow index of the barrier material is from about 80 percent to about 120 percent of the melt flow index of the barrier material per 10 minutes when measured at 190 degrees Celsius when using a weight of 2.16 kilograms.
• melt flow index can be measured using ASTM D1238.
• 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.
• the barrier material has a melting temperature of from about 165 degrees Celsius to about 183 degrees Celsius
• the second material has a melting temperature of from about 155 degrees Celsius to about 165 degrees Celsius.
• melting temperature can be measured using ASTM D3418.
• the barrier layers 118 include a first, upper barrier layer 118 forming the top side 114 of the bladder 106 A, and a second, lower barrier layer 118 forming the bottom side 116 of the bladder 106A.
• interior, opposing surfaces (i.e. facing each other) of the barrier layers 118 are joined together at discrete locations to form a web area 120 and a peripheral seam 122.
• the peripheral seam 122 extends around the outer periphery of the bladder 106A and defines an outer peripheral profile of the bladder 106A. As shown in FIGS.
• the bladder 106A may include a plurality of U-shaped or horseshoe-shaped chambers 126a-126c such as shown in Chan et al., U.S. Patent Application Serial No. 17/133,732, the disclosure of which is incorporated by reference in its entirety. As discussed in greater detail below, portions of these chambers 126a-126c extend along the medial and lateral sides 22, 24 in the peripheral region 28.
• peripheral chambers 126a- 126c may be referred to as peripheral chambers 126a-126c.
• the peripheral chambers 126a-126c include a heel peripheral chamber 126a, a forefoot peripheral chamber 126b, and a toe peripheral chamber 126c.
• the peripheral chambers 126a-126c are arranged in series along the longitudinal axis Ak1 ⁇ 2 from the first end 110 of the bladder 106 A to the second end 112 of the bladder 106 A. Accordingly, the chambers 126a- 126c are aligned with each other along the direction of the length of the bladder 106 A.
• one or more of the peripheral chambers 126a-126c may have a variable cross-sectional area from end to end.
• the bladder 106A includes one or more interior chambers 128a, 128b disposed in the interior region 26 of the bladder 106 A.
• each of the interior chambers 128a, 128b is at least partially surrounded by a respective one of the peripheral chambers 126a, 126b.
• the peripheral chambers 126a-126c and the interior chambers 128a, 128b bound an interior void 130.
• each of the interior chambers 128a, 128b extends from a first end 132a, 132b connected to an intermediate segment 134a, 134b of an adjacent one of the peripheral chambers 126b, 126c, to a terminal second end 136a, 136b adjacent to the posterior end 20 of the respective one of the peripheral chambers 126a, 126b.
• the intermediate segments 134a, 134b fluidly couple the medial side 22 of the bladder 106 A to the lateral side 24 of the bladder 106 A.
• the heel peripheral chamber 126a, the forefoot peripheral chamber 126b and the toe peripheral chamber 126c include a series of lobes 138a-138i that are interconnected to each other and are disposed along the periphery of the bladder 106A.
• the series of lobes 138a-138i extend in a direction along the longitudinal axis A IO6 of the bladder 106A.
• 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 the ends of the respective lobes 138a-138i.
• 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.
• each of the lobes 138a-138i tapers towards the respective first end 140a-140i and second end 142a-142i from the intermediate portion 144a-144i so as to define a first series of recesses 146a-146h, wherein each recess 146a-146h is disposed between a pair of adjacent lobes 138a-138i so as to alternate with the series of lobes 138a-138i along the length of the chambers 126a-126c.
• both the width and the thickness of each of the lobes 138a-138i tapers from the intermediate portion 144a-144i.
• the plurality of the lobes 138a-138i are arranged end-to-end in series along the peripheral region 28 such that the cross-sectional area of the heel peripheral chamber 126a alternates between larger and smaller sizes.
• 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 mid-foot lobes 138e, 138f disposed in the mid-foot region 14 at an anterior end of the heel peripheral chamber 126a, a pair of heel lobes 138g, 138h disposed in the heel region 16 between the mid-foot lobes 138e, 138f and the second end 112, and a posterior lobe 138i disposed at the second end 112 of the bladder 106A.
• the mid-foot lobes 138e, 138f, the heel lobes 138g, 138h, and the posterior lobe 138i define a first series 148 of lobes that form the heel peripheral chamber 126a.
• the pair of toe lobes 138a, 138b and the pair of forefoot lobes 138c, 138d define a second series 150 of lobes.
• the pair of toe lobes 138a, 138b are spaced apart from each other to define a generally U-shaped recess as viewed along a plane defined by a width and length of the chassis 108.
• the mid-foot lobes 138e, 138f of the heel peripheral chamber 126a include a medial mid-foot lobe 138e disposed at the anterior end of the heel region 16 on the medial side 22 of the bladder 106, and a lateral mid-foot lobe 138f disposed at the anterior end of heel region 16 on the lateral side 24 of the bladder 106 A.
• Each of the medial mid-foot lobe 138e and the lateral mid foot lobe 138f extends from a respective first end 140e, 140f and along the peripheral region 28 to its respective second end 142e, 142f.
• the posterior lobe 138i is disposed at the second end 112 of the bladder 106A and the intermediate portion 144i of the posterior lobe 138i is aligned with the longitudinal axis A IO6 of the bladder 106A.
• the posterior lobe 138i extends from a first end 140i on the medial side 22 of the bladder 106 A to a second end 142i on the lateral side 24 of the bladder 106A.
• the intermediate portion 144i has a greater cross-sectional area than each of the first end 140i and the second end 142i.
• the heel lobes 138g, 138h of the heel peripheral chamber 126a include a medial heel lobe 138g disposed on the medial side 22 of the bladder 106A, and a lateral heel lobe 138h disposed on the lateral side 24 of the bladder 106 A.
• first ends 140g, 140h of the heel lobes 138g, 138h are connected to the second ends 142e, 142f of the medial and lateral mid-foot lobes 138e, 138f, respectively.
• the second end 142g of the medial heel lobe 138g is connected to the first end 140i of the posterior lobe 138i.
• the second end 142f of the lateral heel lobe 138h is connected to the second end 142i of the posterior lobe 138i. Similar to the mid-foot lobes 138e, 138f and the posterior lobe 138i, the heel lobes 138e-138h, provide the heel peripheral chamber 126a with protruding portions along the medial and lateral sides 22, 24 of the bladder 106 A. [0085] With continued reference to FIGS. 3-5, the posterior lobe 138i is disposed at the second end 112 of the bladder 106A and the intermediate portion 144i of the posterior lobe 138i is aligned with the longitudinal axis A IO6 of the bladder 106A.
• the posterior lobe 138i extends from a first end 140i on the medial side 22 of the bladder 106 A to a second end 142i on the lateral side 24 of the bladder 106A.
• the intermediate portion 144i has a greater cross-sectional area than each of the ends 140i, 142i.
• the heel lobes 138g, 138h of the heel peripheral chamber 126a include a medial heel lobe 138g disposed on the medial side 22 of the bladder 106A, and a lateral heel lobe 138h disposed on the lateral side 24 of the bladder 106 A.
• first ends 140g, 140h of the heel lobes 138g, 138h are connected to the second ends 142e, 142f of the medial and lateral mid-foot lobes 138e, 138f, respectively.
• the second end 142g of the medial heel lobe 138g is connected to the first end 140i of the posterior lobe 138i.
• the second end 142h of the lateral heel lobe 138h is connected to the second end 142i of the posterior lobe 138i. Similar to the mid-foot lobes 138e, 138f and the posterior lobe 138i, the heel lobes 138g, 138h provide the heel peripheral chamber 126a with protruding portions along the medial and lateral sides 22, 24 of the bladder 106 A. [0087]
• the intermediate segments 134a, 134b extend across the width of the bladder 106A.
• the intermediate segment 134b is adjacent to the mid-foot region 14 and connects the pair of forefoot lobes 138c, 138d to each other.
• the intermediate segment 134b extends along an arcuate path from the medial side 22 to the lateral side 24.
• Intermediate segment 134a separates the toe portion 12T from the mid-foot region 14 and connects the second ends 142a, 142b of the pair of toe lobes 138a, 138b to each other.
• the intermediate segment 134a extends along an arcuate path from the medial side 22 to the lateral side 24 so as to help form a U-shaped recess between the pair of toe lobes 138a, 138b.
• the forefoot peripheral chamber 126b includes the pair of forefoot lobes 138c, 138d that extends through the ball portion 12 B of the forefoot region 12, and are disposed between the heel peripheral chamber 126a and the toe peripheral chamber 126c.
• the forefoot lobes 138c, 138d include a medial forefoot lobe 138c and a lateral forefoot lobe 138d.
• a first recess 146a is formed where the second end 142a of the medial toe lobe 138a joins with the first end 140c of the medial forefoot lobe 138c.
• a second recess 146b is formed where the second end 142b of the lateral toe lobe 138b joins with the first end 140d of the lateral forefoot lobe 138d.
• a third recess 146c is formed where the second end 142c of the medial forefoot lobe 138c joins with the first end 140e of the medial mid-foot lobe 138e.
• a fourth recess 146d is formed where the second end 142d of the lateral forefoot lobe 138d joins with the first end 140f of the lateral mid-foot lobe 138f [0089]
• one or both of the forefoot lobes 138c, 138d of the forefoot peripheral chamber 126b may be bulbous, whereby a size (e.g., cross-section, width, thickness) of the intermediate portion 144c, 144d is greater than the first end 140c, 140d and the second end 142c, 142d.
• a width of each of the first ends 140c, 140d and the second ends 142c, 142d increases from the respective intermediate portion 144c, 144d such that the first ends 140c, 140d and the second ends 142c, 142d converge inwardly towards the longitudinal axis A IO6 of the bladder 106A.
• one or both of the toe lobes 138a, 138b of the toe peripheral chamber 126c may be bulbous, whereby a size (e.g., cross-section, width, thickness) of the intermediate portion 144a, 144b is greater than the first end 140a, 140b and the second end 142a, 142b.
• the toe peripheral chamber 126c may only be partially attached to the web area 120.
• the toe lobes 138a, 138b of the toe peripheral chamber 126c may project beyond the web area 120, such that each of the distal ends of the toe lobes 138a, 138b is free-hanging. Accordingly, each of the toe lobes 138a, 138b may move independent of the other.
• the toe lobes 138a, 138b of the toe peripheral chamber 126c may be formed to have a substantially circular shape (not shown).
• a forefoot interior chamber 128b extends along the longitudinal axis A IO6 from a first end 132b connected to the intermediate segment 134a of the toe peripheral chamber 126c, to a terminal second end 136b adjacent to the intermediate segment 134b of the forefoot peripheral chamber 126b.
• an outer perimeter of the forefoot interior chamber 128b is inwardly offset from an inner perimeter of the forefoot peripheral chamber 126b by a substantially constant distance.
• the forefoot interior chamber 128b includes a necked portion 152 adjacent to the first end 132b, which extends between the recesses 146a, 146b of the forefoot peripheral chamber 126b.
• the second end 136b of the forefoot interior chamber 128b may also be bulbous, and is circumscribed by the forefoot lobes 138c, 138d of the forefoot peripheral chamber 126b.
• a heel interior chamber 128a extends along the longitudinal axis A IO6 from a first end 132a connected to the intermediate segment 134b of the forefoot peripheral chamber 126b, to a terminal second end 136a adjacent to the posterior lobe 138i of the heel peripheral chamber 126a.
• An outer perimeter of the heel interior chamber 128a is inwardly offset from an inner perimeter of the heel peripheral chamber 126a by a substantially constant distance. As such, a width of the heel interior chamber 128a may increase along the direction from the first end 132b to the second end 136b.
• the interior chambers 128a, 128b are attached to the respective peripheral chambers 126a, 126b by the web area 120, such that each of the interior chambers 128a, 128b is surrounded by a portion the web area 120.
• the web area 120 includes a first portion 154a having a substantially U-shape surrounding the heel interior chamber 128a, and a second portion 154b having a substantially U-shape surrounding the forefoot interior chamber 128b.
• the U- shaped first portion 154a of the web area 120 extends between and attaches the outer perimeter of the heel interior chamber 128a and the inner perimeter of the heel peripheral chamber 126a.
• the U-shaped second 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 term “U-shaped” is not limited strictly to shapes having two straight legs connected by a constant curvature, but instead refers to any shape the extends from a first end along a general first direction, and then turns back and extends along the first direction to a second end adjacent to or across from the first end.
• the U-shaped portions of the web area could also be described as being horseshoe-shaped, bell-shaped, or hairpin-shaped, for example.
• Adjacent ones of the chambers 126a- 126c, 128a- 128b are separated from each other by the portions of the web area 120, such that pockets or spaces 156a-156c, 158a-158c are formed on opposite sides 114, 116 of the bladder 106A between adjacent ones of the chambers 126a-126c, 128a-128b, as best shown in FIGS. 6A, 7 and 8.
• the bladder 106A includes a series of upper pockets 156a-156c formed by the web area 120 and adjacent chambers 126a-126c, 128a- 128b on the top side 114 of the bladder 106 A, and a series of lower pockets 158a- 158c formed by the web area 120 and adjacent chambers 126a-126c, 128a-128b on the bottom side 116 of the bladder 106 A.
• 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 fluidly coupling adjacent ones of the peripheral chambers 126a- 126c to each other. Accordingly, the portions of the interior void 130 formed by each of the peripheral chambers 126a- 126c and the interior chambers 128a, 128b are in fluid communication with each other, such that fluid can be transferred between the peripheral chambers 126a-126c.
• the cushion member 106 is a foam element 106B.
• the foam element 106B is a solid unitary piece extending a length, width and height of the cushion member 106.
• the top side 114 and the bottom side 116 of the foam element 106B defines the shape of the foam element 106B.
• the foam element 106B comprises a foam material comprising one or more polymers, examples of which are provided below.
• the shape of the foam element 106B is the same as the shape of the cushion member 106 shown throughout the figures.
• the foam element 106B may be formed solely of a polymeric material having a shape that is identical to the shape defined by the barrier layers 118 shown in FIGS. 5A and 6A. It should be noted that foam element 106B may have the same shape as the peripheral chambers 126a- 126c and interior chambers 128a, 128b described with respect to the fluid-filled bladder 106A, but does not enclose a space or define an inner void, as the foam element 106B is formed as a unitary piece.
• Features such as the web area 120 of the fluid-filled bladder 106A are also formed of a resilient polymeric material when the cushion 106 is formed as a foam element 106B.
• the polymeric material may be formed to provide substantially the same cushioning and load bearing characteristics as the fluid-filled bladder 106A shown in FIGS. 5A and 6A; however, the ground-reacting forces may be different, as described above. Namely, the ground-reacting forces are primarily dissipated by the foam element 106B as opposed to being distributed throughout the fluid-filled bladder 106A. As such, an applied load is generally absorbed rather than dissipated or otherwise attenuated to other locations of the cushion member 106.
• the cushion member 106 includes a foam element 106B formed as a solid body that comprises a foam material comprising one or more polymers received within and between the barrier layers 118 so as to be encapsulated.
• the polymeric material and associated barrier layers 118 may be formed to provide substantially the same cushioning and load bearing characteristics as the fluid-filled bladder 106A shown in FIGS. 5A and 6A; however, the ground-reacting forces are different due to the foam element 106B disposed therein.
• the combination of the barrier layers 118 and encapsulated foam element 106B provides a hybrid cushion that shares properties of the fluid-filled bladder 106 A and the foam element 106B. Namely, an applied load will (i) cause displacement of fluid trapped between the barrier layers 118 and (ii) be absorbed by the polymeric material of the foam element 106B. Encapsulating the polymeric material within the barrier layers 118 helps keep the polymeric material of the foam element 106B clean and dry and helps the foam element 106B retain a desired shape. Regardless of whether the cushion member 106 includes barrier layers 118 and a polymeric material or just a polymeric material defining the cushion member 106, the thickness Tio 6 of the cushion member 106 shown in FIG.
• the cushion member 106 comprises a foam material comprising one or more polymers, or is formed of a foam material comprising one or more polymers encapsulated within barrier layers 118.
• the chassis 108 is configured to interface with the cushion member 106 to provide a unitary midsole 102. It should be appreciated that the chassis 108 is configured to interface with any aspect of the cushion member 106 described herein.
• the chassis 108 extends from a first end 160 at the anterior end 18 of the sole structure 100 to a second end 162 at the posterior end 20 of the sole structure 100.
• the chassis 108 further includes a top surface 164 defining a portion of a footbed, and a bottom surface 166 formed on the opposite side of the chassis 108 than the top surface 164 and configured to interface with the top side 114 of the cushion member 106.
• the chassis 108 may be formed as a unitary piece, or may be formed of a plurality of elements as discussed in greater detail below.
• the chassis 108 includes a series of supports 168a- 168g extending along a length of the chassis 108.
• a plurality of medial supports 168a, 168c, 168e and 168g extends along a medial side 22 of the chassis 108
• a plurality of lateral supports 168b, 168d, 168f and 168h extends along a lateral side 24 of the chassis 108
• a posterior support 168i is disposed at the posterior end 20 of the chassis 108.
• the posterior support 168i is disposed between the series of medial supports 168a, 168c, 168e and the series of lateral supports 168b, 168d, 168f.
• the series of supports 168a-168i alternate with a series of recesses 170a-170f, which also extend along the length of the chassis 108.
• lateral recesses 170a, 170c and 170e of the second series of recesses 170a-170f extend along the lateral side 24 of the chassis 108 and medial recesses 170b, 170d and 170f of the second series of recesses 170a- 170f extend along the medial side 22 of the chassis 108.
• a lateral recess 170a and a medial recess 170b are disposed between the mid-foot region 14 from the forefoot region 12.
• the lateral recess 170a and the medial recess 170b each taper in width and height from a peripheral edge of the chassis 108 to a center of the chassis 108 and terminate at an outer surface that is co-planar with a bottom of the chassis 108 so as to form the shape of a half of a cone as viewed from a cross-section taken along a length of the cone.
• a lateral recess 170c and a medial recess 170d form a mid-foot continuous recess 172 extending the width of the chassis 108.
• the mid-foot continuous recess 172 separates the heel region 16 from the mid foot region 14.
• the mid-foot continuous recess 172 is positioned so as to facilitate a flex of the outsole 104 between the heel region 16 and the mid-foot region 14.
• the series of supports 168a-168i are aligned and in contact with the series of lobes 138a- 138i.
• a distal end of each of the supports 168a-168i is generally concave, having a generally U-shaped cross-section as taken along a width of the chassis 108, so as to receive a top surface of a respective lobe in the first series of lobes 138a-138i.
• the supports 168c-168i define a first series 174 of supports 168c-168i configured to be aligned with and contact the first series 148 of lobes 138c-138i.
• Supports 168a-168b define a second series 176 of supports configured to be aligned with the second series 150 of lobes 138a-138b disposed in the toe portion 12 T of the forefoot region 12.
• the chassis 108 may include a cushion support 178 and a plate 180.
• the plate 180 is wider than the cushion support 178 and the cushion support 178 is configured to be seated underneath the plate 180 and over the cushion member 106.
• the plate 180 has a continuous surface bound by the peripheral edge of the plate 180.
• the first series 174 of supports 168c- 168i are formed wholly on the bottom surface of the cushion support 178 and the second series 176 of second supports 168a- 168b are formed wholly on the bottom surface of the plate 180.
• the chassis 108 may be configured to support the periphery of a user’s foot.
• the chassis 108 may further include a series of upper portions 184a-184h disposed on the peripheral edge of the chassis 108.
• the series of upper portions 184a-184h are formed solely on the plate 180.
• the series of upper portions 184a-184h is disposed along the periphery of the chassis 108 and is curved along both the width and the height of the chassis 108 so as to conform to the shape of the bottom of a foot.
• the series of upper portions 184a-184h includes an anterior upper portion 184a, a posterior upper portion 184h, a series of medial upper portions 184b, 184d, 184f and a series of lateral upper portions 184c, 184e, 184g extending along a periphery of the respective medial side 22 and lateral side 24 of the chassis 108.
• the posterior upper portion 184h is disposed on the posterior end 20 of the chassis 108 and the anterior upper portion 184a is disposed on the anterior end 18 of the chassis 108.
• the series of medial upper portions 184b, 184d, 184f and the series of lateral upper portions 184c, 184e, 184g extend from opposite ends of the posterior upper portion 184h to corresponding ends of the anterior upper portion 184a.
• the posterior upper portion 184h forms a cup for assisting in the support of the back of a heel.
• the anterior upper portion 184a is curved along the periphery of the posterior end 20 of the chassis 108 and may have a generally constant height. A height to the upper portions 184a-184h may be the same or may be varied.
• the upper portion 184a-184h is contiguous with the series of supports 168a-168i.
• the series of upper portions 184a-184h may be formed wholly on the plate 180.
• the chassis 108 may be formed of the cushion support 178 assembled to the plate 180.
• the plate 180 is mounted to a top surface of the cushion support 178 so as to be disposed between the upper 200 and the cushion support 178.
• the plate 180 is longer than the cushion support 178 and the lateral and medial supports 168a, 168b (which are configured to align with and contact respective toe lobes 138a, 138b) are formed on a bottom surface of the plate 180.
• the bottom surface of the plate 180 includes an inner peripheral wall 186 bounding a space defining a cushion pocket 188.
• the cushion pocket 188 is configured to receive the cushion support 178 where the cushion support 178 may be fixed to the plate 180 so as to form a unitary piece.
• the cushion support 178 may be fixed to the cushion pocket 188 using any fixing device or technique, illustratively including singularly or in combination an adhesive, a stitch, a weld vibrational fusing or the like.
• the cushion support 178 includes a series of wings 190a-190h disposed along the periphery of the chassis 108 so as to extend from the anterior end 18 to the posterior end 20 along the medial side 22 and the lateral side 24.
• the series of wings 190a-190h includes an anterior wing 190a disposed on the anterior end 18 of the chassis 108, a posterior wing 190h disposed on the posterior end 20 of the chassis 108, a series of medial wings 190b, 190d, 190f disposed between the posterior wing 190h and the anterior wing 190a along the medial side 22 of the chassis 108 and a series of lateral wings 190c, 190e, 190g disposed between the posterior wing 190h and the anterior wing 190a along the lateral side 24 of the chassis 108.
• the inner peripheral wall 186 of the plate 180 is dimensioned to receive the cushion support 178.
• the inner peripheral wall 186 includes a series of flanges 192a-192h that define the cushion pocket 188.
• the inner peripheral wall 186 has a height that is substantially the same as a height of the series of wings 190a-190h so as to form a generally seamless transition between the series of wings 190a-190h and the bottom surface of the plate 180.
• Each flange in the series of flanges 192a-192h is dimensioned to be seated between a pair of adjacent wings in the series of wings 190a-190h.
• the series of flanges 192a-192h includes a pair of anterior flanges 192a, 192b disposed on the anterior end 18 of the chassis 108 and spaced apart from each other so as to accommodate the anterior wing 190a.
• the series of flanges 192a-192h include a pair of posterior flanges 192g, 192h disposed on the posterior end 20 of the chassis 108 and spaced apart from each other so as to accommodate the posterior wing 190h.
• a series of medial flanges 192c, 192e, are disposed on the medial side 22 of the plate 180 between the pair of posterior wings 190g, 190h and the pair of anterior wings 190a, 190b.
• a series of lateral flanges 192d, 192f are disposed on the lateral side 24 of the plate 180 between the pair of posterior wings 190g, 190h and the pair of anterior wings 190a, 190b.
• the series of medial wings 190b, 190d, 190f are disposed between corresponding flanges of the series of medial flanges 192c, 192e.
• the series of lateral wings 190c, 190e, 190g are disposed between corresponding flanges of the series of lateral flanges 192d, 192f.
• the chassis 108 includes a series of ridges 194a- 194c that are configured to be seated in a respective one of the upper pockets 156a- 156c when the chassis 108 is assembled to the cushion member 106.
• the series of ridges 194a-194c are formed on the bottom side of the cushion support 178 and includes an anterior ridge 194a, an intermediate ridge 194b and a posterior ridge 194c.
• the anterior ridge 194a is disposed on the forefoot region 12 and has a generally U-shaped structure forming an anterior depression 198a configured to engage interior chamber 128b.
• the intermediate ridge 194b is formed by a pair of spaced apart legs 196a, 196b disposed on a respective lateral side 24 and the medial side 22 of the chassis 108 so as to form an elongated intermediate depression 198b configured to engage the interior chamber 128b.
• the posterior ridge 194c forms a generally U-shaped dimension so as to define a posterior depression 198c configured to engage the interior chamber 128a.
• the ridges 194a- 194c may be configured to fully extend into the web area 120 of the upper pockets 158a- 158c in some areas and be spaced apart from the web area 120 of the upper pockets 158a-158c in other areas when the midsole 102 is assembled.
• bottom surfaces of the ridges 194a-194c may contact the web area 120 in selected locations.
• one or more of the ridges 194a- 194c may be configured so that the distal ends are spaced apart from the web area 120, or may be omitted from the chassis 108.
• the chassis 108 is formed of the cushion support 178 and the plate 180.
• the cushion support 178 and the plate 180 may be secured to each other to form a unitary piece using any technique such as adhesives, welding or the like. Alternatively, the cushion support 178 and the plate 180 may be simply mounted to each other and held by an attachment to the outsole 104 and the upper 200.
• the plate 180 has a top surface that is continuous between the peripheral edge of the plate 180.
• the chassis 108 and the outsole 104 are shown assembled to the cushion member 106.
• the ridge 194c is shown contacting the web area 120 while ridge 194a is spaced apart from the web area 120.
• the plate 180 is longer than the cushion support 178 with the second series 150 of lobes 138a-138b extending beyond the anterior end of the cushion support 178.
• the outsole 104 is mounted to a bottom surface of the cushion member 106 so as to protect the cushion member 106 during an engagement with a ground surface.
• the top surface of the respective interior chambers 128a, 128b are seated within respective depressions 198a- 198c of the corresponding ridges 194a-194c.
• the posterior support 168i has a generally hemispherical cross section that corresponds to the top surface of the posterior lobe 138i. A posterior end of the posterior ridge 194c is spaced apart from the web area 120.
• FIG. 12 shows the engagement of the toe lobes 138a, 138b with the chassis 108.
• the second series 176 of second supports 168a-168b is formed fully by the plate 180.
• the cushion support 178 does not extend to the toe lobes 138a, 138b and a gap 202 is formed between the pair of toe lobes 138a, 138b.
• the gap 202 allows for the toe lobes 138a, 138b to flex freely relative to lobes 138c-138i, which are connected at a respective first end 140a-140i and second end 142a-142i.
• FIG. 13 a cross-sectional view taken along Line 13-13 of FIG. 10 is provided.
• the chassis 108 is fully seated against the top side 114 of the cushion member 106.
• the medial support 168c and lateral support 168d are engaged with the pair of forefoot lobes 138c, 138d.
• the lateral support 168c is formed wholly on the cushion support 178 and the plate 180 rests on the top surface of the cushion support 178.
• the posterior depression 198c of the cushion support 178 bound by the posterior ridge 194c is arcuate so as to be seated against the top surface of the forefoot interior chamber 128a.
• the bottom surface of the anterior ridge 194a is engaged with the web area 120.
• FIG. 14 a cross-sectional view taken along Line 14-14 of FIG. 10 is provided.
• the medial support 168e and the lateral support 168f are aligned with and contact a top surface of a respective one of the pair of mid-foot lobes 138e, 138f.
• the medial support 168f and the lateral support 168e are dimensioned to be fully seated against the respective mid-foot lobes 138e, 138f.
• the intermediate depression 198b between the legs 196a, 196b of the intermediate ridge 194b is arcuate so as to be seated against the top surface of interior chamber 128b.
• FIG. 14 shows an aspect where the bottom surface of the intermediate ridge 194b is spaced apart from the web area 120.
• FIG. 15 a cross-sectional view taken along Line 15-15 of FIG. 10 is provided.
• the medial support 168h and the lateral support 168g are aligned with and contact a top surface of a respective one of the pair of heel lobes 138h, 138g.
• the medial support 168h and the lateral support 168g are dimensioned to be fully seated against the respective heel lobes 138h, 138g.
• the posterior depression 198c bound by the posterior ridge 194c is arcuate so as to be seated against the top surface of interior chamber 128b.
• FIG. 14 shows an aspect where the bottom surface of the intermediate ridge 194b is spaced apart from the web area 120.
• the components 178, 180 of the chassis 108 may include a chassis material comprising one or more polymers, such as foam or rubber, to impart properties of cushioning, responsiveness, and energy distribution to the foot of the wearer.
• the cushion support 178 comprises a first foam material and the plate 180 comprises a second foam material.
• the cushion support 178 may include foam materials providing greater cushioning and impact distribution, while the plate 180 includes a foam material having a greater stiffness in order to provide increased lateral and medial stiffness to the peripheral region 28 of the upper 200.
• the upper portions 184b-184h is seated within a corresponding wing 190b-190h.
• the wings 184b- 184h and the upper portions 184b-184h extend outwardly and upwardly from a periphery of the plate 180.
• the wings 184b-184h and the upper portions 184b-184h align with a corresponding support 168c-168i.
• the cushion support 178 has a generally v-shaped cross-section taken along a height of the cushion support 178.
• the center of the cushion support 178 defining the wing 190b-190h from the support 168c-168i is recessed inwardly with respect to the wing 190b-190h and the corresponding support 168c-168i.
• the series of supports 168c-168i cooperate with a corresponding wing 184b-184h to provide a compressive and reactive force in response to a load.
• the series of supports 168c-168i and the corresponding wing 184b-184h function as a spring in response to a compressive load.
• the chassis material comprises one or more polymers.
• Example chassis materials include foamed or solid materials, including molded foamed and molded solid materials.
• the various materials described herein comprise, consist of, or consist essentially of one or more polymers.
• the one or more polymers may include one or more thermoplastic polymers, one or more thermosetting or thermosettable polymers (i.e., polymers which are capable of being crosslinked, but which have not yet been 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 mixtures of both; and may include homopolymers, copolymers (including terpolymers), or mixtures of both. [0122] In some aspects, the one or more polymers may include olefmic homopolymers, olefmic copolymers, or blends thereof. Examples of olefmic polymers include polyethylene, polypropylene, and combinations thereof.
• the one or more polymers may include one or more ethylene copolymers, such as, ethyl ene-vinyl acetate (EVA) copolymers, EVOH copolymers, ethylene-ethyl acrylate copolymers, ethylene-unsaturated mono-fatty acid copolymers, and combinations thereof.
• EVA ethyl ene-vinyl acetate
• EVOH ethylene-ethyl acrylate copolymers
• ethylene-unsaturated mono-fatty acid copolymers and combinations thereof.
• the one or more polymers may include one or more polyacrylates, such as polyacrylic acid, esters of polyacrylic acid, polyacrylonitrile, polyacrylic acetate, polymethyl acrylate, polyethyl acrylate, polybutyl acrylate, polymethyl methacrylate, and polyvinyl acetate; including derivatives thereof, copolymers thereof, and any combinations thereof.
• polyacrylates such as polyacrylic acid, esters of polyacrylic acid, polyacrylonitrile, polyacrylic acetate, polymethyl acrylate, polyethyl acrylate, polybutyl acrylate, polymethyl methacrylate, and polyvinyl acetate; including derivatives thereof, copolymers thereof, and any combinations thereof.
• the one or more polymers may include one or more ionomeric polymers.
• the ionomeric polymers may include polymers with carboxylic acid functional groups, sulfonic acid functional groups, salts thereof (e.g., sodium, magnesium, potassium, etc.), and/or anhydrides thereof.
• the ionomeric polymer(s) may include one or more fatty acid-modified ionomeric polymers, polystyrene sulfonate, ethylene-methacrylic acid copolymers, and combinations thereof.
• the one or more polymers may include one or more styrenic block copolymers, such as acrylonitrile butadiene styrene block copolymers, styrene acrylonitrile block copolymers, styrene ethylene butylene styrene block copolymers, styrene ethylene butadiene styrene block copolymers, styrene ethylene propylene styrene block copolymers, styrene butadiene styrene block copolymers, and combinations thereof.
• 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
• 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., cross- linked polyurethanes and/or thermoplastic polyurethanes). Examples of suitable polyurethanes include those discussed above for barrier layers 118.
• the one or more polymers may include one or more natural and/or synthetic rubbers, such as polybutadiene and polyisoprene.
• the foamed material may be foamed using a physical blowing agent which phase transitions to a gas based on a change in temperature and/or pressure, or a chemical blowing agent which forms a gas when heated above its activation temperature.
• the chemical blowing agent may be an azo compound such as adodicarbonamide, sodium bicarbonate, and/or an isocyanate.
• the foamed material may be a crosslinked foamed material. In these configurations, a peroxide-based crosslinking agent such as dicumyl peroxide may be used.
• the foamed material may include one or more fillers such as pigments, modified or natural clays, modified or unmodified synthetic clays, talc glass fiber, powdered glass, modified or natural silica, calcium carbonate, mica, paper, wood chips, and the like.
• fillers such as pigments, modified or natural clays, modified or unmodified synthetic clays, talc glass fiber, powdered glass, modified or natural silica, calcium carbonate, mica, paper, wood chips, and the like.
• the material may be formed using a molding process.
• the uncured material e.g., uncured rubber
• the material may be mixed in a Banbury mixer with an optional filler and a curing package such as a sulfur-based or peroxide- based curing package, calendared, formed into shape, placed in a mold, and vulcanized.
• the material when the material is a foamed material, the material may be foamed during a molding process, such as an injection molding process.
• a thermoplastic material may be melted in the barrel of an injection molding system and combined with a physical or chemical blowing agent and optionally a crosslinking agent, and then injected into a mold under conditions which activate the blowing agent, forming a molded foam.
• the foamed material when the material is a foamed material, the foamed material may be a compression molded foam. Compression molding may be used to alter the physical properties (e.g., density, stiffness and/or durometer) of a foam, or to alter the physical appearance of the foam (e.g., to fuse two or more pieces of foam, to shape the foam, etc.), or both.
• Compression molding may be used to alter the physical properties (e.g., density, stiffness and/or durometer) of a foam, or to alter the physical appearance of the foam (e.g., to fuse two or more pieces of foam, to shape the foam, etc.), or both.
• the compression molding process desirably starts by forming one or more foam preforms, such as by injection molding and foaming a material, by forming foamed particles or beads by foaming a material, by cutting foamed sheet stock, and the like.
• the compression molded foam may then be made by placing the one or more foam preforms in a compression mold, and applying sufficient pressure to the one or more foam preforms to compress the one or more foam preforms in a closed mold.
• the mold is closed, sufficient heat and/or pressure is applied to the one or more foam preforms in the closed mold for a sufficient duration 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 each other, or increasing the density of the foam(s) which is retained in the finished product, or any combination thereof.
• the mold is opened and the molded foam article is removed from the mold.
• the outsole 104 extends over the midsole 102 to provide increased durability and resiliency.
• the outsole 104 is provided as a polymeric layer that is overmolded onto the cushion member 106 to provide increased durability to the exposed portions of the lower barrier layer 118 of the cushion member 106.
• the outsole 104 is formed of a different material than the cushion member 106, and includes at least one of a different thickness, a different hardness, and a different abrasion resistance than the lower barrier layer 118.
• the outsole 104 may be formed integrally with the lower barrier layer 118 of the cushion member 106 using an overmolding process.
• the outsole 104 may be formed separately from the lower barrier layer 118 of the cushion member 106 and may be adhesively bonded to the lower barrier layer 118.
• the upper 200 is attached to the sole structure 100 and includes interior surfaces that define an interior void configured to receive and secure a foot for support on sole structure 100.
• the upper 200 may be formed from one or more materials that are stitched or adhesively bonded together to form the interior void. Suitable materials of the upper may include, but are not limited to, mesh, textiles, foam, leather, and synthetic leather. The materials may be selected and located to impart properties of durability, air-permeability, wear-resistance, flexibility, and comfort. [0135]
• the following Clauses provide exemplary configurations for a bladder, a sole structure, and an article of footwear described above.
• a sole structure for an article of footwear having an upper, comprises a cushion member and a chassis.
• the cushion member extends from a forefoot region of the sole structure to a heel region of the sole structure and includes a first series of lobes alternating with a first series of recesses along a length of the cushion member.
• the first series of lobes and the first series of recesses extend along one of a medial side of the sole structure and a lateral side of the sole structure.
• the cushion member further includes a second series of lobes in a toe portion.
• the chassis includes a first series of supports each aligned and in contact with a respective lobe of the first series of lobes and a second series of supports each aligned and in contact with a respective lobe of the second series of lobes, each of the first series of supports includes a first material and each of the second series of supports includes a second material different than the first series of supports.
• Clause 2 The sole structure of Clause 1, wherein at least one support of the first series of supports and the second series of supports includes an upper portion extending in a direction outwardly from a body of the at least one support.
• Clause 3 The sole structure of Clause 2, wherein the chassis includes a cushion support.
• Clause 4 The sole structure of Clause 3, wherein the cushion support includes a continuous recess extending across a width of the cushion support between the heel region and a mid-foot region.
• Clause 5 The sole structure of Clause 3, wherein the chassis further includes a plate attached on an opposite side of the cushion support than the cushion member.
• Clause 6 The sole structure of Clause 5, wherein the plate is longer than the cushion support.
• Clause 8 The sole structure of any of the preceding Clauses, wherein the first material includes a foam material.
• Clause 9 The sole structure of any of the preceding Clauses, wherein the second series of supports includes a pair of supports configured to be aligned with and contact a pair of toe lobes of the second series of lobes, the toe lobes being disposed in the forefoot region.
• Clause 10 The sole structure of any of the preceding Clauses, wherein the first series of supports includes a plurality of forefoot supports and a plurality of heel supports, the plurality of forefoot supports and the plurality of heel supports wholly formed of the first material.
• Clause 12 The sole structure of Clause 11, wherein the fluid-filled bladder is formed of an opposing pair of barrier layers.
• Clause 14 An article of footwear incorporating the sole structure of any of the preceding Clauses.
• a sole structure comprises a cushion member including (i) a peripheral chamber including a first series of lobes arranged along a peripheral region of the sole structure from a forefoot region to a heel region of the bladder and (ii) an interior chamber at least partially surrounded by the peripheral chamber and spaced apart from the peripheral chamber by a web area; and a chassis including a cushion support defining a first series of supports arranged along the peripheral region of the sole structure, each of the first series of supports separated from an adjacent one of the supports by a recess and contacting a respective one of the lobes.
• Clause 16 The sole structure of Clause 15, wherein the chassis further includes a plate attached on an opposite side of the cushion support than the cushion member.
• Clause 17 The sole structure of Clause 16, wherein the plate is longer than the cushion support.
• Clause 18 The sole structure of Clause 16, wherein the cushion support includes a series of wings extending along a periphery of the cushion support, the series of wings configured to be positioned against a bottom surface of the plate.
• Clause 19 The sole structure of any of the preceding Clauses, wherein at least one of the first series of supports includes an upper portion extending upwardly and outwardly from a body of the at least one of the first series of supports.
• Clause 20 The sole structure of any of the preceding Clauses, wherein the recess extends across width of the cushion support.
• Clause 21 The sole structure of any of the preceding Clauses, wherein the recess is disposed between a mid-foot region and the heel region.
• Clause 24 The sole structure of any of the preceding Clauses, wherein the first series of supports includes a plurality of forefoot supports and a plurality of heel supports, the plurality of forefoot supports and the plurality of heel supports wholly formed from the cushion support.
• Clause 25 The sole structure of any of the preceding Clauses, wherein the cushion member is one of a foam element and a fluid-filled bladder, the foam element being a solid unitary piece extending a length, width and height of the cushion member.
• Clause 26 The sole structure of Clause 25, wherein the fluid-filled bladder is formed of an opposing pair of barrier layers.
• Clause 28 An article of footwear incorporating the sole structure of any of the preceding Clauses.

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• Chemical & Material Sciences (AREA)
• Engineering & Computer Science (AREA)
• Materials Engineering (AREA)
• Laminated Bodies (AREA)
• Footwear And Its Accessory, Manufacturing Method And Apparatuses (AREA)

Applications Claiming Priority (8)

Publications (1)

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• 2022
  • 2022-04-04 EP EP22719691.2A patent/EP4346491A1/de active Pending
  • 2022-05-30 CN CN202210597701.2A patent/CN115399547A/zh active Pending

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