TWI616148B - Article of footwear having a sole structure including a fluid-filled chamber and an outsole, the sole structure, and methods for manufacturing - Google Patents

Abstract

The invention relates to an article of footwear including an upper and a sole structure, the sole structure, a method for manufacturing the sole structure, and a method for manufacturing the footwear. The sole structure includes a fluid-filled chamber and an outsole that at least partially surrounds the chamber.

Description

Footwear article having a sole structure including a fluid-filled chamber and an outsole, a sole structure, and a manufacturing method

The invention relates to a sole structure for an article of footwear, an article of footwear including a sole structure, and a method for manufacturing a sole structure.

The present invention relates generally to an article of footwear having an upper and a sole structure including a co-molded fluid-filled chamber and an outsole. The present invention also relates to a sole structure, a method for manufacturing a sole structure, and a method for manufacturing an article of footwear having a sole structure.

The conventional sports footwear article includes two main elements: an upper and a sole structure. The upper is generally formed of a plurality of elements (e.g., fabric, foam, leather, synthetic leather) that are stitched or adhesively bonded together to form a secure and comfortable reception of an internal void of one foot. The sole structure also has multiple layers known as a sock liner, a midsole and a large sole. An insole is a thin, compressible component positioned within a gap in the upper and adjacent to the sole (ie, lower) surface of the foot for improved comfort. The midsole is fixed to the upper and forms one of the middle layers of the sole structure, which attenuates ground reaction forces (ie, provides cushioning) during walking, running, or other walking activities. Outsole forming one of the footwear ground contact elements And is usually made of one of the durable and abrasion-resistant rubber materials that includes texture to impart traction.

The main material that forms many conventional midsoles is a polymer foam, such as polyurethane or ethyl acetate. In some footwear items, the midsole may also have a fluid-filled chamber that increases the durability of the footwear and enhances the ground reaction force attenuation of the sole structure. In some footwear configurations, such as in US Pat. No. 5,755,001 to Potter et al., US Pat. No. 6,837,951 to Rapaport and US Pat. No. 7,132,032 to Tawney et al., The fluid-filled chamber may be at least partially encapsulated in a polymer Foam inside. In other footwear configurations, such as in U.S. Patent No. 7,086,132 to Dojan et al., A fluid-filled chamber can substantially replace a polymer foam. In general, a fluid-filled chamber is formed from a polymer material that is sealed and pressurized, but can also be substantially unpressurized or from an external source. In some configurations, a fabric or foam tensile member may be positioned inside the room, or a reinforcing structure may be bonded to an exterior surface of the room to give the room a shape or maintain one of the desired shapes of the room.

Fluid-filled chambers suitable for footwear applications can be manufactured through a variety of processes, including a double membrane technology, thermoforming, and blow molding. In the double-membrane technology, two sheets of planar polymer material are bonded together in various positions to form a chamber. To pressurize the chamber, a nozzle or needle connected to a fluid pressure source is inserted into a fill inlet formed in the chamber. After pressurization, the fill inlet is sealed and the nozzle is removed. Thermoforming is similar to double film technology, but utilizes a heated mold during the manufacturing process to form or otherwise shape one of the thin sheets of polymer material. In blow molding, a molten or otherwise softened elastic material (ie, a parison) in the shape of a tube is placed in a mold having the desired overall shape and configuration of the chamber. The mold has an opening at one location through which pressurized air is provided. The pressurized air induces the liquefied elastic material to conform to the shape of the inner surface of the mold, thereby forming a chamber, which can then be pressurized.

The manufacture of articles of footwear generally involves ensuring that the relevant parts are in the correct position relative to each other. The manufacture of articles of footwear may also involve ensuring that parts are assembled during assembly (e.g., during adhesives) During curing and hardening) does not move when placed. Also, consumers need products that are attractive, well-structured, and provide selected properties and characteristics.

Therefore, there is a need in the art for an article of footwear that provides the properties and characteristics sought by a customer.

Cross-reference to related applications

This application is a partial continuation of the U.S. Patent Application Publication No. 2014/0230276 of Campos II et al., Published on August 21, 2014 and titled "Article of Footwear Incorporating a Chamber System and Methods for Manufacturing the Chamber System." , The entire disclosure of that application is incorporated herein by reference.

One aspect of the present invention is a sole structure for an article of footwear that includes an upper and a sole structure. The sole structure includes a component including a fluid-filled chamber having an edge and an upper surface. And a bottom surface, and a large bottom having a chamber engagement surface and a grip surface, wherein the large bottom is attached to at least a portion of the lower surface of the fluid-filled chamber and an area of the fluid-filled chamber via an adhesive layer At least a portion of the edge; and at least a portion of the outsole coextensive with the lower surface of the chamber and at least a portion of the edge of the chamber; wherein the chamber-engaging surface of the outsole is textured with a high area of texture And a low region having a depth; and one of the adhesives has a thickness smaller than the depth of the low regions.

100‧‧‧Footwear / Shoes

111‧‧‧ Forefoot area

112‧‧‧ Midfoot

113‧‧‧ Heel Zone

114‧‧‧ outside

115‧‧‧ inside

120‧‧‧ Upper

121‧‧‧ Ankle opening

122‧‧‧Shoelaces

123‧‧‧ Tongue

124‧‧‧ Shoelaces

125‧‧‧ insole

130‧‧‧ sole structure

131‧‧‧ Forefoot structure / Forefoot sole structure

132‧‧‧Heel structure / Heel sole structure

135‧‧‧Grasp bumps / parts

140‧‧‧ Forefoot Components

141‧‧‧ Upper surface of forefoot component

142‧‧‧ Lower surface of forefoot component

143‧‧‧Forefoot component edge

145‧‧‧ Forefoot component fluid filled chamber

150‧‧‧ Heel Components

151‧‧‧ Heel component upper surface

152‧‧‧ Heel component lower surface

153‧‧‧ Heel component edge

155‧‧‧ Heel component fluid filled chamber

160‧‧‧ Forefoot Outsole

162‧‧‧ Outer lower surface of forefoot outsole

163‧‧‧ Outer edge of forefoot outsole

164‧‧‧Inner surface / inner edge of forefoot outsole

165‧‧‧ Forefoot compartment

166‧‧‧ Inner and lower surface of forefoot outsole

170‧‧‧ Heel outsole

175‧‧‧ Heel outsole compartment

900‧‧‧ Feature Department

1131‧‧‧ Forefoot sole structure / Forefoot structure

1135‧‧‧Grip bump

1140‧‧‧ Forefoot Components

1141‧‧‧ Upper surface of forefoot component

1142‧‧‧ Lower surface of forefoot component / lower surface of fluid-filled chamber of forefoot component

1143‧‧‧Edge of forefoot component / Forefoot component fluid filled chamber edge

1145‧‧‧ Forefoot component fluid filled chamber / fluid filled component

1146‧‧‧Forefoot component flange

1147‧‧‧ Mesh area of forefoot component

1150‧‧‧Heel Kit

1152‧‧‧ Heel component lower surface

1155‧‧‧ Heel Assembly Fluid Filled Chamber

1156‧‧‧ Heel Assembly Flange

1157‧‧‧ Heel component mesh area

1160‧‧‧ Outsole

1163‧‧‧Edge of forefoot outsole compartment

1170‧‧‧ Heel outsole

1181‧‧‧first polymer layer

1182‧‧‧Second polymer layer

1190‧‧‧mould

1191‧‧‧The first mold part

1192‧‧‧The second mold part

1198‧‧‧Void volume

1700‧‧‧mould

1710‧‧‧The first mold part

1720‧‧‧The second mold part

1730‧‧‧ pinched surface

1740‧‧‧First seam forming surface

1750‧‧‧compressed surface

1760‧‧‧ pinched edge

1770‧‧‧Second seam forming surface

1780 ‧ ‧ sag

1790‧‧‧Void volume

1810‧‧‧first polymer layer

1820‧‧‧Second polymer layer

1932‧‧‧Heel sole structure

1955‧‧‧heel component fluid-filled chamber

1957‧‧‧ Heel component mesh area

1970‧‧‧Heel outsole

2060‧‧‧Forefoot outsole part / Forefoot outsole part

2069‧‧‧ Gas escape opening in forefoot outsole

2070‧‧‧Heel outsole / Heel outsole

2079‧‧‧Gas escape opening in heel outsole

2130‧‧‧sole structure

2131‧‧‧ Forefoot sole structure

2132‧‧‧ Heel sole structure

2135‧‧‧Grip bumps / parts

2140‧‧‧ Forefoot Components

2150‧‧‧Heel Components

2170‧‧‧ Heel outsole

2178‧‧‧Gas accumulation area

2179‧‧‧Gas escape opening / gas escape path

2181‧‧‧Gas accumulation pathway

2182‧‧‧Gas accumulation area

2189‧‧‧Gas escape opening

2270‧‧‧Outsole

2278‧‧‧Gas accumulation path

2279‧‧‧Gas escape opening / gas escape path

2732‧‧‧ Heel sole structure

2755‧‧‧ Heel component fluid filled chamber

2770‧‧‧Heel outsole

2832‧‧‧ Heel sole structure

2855‧‧‧ Heel Assembly Fluid Filled Chamber

2870‧‧‧ Heel outsole

The invention can be better understood with reference to the following drawings and description. The components in the figures are not necessarily to scale, but rather focus on illustrating the principles of the present invention. Further, in the drawings, like-element symbols refer to corresponding parts throughout the different views.

FIG. 1 is a lateral elevation view of an embodiment of an article of footwear; FIG. 2 is a bottom view of an article of footwear; Fig. 3 is a cross-sectional view of one of the footwear items of Fig. 2; Fig. 4 is a bottom view of one of the forefoot sole structures of an article of footwear; 6 is a bottom perspective view of a forefoot outsole of FIG. 2; FIG. 7 is an exploded view showing a relationship between a forefoot outsole and a forefoot component forming a forefoot sole structure of FIG. 2 8 is an exploded view showing a relationship between a heel outsole and a heel component forming one of the heel sole structure of FIG. 2; FIG. 9 is a front forefoot sole forming one of the forefoot sole structure of FIG. 4 An exploded view of a relationship between the sole and a forefoot component; FIG. 10 is a cross-sectional view of an open mold showing a relationship of a part of the mold used to form a forefoot sole structure of FIG. 4; 4 is a cross-sectional view of a closed mold of a forefoot sole structure of FIG. 4 formed in a mold; FIG. 12 is a view of an open mold of a relationship between a part of the mold used to form a heel sole structure of FIG. 2 A cross-sectional view; Figure 13 is a portion of Figure 2 in a partially open mold A cross-sectional view of a molded heel sole structure; FIG. 14 is a cross-sectional view of a closed mold of the heel sole structure of FIG. 2 formed in a mold; FIG. 15 is removed from an open mold after the structure is formed Figure 2 is a cross-sectional view of a heel sole structure; Figure 16 is a top view of the inside of a forefoot outsole of Figure 4; Figure 17 is a cross-sectional view of an embodiment of a heel sole structure; Figure 18 is a A cross-sectional view of one of another embodiment of a heel sole structure; FIG. 19 is a cross-sectional view of one of another embodiment of a heel sole structure; Figure 20 is a bottom view of one embodiment of a footwear article; Figure 21 is a bottom view of one embodiment of a heel outsole; Figure 22 is a bottom view of one embodiment of a heel outsole showing internal structure Figures; and Figure 23 is a bottom view of another embodiment of a heel outsole.

The present invention provides an article of footwear that provides the properties and characteristics sought by a customer. An embodiment of the present invention provides a sole structure for an article of footwear, which includes a fluid-filled chamber co-molded with a large sole, the large sole at least partially surrounding the chamber. An embodiment of the present invention also provides an article of footwear including an upper and a sole structure. An embodiment of the present invention provides a method for manufacturing a sole structure. The invention also relates to a method for manufacturing an article of footwear.

In one aspect, the invention relates to a sole structure for an article of footwear. The sole structure includes a fluid-filled chamber and a large sole. The fluid-filled chamber has an edge, an upper surface, and a lower surface. The outsole is co-molded to at least a portion of the lower surface of the fluid-filled chamber and at least a portion of the edge of the fluid-filled chamber. The outsole is coextensive with at least a portion of the lower surface of the fluid-filled chamber and at least a portion of the edge of the fluid-filled chamber.

In another aspect, the present invention relates to an article of footwear having an upper and a sole structure. The sole structure includes a fluid-filled chamber and a large sole. The fluid-filled chamber has an edge, an upper surface, and a lower surface. The outsole is co-molded to at least a portion of the lower surface of the fluid-filled chamber and at least a portion of the edge of the fluid-filled chamber. The outsole is coextensive with at least a portion of the lower surface of the fluid-filled chamber and at least a portion of the edge of the fluid-filled chamber. At least part of the upper is fixed to at least part of the sole structure.

One aspect of the present invention relates to a method for manufacturing a sole structure including a fluid-filled chamber and a large sole. The fluid-filled chamber has an edge, an upper surface, and a lower surface. According to the method, the outsole is positioned in an appropriate position in the second part of a mold having a first mold part and a second mold part so that it contacts the edge of the chamber At least a portion of the chamber and at least a portion of the lower surface of the chamber. A fluid-filled chamber precursor is placed in the mold and the first mold portion and the second mold portion are closed. By a technique, the upper surface of the fluid-filled chamber conforms to the shape of the first mold portion, the lower surface of the fluid-filled chamber conforms to the shape of the second mold portion having the large bottom therein, and The edge of the fluid-filled chamber precursor conforms to the shape of the mold having the outsole therein to form the fluid-filled chamber and the outsole co-molded therewith. The technique is selected from a vacuum in one of the suction molds. Pressure is introduced into the fluid-filled chamber precursor and a mixture thereof.

In another aspect, the invention relates to a method for minimizing the harmful effects of incomplete bonding caused by gas-related inclusions in the bonding between the bonding surface of a fluid-filled chamber and the bonding surface of a large bottom. . At least one of the bonding surfaces includes a texture having a land and a groove to ensure a bond between the convex surfaces and another surface. The groove is deeper than an adhesive or a portion of the molten opposing surface.

In some embodiments, at least a portion of the upper is secured to at least a portion of the sole structure.

In some embodiments, at least a portion of the ground-engaging surface of the outsole is textured.

In some embodiments, the edges of the fluid-filled chamber are flush with the outsole.

In some embodiments, the outsole is adhered to the fluid-filled chamber by partially melting at least one of a chamber joining surface of the outsole, a lower surface of the fluid-filled chamber, and an edge of the fluid-filled chamber.

In some embodiments, the outsole is adhered to the fluid-filled chamber by an adhesive layer having a thickness.

In some embodiments, the chamber bonding surface of the outsole is textured, the texture has high areas and low areas with depth, wherein the thickness of the adhesive is less than the depth of these low areas.

In some embodiments, the chamber joining surface of the outsole is textured, the texture has high areas and low areas with depth, and the outsole further has gas escape openings.

In some embodiments, the chamber junction surface of the outsole is textured, the texture has a high area and a low area with a depth, and the outsole further has a gas escape opening in fluid communication with the gas accumulation area and the passage.

In some embodiments, the chamber junction surface of the outsole is textured, the texture has high areas and low areas with depth, and the outsole further has gas escape openings in fluid communication with the low areas.

In other aspects, the invention relates to a method of manufacturing a sole structure for an article of footwear that includes an upper and a sole structure. According to the method, an assembly is provided that includes a fluid-filled chamber having an edge, an upper surface, and a lower surface. A large bottom is co-molded to at least a portion of the lower surface of the fluid-filled chamber and at least a portion of the edge of the fluid-filled chamber. The outsole is at least partially coextensive with the lower surface of the chamber and at least a portion of the edge of the chamber, and the outsole has a chamber engaging surface and a grip surface.

In some embodiments, the method further comprises: positioning the outsole in an appropriate position in the second portion of a mold having a first mold portion and a second mold portion such that it contacts the edge of the chamber At least a portion of the chamber and at least a portion of the lower surface of the chamber. A fluid-filled chamber precursor is placed in the mold and the first mold portion and the second mold portion are closed.

Using a technique to make the upper surface of the fluid-filled chamber conform to the shape of the first mold part, make the lower surface of the fluid-filled chamber conform to the shape of the second mold part with the outsole therein, and fill the fluid The edge of the chamber precursor conforms to the shape of the mold having the outsole therein to form the fluid-filled chamber and the outsole co-molded therewith. The technique is selected from the vacuum in one of the molds to introduce pressure to A group of fluid-filled chamber precursors and their mixtures.

In some embodiments, at least a portion of the upper is connected to at least a portion of the sole structure Minute.

In some embodiments, an adhesive is applied to the chamber-engaging surface of the outsole before placing the fluid-filled chamber precursor into the mold.

In some embodiments, the adhesive is dried before placing the fluid-filled chamber precursor in a mold.

In some embodiments, the method further comprises: coextruding the outsole and the lower surface of the fluid-filled chamber precursor.

In some embodiments, the method further comprises at least one of a lower surface of the partially filled fluid-filled chamber, an edge of the fluid-filled chamber, and a chamber bottom surface of the outsole.

In some embodiments, the method further includes forming a texture on the chamber bonding surface, the texture having high and low areas, and forming a gas escape opening in the outsole.

In some embodiments, the chamber junction surface of the outsole is textured, the texture has a high area and a low area with a depth, and the outsole further has a gas escape opening in fluid communication with the gas accumulation area and the passage.

In some embodiments, the chamber junction surface of the outsole is textured, the texture has high areas and low areas with depth, and the outsole further has gas escape openings in fluid communication with the low areas.

In some embodiments, the edge of the fluid-filled chamber conforms to the edge of the mold by introducing pressure into the fluid-filled chamber precursor.

In another aspect, the present invention relates to a method for manufacturing an article of footwear having an upper and a sole structure. According to the invention, the method includes fixing at least a portion of the upper to at least a portion of the sole structure. The sole structure includes a fluid-filled chamber having an edge, an upper surface, and a lower surface. The outsole is co-molded to at least a portion of the lower surface of the fluid-filled chamber and at least a portion of the edge of the fluid-filled chamber. The outsole is coextensive with at least a portion of the lower surface of the fluid-filled chamber and at least a portion of the edge of the fluid-filled chamber.

Those skilled in the art will understand or will become aware of other systems, methods, features and advantages of the present invention after examining the following drawings and [Embodiment]. It is contemplated that all such additional systems, methods, features, and advantages are included in this description and this summary, are within the scope of the present invention, and are protected by the scope of the following patent applications.

The present invention provides an article of footwear that provides the properties and characteristics sought by a customer. An embodiment of the present invention provides a sole structure for an article of footwear, which includes a fluid-filled chamber co-molded with a large sole, the large sole at least partially surrounding the chamber. An embodiment of the present invention also provides an article of footwear including an upper and a sole structure. An embodiment of the present invention provides a method for manufacturing a sole structure. The invention also relates to a method for manufacturing an article of footwear.

The following discussion and drawings disclose various fluid-filled chambers. Refer to footwear suitable for running to reveal room related concepts. However, the room is not limited to footwear designed for running and can be used with a wide range of athletic footwear styles including, for example, basketball shoes, cross training shoes, cycling shoes, football shoes, soccer shoes, tennis shoes And walking shoes. The various configurations of the chamber can be used with footwear styles that are generally considered non-sports, including slippers, flats, sandals and boots. Therefore, room-related concepts can be applied to various footwear styles.

General footwear structure

An article of footwear 100 is depicted in FIGS. 1 and 2 as including an upper 120 and a sole structure 130. The upper 120 provides a comfortable and firm covering for one of the wearer's feet. Thus, the foot may be positioned within the upper 120 to effectively secure the foot within the article of footwear 100, or otherwise combine the foot with the article of footwear 100. The sole structure 130 is fixed to a lower region of the upper 120 and extends between the foot and the ground to, for example, reduce ground reaction forces (ie, cushion the foot), provide traction, enhance stability, and affect foot movement. Actually, the sole structure 130 is positioned under the foot and supports the foot.

For reference purposes, the footwear 100 may be divided into three general regions: a forefoot region 111, a midfoot region 112, and a heel region 113. Forefoot region 111 generally includes toes and joints with the feet The part of the article of footwear 100 corresponding to the joint of the cheekbones and the phalanges. The midfoot region 112 generally includes a portion of the footwear 100 corresponding to one arch region of the foot. The heel region 113 generally corresponds to the posterior part of the foot (including the calcaneus). The article of footwear 100 also includes an outer side 114 and an inner side 115 that correspond to opposite sides of the article of footwear 100 and extend through each of the forefoot region 111, the midfoot region 112, and the heel region 113. More specifically, the outer side 114 corresponds to an outer region of one foot (ie, the surface facing away from the other foot), and the inner side 115 corresponds to an inner region of one foot (ie, the surface facing the other foot). The forefoot region 111, the midfoot region 112, the heel region 113, the outer side 114, and the inner side 115 are not intended to delimit the precise regions of the footwear 100. Instead, the forefoot region 111, the midfoot region 112, the heel region 113, the outer side 114, and the inner side 115 are intended to represent the general regions of the footwear 100 to assist the following discussion. The characteristics of forefoot region 111, midfoot region 112, heel region 113, lateral 114 and medial 115 can be applied to footwear article 100, and can also be applied to upper 120, sole structure 130, forefoot structure 131, heel structure 132, and And other individual components.

The upper 120 is depicted as having a substantially conventional configuration. The majority of the upper 120 is stitched or adhesively bonded together to form various material elements (e.g., fabric, foam, leather, and synthetic leather) for firmly and comfortably receiving an internal void of one foot . The material element may be selected and positioned in the upper 120 to selectively impart properties such as durability, breathability, abrasion resistance, flexibility, and comfort. The voids in the upper 120 are shaped to accommodate the feet. Therefore, when the foot is positioned within the gap, the upper 120 extends along the outside of one foot, along the inside of one foot, above the foot, around the heel, and below the foot. One of the ankle openings 121 in the heel region 113 provides an entrance for the foot to the gap. A lace 122 extends above a tongue 123 and extends through each lace aperture 124 or other lace receiving element in the upper 120. The size of the ankle opening 121 and the internal space can be modified in a conventional manner by using the adjustability provided by the shoelace 122 and the tongue 123, thereby fixing the foot in the internal space and facilitating the foot to extend into and from the internal The gap is drawn out.

The further configuration of the upper 120 may also include one or more of the following: (a) a toe guard positioned in the forefoot region 111 and formed of a wear-resistant material; (b) positioned on the heel Zone 113 includes a heel counter for enhanced stability; and (c) logos, trademarks, and signs with maintenance instructions and material information. In the case where the various aspects of this discussion are primarily about the sole structure 130, the upper 120 may exhibit the general configuration discussed above or virtually any other conventional or non-conventional upper configuration. Therefore, the structure of the upper 120 may vary significantly within the scope of the present invention.

Sole structure

The main components of the sole structure 130 include a forefoot component 140 and a forefoot sole structure 131, and a heel sole structure including a heel component 150 and a heel sole 170. In some embodiments, each of the forefoot component 140 and the heel component 150 may be directly fixed to a lower region of the upper 120. The forefoot component 140 and the heel component 150 are formed of a polymer material that encloses a fluid (which may be a gas, liquid, or gel). For example, during walking and running, the forefoot component 140 and the heel component 150 may be compressed between the foot and the ground, thereby reducing the ground reaction force. That is, the forefoot component 140 and the heel component 150 are inflated and substantially pressurized by a fluid to cushion the foot.

In some configurations, sole structure 130 may include, for example, a foam layer extending between upper 120 and one or both of forefoot component 140 and heel component 150, or a foam element may be positioned on the forefoot component. 140 and depressions in the lower region of the heel assembly 150. In other configurations, the forefoot sole structure 131 may be provided with a plate, a cushion, a lasting element, or a motion control component that further weakens the force, enhances stability, or affects the movement of the foot. Heel sole structure 132 may also include these components to further reduce force, enhance stability, or affect the movement of the foot.

In addition to providing one of the wear surfaces of the article of footwear 100, the forefoot outsole 160 and the heel outsole 170 can also enhance various properties and characteristics of the sole structure 130. Can change or select the properties and characteristics of the outsole (such as thickness, flexibility, properties and characteristics of materials used to make outsoles and stretchability) to modify or otherwise tune the cushioning response of the sole structure 130, compressible Flexibility, flexibility and other properties and characteristics. Outsole reinforcement (for example, including Structural elements), porosity, overlapping height, number and location of overlapping edges, or other features of the outsole can be used to tune the response of the sole structure. The outsole can also incorporate traction-reading tread elements, such as protrusions, ridges, or lugs or sections. In some embodiments, the outsole can be replaced by a plate or other structural element. A plate may have features that help secure a large outsole or other element to the heel assembly 150.

In particular, the elastic response and cushioning response of the resulting sole structure may be tuned using the overlap of a portion of a large sole away from the grip portion and above the edge of a forefoot component or a heel component. Using the guidance provided in this article, users can consider these and other properties and characteristics of the outsole in conjunction with the properties and characteristics of the fluid-filled components of the component to adjust the response of a sole structure.

The sole structure 130 may be translucent or transparent, and is aesthetically pleasing and may be colored or patterned.

The forefoot outsole 160 is fixed to a lower area of the forefoot assembly 140. In some embodiments, the forefoot sole structure 131 may extend into the midfoot region 112. The forefoot outsole 160 may also be fixed to the lower region of the forefoot component 140 in the midfoot region 112. The heel outsole 170 is fixed to a lower area of the heel assembly 150. Both the heel assembly 150 and the heel outsole 170 can extend into the midfoot region 112. The forefoot outsole 160 and the heel outsole 170 may be formed of a wear-resistant material. The abrasion resistant material may be transparent or translucent to provide a pleasing effect. The abrasion resistant material may be textured on the grip to impart traction. In some embodiments, the abrasion-resistant material may have grip bumps or portions 135, as shown in FIGS. 1 and 2.

FIG. 3 illustrates a cross-sectional view of one of the articles of footwear 100 having a forefoot sole structure 131 including a forefoot component 140 and a forefoot outsole 160 with a grip 135 at section line 3-3. As depicted in FIG. 3, the upper 120 also includes an insole 125 positioned in the gap and positioned to extend below a lower surface of one of the feet to improve the comfort of the article of footwear 100.

FIG. 4 illustrates a bottom view of another embodiment of a forefoot sole structure 1131 including a forefoot component 1140 and a forefoot outsole 1160 associated with the grounding protrusion 1135. Forefoot group The piece 1140 is directly fixed to a lower region of the upper 120 and is formed of a polymer material that encloses a fluid (which may be a gas, liquid, or gel). The forefoot component 1140 may extend into the midfoot region 112. The forefoot assembly 1140 can be compressed between the foot and the ground, thereby reducing ground reaction forces. The fluid-filled chamber 1145 of the forefoot assembly 1140 may be inflated and substantially pressurized by a fluid to cushion the foot.

The forefoot outsole 1160 (which can also extend into the midfoot region 112) is fixed to the lower region of the forefoot component 1140. The forefoot outsole 1160 may include individual portions that cover individual lower regions of the fluid-filled chamber 1145 of the forefoot component 1140. The forefoot outsole 1160 may be formed of an abrasion-resistant material, and in some embodiments may include a grip portion or a bump 1135. The forefoot outsole 1160 may be transparent or translucent, and in some embodiments may be textured to improve traction.

FIG. 5 illustrates a cross-sectional view of an article of footwear 100 at another section of a forefoot sole structure 1130 including a forefoot component 1140 and a forefoot outsole 1160 at section line 3-3. The upper 120 includes a lace 122, a tongue 123, and an insole 125.

The forefoot component 140 and the heel component 150 are formed of a polymer material defining an upper surface, a lower surface, and an edge. The forefoot assembly 140 may include a plurality of forefoot assembly fluid-filled chambers 145, and the heel assembly 150 may include a plurality of fluid-filled chambers 155, each of which may be in fluid communication with at least one other chamber of the assembly. In FIG. 7, the upper surface 141 of the forefoot component 140 faces downward, so that the forefoot component lower surface 142 and the forefoot component edge 143 of the forefoot component fluid-filled chamber 145 are clearly visible. Similarly, in FIG. 9, the upper surface 1141 of the forefoot component 1140 faces downward, so that the forefoot component fluid-filled chamber 1145 forefoot component lower surface 1142 and the forefoot component edge 1143 are clearly visible. FIG. 8 illustrates the heel component fluid filling chamber 155 of the heel component 150, the heel component upper surface 151, the heel component lower surface 152, and the heel component edge 153.

FIG. 6 illustrates an exemplary bottom surface of the forefoot outsole 160. The forefoot outsole 160 includes a forefoot outsole compartment 165 having a grip bump 135 on the outer lower surface 162 of the forefoot outsole. The forefoot outsole compartment 165 also includes a forefoot outsole outer edge 163.

A relationship between an embodiment of a forefoot component 140 and an embodiment of a forefoot outsole 160 is depicted in FIG. 7. Similarly, FIG. 8 illustrates one of the relationships between one embodiment of the heel assembly 150 and one embodiment of the heel outsole 170.

The relationship between one embodiment of the forefoot assembly 140 and one embodiment of the forefoot outsole 160 is shown in FIG. 7. In this embodiment, each forefoot component fluid-filled chamber 145 corresponds to a similarly sized and shaped forefoot compartment 165. In this embodiment, each forefoot outsole compartment 165 is aligned with a similarly sized and shaped forefoot component fluid filling chamber 145 and is large enough to accommodate the forefoot component fluid filling chamber 145. In some embodiments, a forefoot component fluid-filled chamber 145 may be combined with a forefoot outsole compartment 165 in a suitable relationship. Next, the forefoot outsole 160 can be associated with the forefoot assembly 140 by inserting the forefoot assembly fluid-filled chamber 145 into the corresponding forefoot outsole compartment 165. In some embodiments, a forefoot outsole compartment 165 is coupled to a forefoot component fluid-filled chamber 145. In some embodiments, the forefoot component 140 is co-molded with the forefoot outsole 160. In some embodiments, the forefoot outsole 160 and at least a portion of the forefoot component lower surface 142 or the inner surface 164 (see FIG. 16) extend or overlap, and the forefoot component edge 1143 and the forefoot component lower surface 1142 or the inner sole surface 1164 At least a portion extends or overlaps. In some embodiments, the forefoot outsole compartment 165 surrounds the forefoot component fluid-filled chamber 145.

FIG. 8 depicts the relationship between one embodiment of the heel assembly 150 and one embodiment of the heel outsole 170. In this embodiment, a heel component fluid-filled chamber 155 corresponds to a heel outsole compartment 175. In the embodiment shown in FIG. 8, a single heel outsole compartment 175 may be associated with a similarly sized, shaped heel component fluid-filled chamber 155. In another embodiment, the heel assembly 150 may include a plurality of fluid-filled chambers 155, and the heel outsole 170 may include a plurality of heel outsole compartments 175. In these embodiments, each heel outsole 170 is assembled in a similar size by ensuring that each heel outsole compartment 175 is aligned with each heel component fluid-filled chamber 155 and is large enough to accommodate the heel component fluid-filled chamber 155. The shape fits on the heel assembly 150. In some embodiments, a heel component fluid-filled chamber 155 may be adapted The relationship is combined with a heel outsole compartment 175. Then, the heel outsole 170 can be associated with the heel assembly 150 by inserting the heel assembly fluid-filled chamber 155 into the corresponding heel outsole compartment 175. In some embodiments, a heel outsole compartment 175 is coupled to a heel assembly fluid-filled chamber 155. In some embodiments, the heel assembly 150 gap is co-molded with the heel outsole 170. In some embodiments, the heel outsole compartment 175 surrounds the heel assembly fluid-filled chamber 155. In some embodiments, the heel outsole 170 is coextensive or at least partially overlaps with at least a portion of the heel component edge 153.

FIG. 9 illustrates a relationship between the forefoot component 1140 and the forefoot outsole 1160 in the forefoot sole structure 1131. Each of the forefoot component fluid-filled chambers 1145 has a section or compartment 1165 of the forefoot outsole 1160 associated with it. Each forefoot outsole section 1165 of the forefoot outsole 1160 may surround the corners between the lower surface 1142 of the forefoot component fluid filling chamber 1145 and the edge 1143 of the forefoot component fluid filling chamber 1145 of each forefoot component fluid filling chamber 1145 of the forefoot component 1140. The bump 1135 may be attached to or formed on the lower surface of the forefoot outsole 1160.

FIG. 9 illustrates another embodiment of a forefoot sole structure. The forefoot sole structure 1131 includes a forefoot component 1140 having a forefoot component fluid-filled chamber 1145 formed of a polymer material that defines a forefoot component upper surface 1141, a forefoot component lower surface 1142, and a forefoot component edge 1143. In FIG. 9, the upper surface 1141 of the forefoot component faces downward.

FIG. 9 also illustrates the relationship between one embodiment of the forefoot outsole 1160 and one embodiment of the forefoot component 1140. As shown in FIG. 9, the forefoot outsole 1160 includes an outer lower surface of the forefoot outsole having a grip bump 1135 thereon. The forefoot outsole 1160 further includes a forefoot outsole compartment edge 1163 extending over at least a portion of the forefoot component edge 1143.

Production method

The outsole can be attached to a corresponding component in any suitable manner. In some embodiments, the outsole and the component are glued by glueing as part of a co-molding process. In some embodiments, the outsole and the corresponding group are adhered by partially melting as part of a co-molding process Pieces.

The forefoot component 140 and the heel component 150 may be formed of any suitable polymeric material. The forefoot component 140 and the heel component 150 may be formed from a single material layer or multiple layers, and may be thermoformed or otherwise shaped. Examples of polymer materials that can be used for the forefoot component or a heel component include any of the following: polyurethane, polyurethane, polyester, polyester polyurethane, polyether, polyether Polyurethane, latex, polycaprolactone, polyoxypropylene, polycarbonate macrogol, and blends thereof. These and other polymeric materials, and an exemplary embodiment of a forefoot component 140 and a heel component 150, and one of the methods used to manufacture them, may be applied for on February 21, 2013 by Campos II and others under the title ARTICLE OF FOOTWEAR INCORPORATING A CHAMBER SYSTEM AND METHODS FOR MANUFACTURING THE CHAMBER SYSTEM is also found in Application Serial No. 13 / 773,360, which is hereby incorporated by reference in its entirety.

In a co-molding process, first a large bottom can be formed in any suitable manner. The outsole is usually formed from any durable material. Generally, outsole materials are tough, durable, abrasion and wear resistant, flexible and non-slip. In some embodiments, the polyurethane material is sufficiently durable for ground contact. Suitable thermoplastic polyurethane elastomer materials include Bayer Texin® 285 available from Bayer. Elastollan® SP9339, Elastollan® SP9324, and Elastollan® C70S, which are commercially available from BASF, are also suitable. In some embodiments, polyurethane and other polymers that may not be sufficiently durable for direct ground contact may be used to form a large outsole portion. In these embodiments, a rubber outsole can be adhered or glued to the outsole. In an embodiment, the outsole material is transparent or translucent. In an embodiment, the grip bumps may be integrally formed as a part of the outsole, or may be separately formed and adhered to the outsole. The outsole may have a textured grip surface to improve traction.

Next, the outsole is placed in a mold that houses the outsole in a proper relationship with the corresponding component to be co-molded with it. In some embodiments, an adhesive may be applied to Appropriate surface for outsole, component, or both. The component can then be co-molded with the corresponding outsole to form a forefoot sole structure or a heel sole structure.

FIGS. 10 and 11 depict a mold for co-molding the forefoot assembly 1140 and the forefoot outsole 1160 with gripping bumps 1135 thereon to form a forefoot sole structure 1131. In some embodiments, the forefoot outsole 1160 covers at least a portion of the forefoot component edge 1143 on the forefoot component fluid-filled chamber 1145. As described herein, the forefoot sole structure 1131 can be tuned using the forefoot outsole section 1165 that covers at least a portion of the forefoot component edge 1143 and the forefoot outsole compartment edge 1163. The covering portion of the forefoot outsole compartment edge 1163 may provide additional strength and flex resistance at the side walls or edges of the forefoot component fluid-filled chamber 1145. In some embodiments, the forefoot outsole compartment edge 1163 covers a short distance above the edge of the fluid-filled compartment 1143. In other embodiments, the forefoot outsole compartment edge 1163 further covers the fluid-filled chamber edge 1143 upwards to provide additional stiffness and better protect the fluid-filled chamber edge 1143 from damage or wear. The forefoot sole structure 1131 is an embodiment of a forefoot sole structure having a forefoot sole 1160 covering most of the forefoot component fluid filling chamber 1145.

10 and 11 are cross-sectional depictions of a mold 1700 for a forefoot component 1140. As shown in FIGS. 10 and 11, the forefoot component 1140 is co-molded with the forefoot outsole 1160 existing in the mold. Adhesives may also be present on appropriate portions of the forefoot component 1140, specifically at the forefoot component fluid-filled chamber edge 1143 and the forefoot component fluid-filled chamber lower surface 1142 or the chamber-engaging surface of the forefoot component 1160 before contacting the forefoot component 1140 on.

A variety of manufacturing procedures may be utilized to form the forefoot sole structure 1131. In some embodiments, the mold 1700 available in the manufacturing process is depicted as including a first mold portion 1710 and a second mold portion 1720. A mold 1700 is used to form a forefoot component 1140 from a first polymer layer 1810 and a second polymer layer 1820. The polymer layers 1810 and 1820 are polymers that form the upper surface 1141 and the lower surface 1142 of the forefoot component, respectively. Floor. More specifically, the mold 1700 facilitates the manufacturing process by: (a) in the area corresponding to the forefoot component fluid-filled chamber 1145, the forefoot component flange 1146, and the conduit between the chambers Shaping the first polymer layer 1810 and the second polymer layer 1820; and (b) joining the first polymer layer 1810 and the second polymer in a region corresponding to the forefoot component flange 1146 and the forefoot component mesh area 1147 Layer 1820.

Various surfaces or other areas of the mold 1700 will now be defined for use in the discussion of the manufacturing process. 10 and 11, the first mold portion 1710 includes a pinch surface 1730, a first slit forming surface 1740, and a compression surface 1750. The pinch surface 1730 and the first slit forming surface 1740 are angled with respect to each other, wherein the pinch surface 1730 is more vertical than the first slit forming surface 1740. The second mold portion 1720 includes a pinch edge 1760 and a second slit-forming surface 1770. Given that the pinch edge 1760 is one of the relatively sharp corners or angled areas of the second mold portion 1720, the second slit-forming surface 1770 extends downwardly and is generally (but not necessarily) parallel to the pinch surface 1730. A void volume 1790 in the mold 1700 and between the mold portions 1710 and 1720 has a shape of the forefoot component 1140 and forms various features of the forefoot component 1140 before pressurization. A portion of this void volume 1790 is identified as a recess 1780 in the second mold portion 1720.

Each of the first polymer layer 1810 and the second polymer layer 1820 is initially positioned between the first mold portion 1710 and the second mold portion 1720, and they are in a separated or open configuration, as shown in Figs. 10 and 11 As described in. In this position, the first polymer layer 1810 is positioned adjacent or closer to the first mold portion 1710, and the second polymer layer 1820 is positioned adjacent or closer to the second mold portion 1720. A shuttle or other device may be used to properly position the first polymer layer 1810 and the second polymer layer 1820. As part of the manufacturing process, one or both of the first polymer layer 1810 and the second polymer layer 1820 are heated to a temperature that is favorable for shaping and bonding. As an example, the first polymer layer 1810 and the second polymer layer 1820 may be heated by various radiant heaters or other devices before the first polymer layer 1810 and the second polymer layer 1820 are positioned between the first mold portion 1710 and the second mold portion 1720. The object layer 1810 and the second polymer layer 1820. As another example, the mold 1700 may be heated such that contact between the mold 1700 and the first polymer layer 1810 and the second polymer layer 1820 will change the temperature later in one of the manufacturing processes Raise to a level that is conducive to shaping and bonding.

Once the first polymer layer 1810 and the second polymer layer 1820 are properly positioned, the first mold portion 1710 and the second mold portion 1720 are translated or otherwise moved toward each other and begin to close upon the first polymer layer 1810. And second polymer layer 1820. When the first mold portion 1710 and the second mold portion 1720 move toward each other, various techniques can be used to pull the first polymer layer 1810 and the second polymer layer 1820 against the first mold portion 1710 and the second mold portion 1720. Surface, thereby starting the process of shaping the first polymer layer 1810 and the second polymer layer 1820. For example, air may be evacuated from areas of (a) between the first mold portion 1710 and the first polymer layer 1810 and (b) between the second mold portion 1720 and the second polymer layer 1820. More specifically, air can be drawn through various vacuum ports in the first mold portion 1710 and the second mold portion 1720. By removing the air, the first polymer layer 1810 is pulled into contact with the surface of the first mold portion 1710, and the second polymer layer 1820 is pulled into contact with the surface of the second mold portion 1720. As another example, air may be injected into a region between the first polymer layer 1810 and the second polymer layer 1820, thereby increasing the pressure between the first polymer layer 1810 and the second polymer layer 1820. During one of the preparation stages of this procedure, an injection needle may be positioned between the first polymer layer 1810 and the second polymer layer 1820, and then a gas, liquid, or gel may be ejected from the injection needle such that the first The polymer layer 1810 and the second polymer layer 1820 are bonded to the surface of the mold 1700. Each of these techniques can be used together or independently.

As the first mold portion 1710 and the second mold portion 1720 continue to move toward each other, the first polymer layer 1810 and the second polymer layer 1820 are pinched between the first mold portion 1710 and the second mold portion 1720. More specifically, the first polymer layer 1810 and the second polymer layer 1820 are compressed between the pinch surface 1730 and the pinch edge 1760. In addition to the process of separating the excess portions of the first polymer layer 1810 and the second polymer layer 1820 from the portion forming the forefoot component 1140, the pinching of the first polymer layer 1810 and the second polymer layer 1820 also began at Bond or join a first polymer layer in the area of the forefoot component flange 1146 1810 and second polymer layer 1820 procedure.

After the first polymer layer 1810 and the second polymer layer 1820 are pinched, the first mold portion 1710 and the second mold portion 1720 continue to move toward each other and into a closed configuration, as depicted in FIG. 11. When the mold is closed, the pinch surface 1730 contacts a portion of the second slit-forming surface 1770 and slides against it. The contact between the pinch surface 1730 and the second seam-forming surface 1770 effectively cuts off the excess portions of the first polymer layer 1810 and the second polymer layer 1820 and the portion forming the forefoot component 1140. In addition, the sliding movement pushes down the portions of the material forming the first polymer layer 1810 and the second polymer layer 1820 and further pushes them into the depression 1780. In addition, the materials forming the first polymer layer 1810 and the second polymer layer 1820 are compacted or otherwise gathered in a region between the first slit-forming surface 1740 and the second slit-forming surface 1770. In the case where the first slit-forming surface 1740 and the second slit-forming surface 1770 are angled relative to each other, the compacted polymer material forms a generally triangular or tapered structure that results in one of the forefoot component flanges 1146. In addition to forming the forefoot component flange 1146, the first polymer layer 1810 and the second polymer layer 1820 are (a) shaped to form the forefoot component fluid filling chamber 1145 and (b) compressed and joined to form a web状 地区 1147。 Shaped area 1147.

At the stage of the procedure depicted in FIG. 11, a void volume 1790 positioned between the compression surface 1750 and the depression 1780 within the mold 1700 effectively has the shape of a forefoot component 1140 before expansion or compression. In addition, a peripheral portion of the gap includes a region forming a forefoot component flange 1146 between the first slit forming surface 1740 and the second slit forming surface 1770. The non-parallel configuration between the first seam-forming surface 1740 and the second seam-forming surface 1770 results in a tapered space in which the polymer material aggregates to form one of the forefoot component flanges 1146. Compared to the area where the first slit-forming surface 1740 intersects the second slit-forming surface 1770, which is separated from a portion of the void forming the forefoot component fluid filling chamber 1145, the void volume 1790 adjacent to the forming fluid filling component 1145 In part, the distance across one of the spaces between the first slit-forming surface 1740 and the second slit-forming surface 1770 is greater. Although the configuration of the tapered space between the first slit forming surface 1740 and the second slit forming surface 1770 may vary, the first slit forming surface An angle formed between 1740 and the second slit-forming surface 1770 may be in a range between 20 degrees and 45 degrees.

As described above, the materials forming the first polymer layer 1810 and the second polymer layer 1820 are compacted or otherwise gathered in a region between the first slit-forming surface 1740 and the second slit-forming surface 1770. This compaction effectively thickens one or both of the first polymer layer 1810 and the second polymer layer 1820. That is, although the first polymer layer 1810 and the second polymer layer 1820 have a first thickness at the stage depicted in FIG. 11, the first polymer layer 1810 and the second polymer layer 1820 in the flange 1146 have a first thickness. One or both may have a second, greater thickness at the stage depicted in FIG. 11. The compression that occurs when the pinch surface 1730 contacts a portion of the second seam-forming surface 1770 and slides against it increases the thickness of the polymer material forming one or both of the first polymer layer 1810 and the second polymer layer 1820 .

When forming the forefoot assembly 1140 is complete, the mold 1700 is opened and the forefoot structure 1131 is removed and allowed to cool. Then, a fluid can be injected into the forefoot component 1140 to pressurize the forefoot component fluid filling chamber 1145, thereby completing the manufacturing of the forefoot sole structure 1131. As one of the last steps in the procedure, the forefoot sole structure 1131 may be incorporated into one of the sole structures of an article of footwear 100.

FIGS. 10 and 11 illustrate an embodiment of a relatively small overlap with a forefoot outsole 1160 on the edge 1143 of the forefoot component before the forefoot component fluid-filled chamber 1145. 10 and FIG. 11 also illustrate the implementation of one of the forefoot sole structures 1131 with a continuous and smooth shape of the forefoot component 1140, and the front foot component edge 1143 is formed from the forefoot component upper surface 1141 to the forefoot component lower surface 1142. example.

FIGS. 12 and 13 illustrate a mold for a heel assembly, in which the heel outsole 1170 is placed in a mold portion that is not formed to accommodate an outsole. Then, the heel component 1150 is co-molded with the heel outsole 1170 and surrounds the heel outsole 1170. This technique produces a heel sole structure 1132 having a heel assembly edge flush with the heel outsole edge.

Although various manufacturing processes are available, the heel sole structure 1132 A procedure is formed similar to one of the procedures discussed above for the forefoot component 1140 and the forefoot sole structure 1131. The mold 1190 available in the manufacturing process is depicted as including a first mold portion 1191 and a second mold portion 1192. A mold 1190 is used to form a heel component 1150 with additional elements from a first polymer layer 1181 and a second polymer layer 1182. These polymer layers 1181 and 1182 form a polymerization of the upper surface 1151 and the lower surface 1152 of the heel component, respectively. Physical layer. More specifically, the mold 1190 facilitates the manufacturing process by: (a) shaping the first polymer layer 1181 and the second polymer in an area corresponding to the heel component fluid filling chamber 1155 and the heel component flange 1156. The physical layer 1182; and (b) the first polymer layer 1181 and the second polymer layer 1182 are connected in a region corresponding to the heel component flange 1156 and the heel component mesh area 1157. In addition, the mold 1190 facilitates coupling the heel outsole 1170 to the heel assembly 1150.

Each of the first polymer layer 1181 and the second polymer layer 1182 is initially positioned between the first mold portion 1191 and the second mold portion 1192, as depicted in FIG. 12. In addition, one or more elements forming the outsole 1170 are also positioned relative to the mold 1190. Once the first polymer layer 1181 and the second polymer layer 1182 are properly positioned and the components of the outsole 1170 must be located within the void volume 1198 in the second mold portion 1192, the first mold portion 1191 and the second mold portion 1192 are translated or Moving otherwise toward each other and starting to surround the first polymer layer 1181 and the second polymer layer 1182, as depicted in FIG. 13. As discussed above, air can be evacuated from the area portions (a) between the first mold portion 1191 and the first polymer layer 1181 and (b) between the second mold portion 1192 and the second polymer layer 1182. In addition, a fluid may be injected into a region between the first polymer layer 1181 and the second polymer layer 1182. The fluid may be selected from the group consisting of air, liquid, gel and blends thereof. Using one or both of these techniques, the first polymer layer 1181 and the second polymer layer 1182 are induced to join the surface of the mold 1190. In addition, the first polymer layer 1181 and the second polymer layer 1182 are also laid against the heel outsole 1170. Therefore, in fact, the first polymer layer 1181 and the second polymer layer 1182 are shaped to abut the surfaces of the mold 1190 and the outsole 1170, as shown in FIG. 13 Show.

When the first mold part 1191 and the second mold part 1192 continue to move toward each other, the first polymer layer 1181 and the second polymer layer 1182 are compressed between the first mold part 1191 and the second mold part 1192, as shown in the figure. Depicted in 14. More specifically, the first polymer layer 1181 and the second polymer layer 1182 are compressed to form a heel component flange 1156 and a heel component mesh region 1157. The polymer layer 1182 is also bonded to the outsole 1170.

When the manufacture of the heel sole structure 1132 is completed, the mold 1190 is opened and the heel sole structure 1132 is removed and allowed to cool, as depicted in FIG. 15. Then, a fluid may be injected into the heel component 1150 to pressurize the fluid filling chamber 1155 of the heel component, thereby completing the manufacture of the heel sole structure 1132. As one of the last steps in the procedure, the heel sole structure 1132 may be incorporated into the sole structure 1130 of an article of footwear 100.

When the first polymer layer 1181 and the second polymer layer 1182 are drawn into the mold 1190 (specifically, the larger volume in the second mold portion 1191), the first polymer layer 1181 and the second polymer layer 1182 is stretched to conform to the contour of mold 1190. When the first polymer layer 1181 and the second polymer layer 1182 are stretched, they are also thinned or otherwise reduced in thickness. Therefore, the initial thickness of the first polymer layer 1181 and the second polymer layer 1182 may be greater than the thickness obtained after the manufacturing process.

FIG. 17, FIG. 18 and FIG. 19 show other embodiments of the heel sole structure. FIG. 17 illustrates a heel sole structure 2732 including a heel outsole portion 2770. In the embodiment shown in FIG. 17, the heel outsole portion 2770 has a first thickness at a grip area (such as a position for traction bumps), and one or both of the heel component fluid-filled chambers 2755 At least a portion of the vertical surface has a second, smaller thickness. The thickness may be changed in a progressive manner, such as by a linear taper, or may be stepwise. The heel outsole portion 2770 is thinner on the vertical surface outside the heel component fluid-filled chamber 2755 than at the grip area. In this way, the elastic response of the heel sole structure 2732 can be tuned.

FIG. 18 shows a heel sole structure 2832 having a heel outsole portion 2870, and The heel outsole portions 2870 are thinner on the two vertical surfaces of the heel component fluid-filled chamber 2855 compared to the ground area. In other embodiments, only the vertical surface within the heel outsole portion 2770 or 2870 may be thinned on the vertical surface of the heel component fluid-filled chamber 2755 or 2855, respectively.

In some embodiments, any combination of these configurations may be used, thus providing an additional opportunity to tune the elastic response of the heel sole structure.

FIG. 19 illustrates another embodiment of a heel sole structure. The heel sole structure 1932 includes a heel outsole portion 1970. The heel outsole portion 1970 extends over the vertical surface within the heel component fluid-filled chamber 1955 to the heel component mesh area 1957. The heel outsole portion also includes a flange extending across a portion of the heel component mesh region 1957. This flange provides an additional feature that can be varied to tune the elastic response of the heel assembly. The heel outsole portion 1970 extends a distance above the vertical surface outside the heel component fluid-filled chamber 1955. This distance can also be changed to adjust the elastic response of the heel outsole.

Any of these and other suitable manufacturing techniques can be used to form a forefoot structure and a heel structure. In particular, a heel structure may be formed using one of the manufacturing techniques described herein for a forefoot structure, and a forefoot structure may be formed using one of the techniques described herein for a heel structure. Individual parts can be bonded to a corresponding component by adhesion or by partial melting. In some embodiments, a large sole may be thermally bonded to a corresponding component during the manufacturing process to form a sole structure. For example, when a second polymer layer and each of the corresponding outsoles are formed from similar or compatible polymer materials, or when the outsole is formed at least in part from a fluid-filled chamber polymer material, the polymer is heated The layer / fluid filled chamber and the outsole can induce thermal bonding between the components. Similarly, the grip bumps may be formed integrally with the outsole, or may be bonded to the outsole using any suitable technique, such as adhesion or partial melting. In some embodiments, the portion may be conveniently bonded using a heat activated adhesive.

In some embodiments, the outsole grip portion may be co-extruded with the outsole grip portion by co-molding a polymer layer attached to a fluid-filled chamber. This way Can simplify the manufacture of components, including, in particular, making molding easier. If bumps will be added, the bumps can be placed in a mold to be co-molded with other parts of the outsole, as described above.

In some embodiments, the fluid-filled chamber layer and the outsole portion may be a compatible composition that can be co-extruded to form a mutually adjacent layer after co-extrusion. In some embodiments, a connection layer may be required to adhere a large bottom portion to a fluid-filled chamber polymer layer. In some embodiments, the bumps forming the portion of the gripping outsole can be placed in a mold and co-molded with the rest of the layer.

Using the guidance provided in this article, users will be able to identify a suitable method without undue experimentation.

In embodiments of the present invention in which the joint is visible to a user, for example, when the pieces forming the sole structure are transparent or translucent, the joint between the bump and the outsole and between the outsole and the component Made beautiful. In some embodiments, it may also be suitable to soften one of the adhesives in response to heat, such as the heat of molding.

In some embodiments, a large bottom piece that can be popped forward can be pressed into a mold. A fluid-filled chamber can be overmolded onto the large base piece. Although thermoform molds can have cutouts, large soles typically do not have cutouts. In these embodiments, a notch-less outsole piece can produce deformation in the outsole element. In particular, the outsole can be pulled away from the mold sidewall. However, the fluid-filled chamber is then overmolded onto the large base piece. When pressure is introduced into the fluid-filled chamber in the mold, overmolding pushes the outsole back into position and thus pushes the outsole into shape. This technique is fully explained in [Applications incorporated by reference].

Method for manufacturing an article of footwear

An article of footwear with an upper and a sole structure can be manufactured by fixing at least a portion of the upper to at least a portion of the sole structure. In some embodiments, the sole structure includes a fluid-filled chamber including an edge, an upper surface, and a lower surface. The sole structure also includes a large sole. The outsole is co-molded to the fluid-filled chamber. At least a portion of the lower surface and at least a portion of the edge of the fluid-filled chamber. The outsole is coextensive with at least a portion of the lower surface of the chamber and at least a portion of the edge of the chamber. The outsole and the fluid-filled chamber may be combined by an adhesive or by partially melting at least one of the surfaces to be bonded.

Method for minimizing gas inclusions

In some embodiments, in particular, when an outsole is bonded to a component to form a sole structure using an adhesive, a feature that some users may find aesthetically offensive may be formed. As shown in FIG. 4, the feature 900 is an example of an inclusion that is a small air bubble between the forefoot outsole 1160 and the lower surface 1142 of the forefoot component fluid-filled chamber (both of which may have a smooth surface) . These inclusions may not be visible in all cases. However, especially under conditions where inclusions are concentrated or ubiquitous in an area, inclusions can weaken the bond between the component and the outsole.

In some embodiments, the bonding between the parts can be more beautiful and stronger by providing a texture on at least one of the lower surface of the component and the inner lower surface of the outsole. In some embodiments, the textured surface may have convexities and grooves or high and low areas. In some embodiments, the gas escape opening in the outsole may allow the trapped gas to escape.

In some embodiments, the thickness of the adhesive is less than the depth of the grooves or low areas of the texture. Excessive adhesive can weaken the bond because this can prevent adequate contact between surfaces (i.e., between the high areas of the textured surface and the other surface) by filling the volume between the low areas of the texture . Filling the low areas of the texture can force the convex or high areas of the texture away from the other surface, thus preventing good bonding.

The texture need not be regular or patterned, but as described above, ensure that high areas have a consistent height and are sufficiently ubiquitous to ensure proper contact between the outsole and the lower surface of the component. In some embodiments, the texture is a regular, repeating, patterned texture, such as a straight groove, a cross groove, a circle, a triangle, or any other shape. In some embodiments, other aesthetic textures such as words, letters, numbers, signs, or slogans can be Suitable for texture.

Although a textured bonding surface can trap a certain amount of gas during bonding, the texture can be used to minimize any reduction in strength and can contribute to an aesthetic appeal. In some embodiments, the texture can be used to ensure that any large inclusions are excluded and broken down into smaller inclusions distributed above the surface. In addition, a regular pattern (such as the pattern shown in FIG. 16) can be more beautiful, because the low point can include a bubble or a bubble appears, and thus present a regular appearance. Furthermore, this pattern can produce a high-strength bond because the adhesive can form a good bond between the high point and another surface. A texture can also form an excellent bond in the area adjacent to the high point, because the adhesive can be spread between the surfaces to form a strong bond.

FIG. 16 illustrates a top view of one of the forefoot outsoles 160 having a forefoot outsole compartment 165 and an inner edge 164 of the forefoot outsole. The forefoot outsole inner and lower surface 166 is textured to have a regular pattern of non-parallel grooves, which forms a square or diamond pattern on the forefoot outsole inner and lower surface 166. In some embodiments, the lines indicate raised areas and the area between the lines is a low area. In some embodiments, the lines indicate grooves cut into the surface. Using the guidance provided in this article, users can identify a suitable texture for one of any surfaces.

20, 21, 22, and 23 illustrate additional embodiments related to minimizing air inclusions between the large bottom portion and the lower surface of the fluid-filled chamber. FIG. 20 is a bottom view of an article of footwear according to some embodiments of the invention. FIG. 21 illustrates an embodiment of a heel outsole. FIG. 22 illustrates an internal structure for enhancing gas movement to a gas escape opening. FIG. 23 illustrates another embodiment of a heel outsole. These and other structures can be used to minimize air inclusions.

FIG. 20 illustrates a sole structure 2130 secured to the lower end of an upper such as one of the upper 120 (FIG. 1). The sole structure 2130 is positioned under the foot and supports the foot. The main components of the sole structure 2130 include a forefoot component 2140 and a forefoot sole structure 2131 of a forefoot outsole portion 2060, and a heel sole structure including a heel component 2150 and a heel outsole 2070. In some embodiments, each of the forefoot component 2140 and the heel component 2150 may be directly fixed to A lower area of an upper (not shown). The forefoot component 2140 and the heel component 2150 are formed of a polymer material that encloses a fluid (which may be a gas, liquid, or gel). For example, during walking and running, the forefoot component 2140 and the heel component 2150 may be compressed between the foot and the ground, thereby reducing the ground reaction force. That is, the forefoot component 2140 and the heel component 2150 are inflated and substantially pressurized by a fluid to cushion the foot.

In some configurations, the sole structure 2130 may include, for example, a foam layer extending between the upper 120 and one or both of the forefoot component 2140 and the heel component 2150, or a foam element may be positioned on the forefoot component. 2140 and the depressions in the lower area of the heel assembly 2150. In other configurations, the forefoot sole structure 2131 may be provided with a plate, a cushion, a chin element, or a motion control component that further reduces the force, enhances stability, or affects the movement of the foot. Heel sole structure 2132 may also include these components to further reduce force, enhance stability, or affect the movement of the foot.

In addition to providing one of the wear surfaces of the article of footwear 100, the forefoot outsole 2060 and the heel outsole 2070 can also enhance various properties and characteristics of the sole structure 2130. Can change or select the properties and characteristics of the outsole (such as thickness, flexibility, properties and characteristics of materials used to make outsoles and stretchability) to modify or otherwise tune the cushioning response of the sole structure 2130, compressible Flexibility, flexibility and other properties and characteristics. Reinforcement of the outsole (e.g., including structural elements such as ribs), voids, overlap height, number and location of overlapping edges, or other features of the outsole can be used to tune the response of the sole structure. The outsole can also incorporate traction elements, such as protrusions, ridges or grip bumps or sections. In some embodiments, the outsole can be replaced by a plate or other structural element. A board may have features that help secure a large outsole or other element to the heel assembly 2150.

In particular, such as described above and at least depicted in FIGS. 17, 18, and 19, a portion of the outsole that is away from the grip and above the edge of a forefoot component or a heel component may be used Overlap to tune the elastic response and cushioning response of the resulting sole structure. Using the guidance provided in this article, users can combine the properties of the component's fluid-filled components with The characteristics consider these and other properties and characteristics of the outsole to adjust the response of a sole structure.

The sole structure 2130 may be translucent or transparent, and it may be colored or patterned for its aesthetic sense.

The forefoot outsole 2060 is fixed to the lower area of the forefoot component 2140. In some embodiments, the forefoot sole structure 2131 may extend into a midfoot area. The forefoot outsole 2060 can also be fixed to the lower area of the forefoot component 2140 in a midfoot area. The heel outsole 2070 is fixed to the lower area of the heel assembly 2150. Both the heel assembly 2150 and the heel outsole 2070 can extend into a midfoot area. The forefoot outsole 2060 and the heel outsole 2070 may be formed of a wear-resistant material. The abrasion resistant material may be transparent or translucent to provide a pleasing effect. The abrasion resistant material may be textured on the grip to impart traction. In some embodiments, the abrasion resistant material may have grip bumps or portions 2135, as illustrated in FIG. 20.

FIG. 20 also shows the gas escape openings 2069 in the forefoot outsole portion 2060 and the gas escape openings 2079 in the heel outsole portion 2070. These gas escape openings allow air or other gases to be trapped between a component and the corresponding outsole during assembly. The inner surface of the large sole can be shaped in such a way that trapped gas can be accumulated and the trapped gas can be directed to a gas escape opening. For example, small vias may be formed on the inner surface of the outsole portion, such as a small tunnel or removed area.

21 and 22 illustrate an embodiment of a heel outsole. FIG. 21 illustrates an embodiment of these gas escape openings 2179. These openings 2179 can be positioned on the bottom surface of the heel outsole 2170 or the forefoot outsole 2060. Some gas escape openings may be close to the grip surface (such as Figs. 21-25), while other gas escape openings may be positioned between the grip portions, such as a gas escape opening 2189. FIG. 21 also illustrates the grip bump 2135 and the gas escape opening 2179.

FIG. 22 illustrates an embodiment of the gas escape path and volume on the inner surface of the heel outsole 2170. FIG. 22 illustrates the presence of a gas accumulation area 2178 associated with the gas escape opening 2179. The gas accumulation area 2178 and the passage 2181 are used to reduce inclusions between the heel assembly and the heel outsole 2170. A gas accumulation passage 2181 may connect a gas escape opening 2189 to Gas accumulation area 2178. As a illustration, the components of the gas accumulation system need not be connected to all other components. For example, the gas accumulation region 2182 is not continuous with or adjacent to the adjacent gas escape path 2179.

FIG. 23 illustrates an embodiment in which the gas accumulation passage 2278 is formed as a regular pattern on the inner surface of the outsole 2270. A gas escape opening 2279 is present in the outsole 2270. Each of the gas escape openings 2279 communicates with a gas accumulation passage 2278. In some embodiments, each of the passages 2278 is associated with other passages, so that the gas accumulated in the pattern of the gas accumulation passage 2278 can escape through a gas escape opening 2279. Therefore, for a clear, clean, flawless appearance, defects due to trapped air bubbles can be minimized. In some embodiments, the gas escape path 2279 that is not positioned on a gripping surface need not be associated with the gas accumulation path 2278.

Although FIG. 21, FIG. 22, and FIG. 23 depict only heel-related objects, the principles expressed in the figures can also be applied to a forefoot segment to generate a forefoot segment, similar to the heel-related disclosures herein. A skilled professional can easily determine how to extend the principles used to form a heel outsole to form a forefoot outsole.

Although various embodiments of the invention have been described, this description is intended to be illustrative, and not restrictive, and one of ordinary skill in the art will understand that many more embodiments and implementations are possible within the scope of the invention. For example, instead of a square or rhombus texture, another pattern such as a triangle, pentagon, or circle may be used on the inside of a large outsole. Therefore, the present invention is not limited except in accordance with the scope of the accompanying patent application and its equivalents. Various modifications and changes can be made within the scope of the attached patent application.

114‧‧‧ outside

115‧‧‧ inside

130‧‧‧ sole structure

131‧‧‧ Forefoot structure / Forefoot sole structure

132‧‧‧Heel structure / Heel sole structure

135‧‧‧Grasp bumps / parts

150‧‧‧ Heel Components

160‧‧‧ Forefoot Outsole

170‧‧‧ Heel outsole

Claims (22)

A sole structure for an article of footwear including an upper and a sole structure, the sole structure including a component including a fluid-filled chamber having an edge, an upper surface, and a lower surface, and A large sole having a chamber engaging surface and a grip surface, wherein the large sole is attached to at least a portion of the lower surface of the fluid-filled chamber and at least a portion of the edge of the fluid-filled chamber via an adhesive layer. And wherein the outsole is at least partially coextensive with the lower surface of the chamber and at least a portion of the edge of the chamber; wherein the chamber-engaging surface of the outsole is textured, the texture has a high area and has a depth of Low areas; and one of the adhesives has a thickness less than the depth of the low areas. The sole structure of claim 1, wherein at least part of the upper is fixed to at least part of the sole structure. The sole structure of any one of claims 1 to 2, wherein at least a portion of the grip surface of the outsole is textured. The sole structure of any one of claims 1 to 2, wherein the edge of the fluid-filled chamber is flush with the outsole. The sole structure of any one of claims 1 to 2, wherein at least one of the chamber-engaging surface of the outsole, the lower surface of the fluid-filled chamber, and the edge of the fluid-filled chamber is partially melted. The outsole is adhered to the fluid-filled chamber. The sole structure of any one of claims 1 to 2, wherein the outsole further has a gas escape opening. The sole structure of any one of claims 1 to 2, wherein the outsole further has a The gas accumulation area and the gas escape opening in fluid communication with the passage. The sole structure of any one of claims 1 to 2, wherein the outsole further has a gas escape opening in fluid communication with the low areas. A method for manufacturing a sole structure for an article of footwear including an upper and a sole structure, the method comprising: providing a component including a fluid-filled chamber having an edge, an upper surface, and Lower surface; before placing a fluid-filled chamber precursor into a mold, an adhesive layer is applied to one of the large chambers and the chamber-engaging surface is attached to at least the lower surface of the fluid-filled chamber A portion and at least a portion of the edge of the fluid-filled chamber; wherein the outsole is at least partially coextensive with the lower surface of the chamber and at least a portion of the edge of the chamber, and the outsole has a grip surface; and Wherein, the joint surface of the chamber of the outsole is textured, and the texture has a high region and a low region with a depth; and one of the adhesives has a thickness smaller than the depth of the low regions. The method of manufacturing a sole structure as claimed in claim 9, further comprising: positioning the outsole in an appropriate position in a second portion of the mold having a first mold portion and a second mold portion such that Contacting at least a portion of the edge of the chamber and at least a portion of the lower surface of the chamber; placing the fluid-filled chamber precursor in the mold; closing the first mold portion and the second mold portion; and by a Technology enables the upper surface of the fluid-filled chamber to conform to the shape of the first mold portion, the lower surface of the fluid-filled chamber to conform to the shape of the second mold portion with the outsole therein, and causes the fluid-filled chamber to be a precursor. The edge of the object conforms to the shape of the mold with the outsole, and forms the fluid-filled chamber and The co-molded outsole is selected from the group consisting of sucking a vacuum in the mold, introducing pressure into the fluid-filled chamber precursor, and a mixture thereof. The method of any one of claims 9 to 10, further comprising: connecting at least a portion of the upper to at least a portion of the sole structure. The method of any one of claims 9 to 10, further comprising: drying the adhesive before placing the fluid-filled chamber precursor in the mold. The method of any one of claims 9 to 10, further comprising: co-extruding the lower surface of the outsole and the fluid-filled chamber precursor. The method of any one of claims 9 to 10, further comprising: partially melting at least one of the lower surface of the fluid-filled chamber, the edge of the fluid-filled chamber, and the chamber-engaging surface of the outsole. The method of any one of claims 9 to 10, further comprising: forming a texture on the chamber joining surface, the texture having a high region and a low region, and forming a gas escape opening in the outsole. The method of any one of claims 9 to 10, wherein the chamber joint surface of the outsole is textured, the texture has a high region and a low region with a depth, and the outsole further has a region and a path for gas accumulation The fluid communicating gas escapes the opening. The method of any one of claims 9 to 10, wherein the chamber joining surface of the outsole is textured, the texture has a high region and a low region with a depth, and the outsole further has fluids with the low regions Connected gas escapes the opening. The method of any of claims 9 to 10, wherein the edge of the fluid-filled chamber conforms to the edge of the mold by introducing pressure into the fluid-filled chamber precursor. A sole structure for an article of footwear that includes an upper and a sole structure. The sole structure includes a component that includes a plurality of fluid-filled chambers. Each fluid-filled chamber has an edge, an upper surface and a lower surface, and a large bottom, which has a grip bump and a plurality of individual compartments. Each individual compartment of the large bottom corresponds to a plurality of fluid-filled chambers. A fluid-filled chamber having a chamber-engaging surface and a grip surface, wherein each individual compartment of the outsole is attached to at least a portion of the lower surface of the corresponding fluid-filled chamber of the plurality of fluid-filled chambers and At least a portion of the edge of the corresponding fluid-filled chamber; and each individual compartment of the outsole is at least partially associated with at least the lower surface of the corresponding fluid-filled chamber and at least the edge of the corresponding fluid-filled chamber Partially extended. A method for manufacturing a sole structure for an article of footwear including an upper and a sole structure, the method comprising: providing a component including a plurality of fluid-filled chambers, each fluid-filled chamber having an edge and an upper surface And the lower surface; attaching an individual compartment of a large bottom to at least a portion of the lower surface of the corresponding fluid-filled chamber and at least a portion of the edge of the corresponding fluid-filled chamber, one of the plurality of fluid-filled chambers, wherein the Each individual compartment of the outsole is at least partially coextensive with the lower surface of the corresponding fluid-filled chamber and at least a portion of the edge of the corresponding fluid-filled chamber, and each individual compartment of the outsole has a chamber-engaging surface 1. A gripping surface and a plurality of gripping bumps. A sole structure for an article of footwear including an upper and a sole structure, the sole structure including a component including a fluid-filled chamber having an edge, an upper surface, and a lower surface, and A large sole with a chamber engagement surface and a grip surface, Wherein the outsole is attached to at least a portion of the lower surface of the fluid-filled chamber and at least a portion of the edge of the fluid-filled chamber, wherein the outsole is at least partially associated with the lower surface of the chamber and the chamber. At least a portion of the edges are coextensive, wherein the chamber joining surface of the outsole is textured, the texture has a high area and a low area with a depth, and the outsole further has a gas escape opening. A method for manufacturing a sole structure for an article of footwear including an upper and a sole structure, the method comprising: providing a component including a fluid-filled chamber having an edge, an upper surface, and Lower surface; attaching a large bottom to at least a portion of the lower surface of the fluid-filled chamber and at least a portion of the edge of the fluid-filled chamber; forming a texture on the joint surface of the chamber, the texture having high areas and low Area, and a gas escape opening is formed in the outsole, wherein the outsole is at least partially coextensive with the lower surface of the chamber and at least a portion of the edge of the chamber, and the outsole has a chamber joint Surface and a gripping surface.