WO2014151379A2 - Sole structures and articles of footwear having lightweight midsole members with protective elements - Google Patents

Sole structures and articles of footwear having lightweight midsole members with protective elements Download PDF

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Publication number
WO2014151379A2
WO2014151379A2 PCT/US2014/025607 US2014025607W WO2014151379A2 WO 2014151379 A2 WO2014151379 A2 WO 2014151379A2 US 2014025607 W US2014025607 W US 2014025607W WO 2014151379 A2 WO2014151379 A2 WO 2014151379A2
Authority
WO
WIPO (PCT)
Prior art keywords
billows
polymeric foam
sole structure
billow
foam member
Prior art date
Application number
PCT/US2014/025607
Other languages
English (en)
French (fr)
Other versions
WO2014151379A3 (en
Inventor
Frederick J. Dojan
Matthew J. Holmes
Troy C. Lindner
Benjamin NETHONGKOME
Dolores S. THOMPSON
Original Assignee
Nike Inc.
Nike Innovate C.V.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US13/838,051 external-priority patent/US9504289B2/en
Priority claimed from US13/835,715 external-priority patent/US9301566B2/en
Priority claimed from US13/837,967 external-priority patent/US9510635B2/en
Priority to MX2015012596A priority Critical patent/MX2015012596A/es
Priority to BR112015023027A priority patent/BR112015023027A2/pt
Priority to CN201480015717.1A priority patent/CN105101829B/zh
Priority to KR1020157028639A priority patent/KR20150132311A/ko
Priority to CA2902810A priority patent/CA2902810C/en
Application filed by Nike Inc., Nike Innovate C.V. filed Critical Nike Inc.
Priority to AU2014235049A priority patent/AU2014235049B2/en
Priority to JP2016501893A priority patent/JP6430480B2/ja
Priority to EP14717322.3A priority patent/EP2967183B1/en
Publication of WO2014151379A2 publication Critical patent/WO2014151379A2/en
Publication of WO2014151379A3 publication Critical patent/WO2014151379A3/en
Priority to ZA2015/06094A priority patent/ZA201506094B/en
Priority to HK16102099.8A priority patent/HK1214482A1/zh

Links

Classifications

    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B1/00—Footwear characterised by the material
    • A43B1/0018—Footwear characterised by the material made at least partially of flexible, bellow-like shaped material
    • 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
    • A43B13/04—Plastics, rubber or vulcanised fibre
    • 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
    • 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
    • A43B13/14—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
    • A43B13/186—Differential cushioning region, e.g. cushioning located under the ball of the foot
    • 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
    • A43B13/22—Soles made slip-preventing or wear-resisting, e.g. by impregnation or spreading a wear-resisting layer
    • A43B13/223—Profiled soles
    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B3/00—Footwear characterised by the shape or the use
    • A43B3/0036—Footwear characterised by the shape or the use characterised by a special shape or design
    • A43B3/0042—Footwear characterised by the shape or the use characterised by a special shape or design with circular or circle shaped parts

Definitions

  • the present invention relates to the field of footwear. More specifically, aspects of the present invention pertain to sole structures and/or articles of footwear (e.g., athletic footwear) that include a relatively soft and/or lightweight, foam midsole component partially covered by protective components.
  • sole structures and/or articles of footwear e.g., athletic footwear
  • foam midsole component partially covered by protective components.
  • Conventional articles of athletic footwear include two primary elements, namely, an upper and a. sole structure.
  • the upper provides a covering for the foot that securely receives and positions the foot with respect to the sole structure.
  • the upper may have a configuration that protects the foot and provides ventilation, thereby cooling the foot and removing perspiration.
  • the sole structure is secured to a lower surface of the upper and generally is positioned between the foot and any contact surface.
  • the sole structure may provide traction and control potentially harmful foot motion, such as over pronation.
  • the upper forms a void on the interior of the footwear for receiving the foot.
  • the void has the general shape of the foot, and access to the void is provided at an ankle opening. Accordingly, the upper extends over the instep and toe areas of the foot, along the medial and lateral sides of the foot, and around the heel area, of the foot, A lacing system often is incorporated into the upper to selectively change the size of the ankle opening and to permit the wearer to modify certain dimensions of the upper, particularly girth, to accommodate feet with varying proportions.
  • the upper may include a tongue that extends under the lacing system to enhance the comfort of the footwear (e.g., to moderate pressure applied to the foot by the laces), and the upper also may include a heel counter to limit or control movement of the heel.
  • the sole structure generally incorporates multiple layers that are conventionally referred to as an "insole,” a “midsole,” and an “outsole.”
  • the insole (which also may constitute a sock liner) is a thin member located within the upper and adjacent the plantar (lower) surface of the foot to enhance footwear comfort, e.g., to wick away moisture and provide a soft, comfortable feel.
  • the midsole which is traditionally attached to the upper along the entire length of the upper, forms the middle layer of the sole structure and serves a variety of purposes that include controlling foot motions and attenuating impact forces.
  • the outsole forms the ground-contacting element of footwear and is usually fashioned from a durable, wear-resistant material that includes texturing or other features to improve traction.
  • the primary element of a conventional midsole is a resilient, polymer foam material, such as polyurethane foam or ethylvinyl acetate (“EVA”) foam, that extends throughout
  • the properties of the polymer foam material in the midsole are primarily dependent upon factors that include the dimensional configuration of the midsole and the specific characteristics of the material selected for the polymer foam, including the density and/or hardness of the polymer foam material. By varying these factors throughout the midsole, the relative stiffness, degree of grou d reaction force attenuation, and energy absorption properties may be altered to meet the specific demands of the activity for which the footwear is intended to be used. ] Despite the numerous available footwear models and characteristics, new footwear models and constructions continue to develop and are a welcome advance in the art.
  • An exposed outer edge of this first polymeric foam member includes a billows structure that, at least in some examples, extends continuously from a medial midfoot or forefoot area of the first polymeric foam member, around the rear heel area, and to a lateral midfoot, or forefoot, area of the first polymeric foam member.
  • Other billows structures e.g., including interwoven billows, support ribs, etc., may be provided in at least some examples of this invention. These billow structures may include two to eight billow outer ridges connected by billow interstitial areas located between adjacent billow outer ridges.
  • Sole structures according to other examples of this invention may include a polymeric foam member (optionally a lightweight, low density polymeric foam material, such as a foam material having a density of less than 0.25 g/cnf ) for supporting at least a heel and midfoot area of a wearer ' s foot.
  • An exposed outer edge of this polymeric foam member may include:
  • a first billows structure that includes: a first outer billow ridge, a
  • a second billows structure that includes: a fourth outer billow ridge, a
  • the exposed outer edge of the polymeric foam member may further include another billows structure, e.g., wherein an outer billow ridge of that billows structure originates in the third interstitial region.
  • One billows structure may extend around a. rear heel area of the sole structure, while another may be located at a side midfoot region of the sole structure.
  • An outsole component may be engaged with a bottom surface of the polymeric foam member.
  • Another sole structure includes: a first polymeric foam member for supporting at least a heel area of a. wearer's foot, wherein the first polymeric foam member constitutes an outer shell having: (a) a lateral side wail, (b) a medial side wall, (c) a rear heel wall connecting the medial side wall and the lateral side wall, (d) a bottom wall connecting the medial side wall, the lateral side wall, and the rear heel wall, and (e) an open end opposite the rear heel wall, and this first polymeric foam member extends around a rear heel area of the sole structure.
  • a second polymeric foam member has a heel portion at least partially received in a space defined by the outer shell of the first polymeric foam member, wherein a. forefoot end of the second polymeric foam member extends beyond the open end of the first polymeric foam member.
  • This second polymeric foam member has a. density that is less than a density of the first polymeric foam member, and a portion of a bottom surface of the second polymeric foam member is exposed at, a bottom forefoot area of the article of footwear. If desired, one or more protective elements may be engaged with the bottom surface of the second polymeric foam, member in the bottom forefoot area.
  • Yet another sole structure in accordance with some examples of this invention will include: (a) a polymeric foam member for supporting an entire plantar surface of a wearer's foot, wherein the polymeric foam member includes a foam material having a density of less than 0.25 g/cm 3 , and (b) a protective member engaged with the polymeric foam member to cover at least 80% of a surface area of a bottom surface of the polymeric foam member, wherein the protective member constitutes a web base surface with a plurality of traction elements extending downward from the web base surface, and wherein a thickness of a majority of the web base surface at locations between the plurality of traction elements is less than 2 mm thick.
  • FIG. 2A-2F illustrate a sole structure according to another example of this invention
  • Figs. 3A and 3B illustrate features of a sole structure according to another example of this invention
  • Fig. 4 illustrates a heel area of a portion of a foam component that may be included in sole structures in accordance with some examples of this invention
  • Fig. 5 illustrates a basketball shoe according to one example of this invention
  • Fig. 6 illustrates a running shoe according to one example of this invention
  • Fig. 7 illustrates a training shoe according to one example of this invention
  • Figs. 8A-8F illustrate a sole structure according to another example of this invention
  • FIG. 9 is an exploded view of a sole structure according to another example of this invention.
  • Figs. 10A and 10B illustrate features of a sole structure according to another example of this invention;
  • Figs, 1 1 A-11C provide various views of an article of footwear according to another example of this invention;
  • Figs. 12A-12C provide various views of an article of footwear according to another example of this invention
  • Some aspects of this invention relate to sole structures and/or articles of footwear (e.g., athletic footwear) that include a relatively soft and lightweight foam midsole component partially covered by at least one more rigid and/or dense cage (protective) component(s) and/or other protective components. More specific features and aspects of this invention will be described in more detail below.
  • Sole structures for articles of footwear may include a first polymeric foam member for supporting at least a heel and midfoot area of a wearer's foot.
  • An exposed outer edge of this first polymeric foam member includes a billows structure that extends continuously from a medial midfoot or forefoot area of the first polymeric foam member, around the rear heel area, to a lateral midfoot or forefoot area of the first polymeric foam member.
  • This billows structure may include two to eight billow outer ridges connected by billow interstitial areas located between adjacent billow outer ridges.
  • Sole stractures in accordance with at least some examples of this invention may include outsole components (e.g., made of rubber, pliylon, phylite, thermoplastic polyurethane, or the like) on the bottom surface(s) of one or more foam protective components and/or the foam midsole component (e.g., in one of the exposed spaces).
  • the outsole components may provide, for example, hardness, strength, wear resistance, and traction (e.g., by providing texture, cleats, or other traction-enhancing structures on the bottom surface of the sole structure).
  • several independent outsole components will be provided at various discrete locations around the bottom of the sole structure.
  • Outsole components also may be considered a "protective" component for the lightweight midsole component.
  • At least some portion of outer side edges of one or more of the lighter- weight and/or less dense foam midsole material components and/or a more dense protective component may include a billowed structure (described in more detail below). Additionally or alternatively, if desired, at least some portion of the foam midsole component may include a billowed structure, e.g., optionally adjacent the billowed structure of the one or more protective components (if they are billowed).
  • an individual sole structure may include from 2 to 8 billows, and in some examples, from 3-6 billows.
  • Sole structures according to other examples of this invention may include a poiymeric foam member (optionally a lightweight, low density polymeric foam material, such as a foam material having a density of less than 0.25 g/cnr') for supporting at least a heel and midfoot area of a wearer's foot.
  • a poiymeric foam member optionally a lightweight, low density polymeric foam material, such as a foam material having a density of less than 0.25 g/cnr'
  • An exposed outer edge of this polymeric foam member may include:
  • a first billows structure that includes: a first outer billow ridge, a second outer billow ridge, a third outer billow ridge, a first interstitial region located between the first and second outer billow ridges, and a second interstitial region located between the second and third outer billow ridges, and
  • a second billows structure that includes: a fourth outer billow ridge, a fifth outer billow ridge, and a third interstitial region located between the fourth and fifth outer billow ridges, wherein the fourth outer billow ridge originates in the first interstitial region and the fifth outer billow ridge originates in the second interstitial region.
  • the exposed outer edge of the polymeric foam member further may include another billows structure, e.g., wherein an outer billow ridge of that billows structure originates in the third interstitial region.
  • One billows structure may extend around a. rear heel area of the sole structure, while another may be located at a side midfoot region of the sole structure.
  • An outsole component may be engaged with a bottom surface of the polymeric foam member.
  • Another example sole structure includes: a first polymeric foam member for supporting at least a heel area of a wearer's foot, wherein the first polymeric foam member constitutes an outer shell having: (a) a lateral side wail, (b) a medial side wall, (c) a rear heel wall connecting the medial side wall and the lateral side wall, (d) a bottom wall connecting the medial side wall, the lateral side wall, and the rear heel wall , and (e) an open end opposite the rear heel wall, and this first, polymeric foam member extends around a rear heel area of the sole structure.
  • a second polymeric foam, member has a heel portion at least partially received in a space defined by the outer shell of the first polymeric foam member, wherein a forefoot end of the second polymeric foam member extends beyond the open end of the first polymeric foam member.
  • This second polymeric foam member has a density that is less than a density of the first polymeric foam member, and a portion of a bottom surface of the second polymeric foam member is exposed at a. bottom forefoot area, of the article of footwear. If desired, a protective element may be engaged with the bottom surface of the second polymeric foam member in the bottom forefoot area.
  • Yet another sole structure in accordance with some examples of this invention will include: (a) a polymeric foam member for supporting an entire plantar surface of a wearer's foot, wherein the polymeric foam member includes a foam material having a density of less than 0.25 g cm 3 , and (b) a protective member engaged with the polymeric foam member to cover at least 80% of a surface area of a bottom surface of the polymeric foam member, wherein the protective member constitutes a web base surface with a plurality of traction elements extending downward from the web base surface, wherein a thickness of a majority of the web base surface at locations between the plurality of traction elements is less than 2 mm thick.
  • additional aspects of this invention relate to articles of footwear including uppers (e.g., of any desired design, construction, or structure, including conventional designs, constructions, or structures) engaged with sole structures of the various types described above (and described in more detail below).
  • Additional aspects of this invention relate to methods of making articles of footwear or various components thereof.
  • One more specific aspect of this invention relates to methods for making sole structures for articles of footwear of the various types and constructions described above. While the various components and parts of the sole structures and articles of footwear according to aspects of this invention may be made in manners that are conventionally known and used in the art, examples of the method aspects of this invention relate to combining the sole structure and/or footwear parts and engaging them together in manners that produce the various structures described above.
  • the sole structures and footwear depicted and discussed are athletic shoes, and the concepts disclosed with respect to various aspects of this footwear may be applied to a wide range of athletic footwear styles, including, but not limited to: walking shoes, tennis shoes, soccer shoes, football shoes, basketball shoes, running shoes, cross-training shoes, cieated shoes, golf shoes, etc.
  • at least some concepts and aspects of the present invention may be applied to a wide range of non-athletic footwear, including work boots, sandals, loafers, and dress shoes. Accordingly, the present invention is not limited to the precise embodiments disclosed herein, but it applies to footwear generally.
  • Figs. 1A through IF illustrate various views of an example sole structure 100 for an article of footwear that includes at least some aspects and features of this invention.
  • portions of an article of footwear may be identified based on regions of the foot located at or near that, portion of the article of footwear when the footwear is worn on the properly sized foot.
  • an article of footwear and/or a sole structure may be considered as having a "forefoot region" at, the front, of the foot, a "midfoot” region at the middle or arch area of the foot, and a "heel region” at the rear of the foot.
  • Footwear and/or sole structures also include a "lateral side” (the “outside” or “little toe side” of the foot) and a “medial side” (the “inside” or “big toe side” of the foot).
  • the forefoot region generally includes portions of the footwear corresponding to the toes and the joints connecting the metatarsals with the phalanges.
  • the midfoot region generally includes portions of the footwear corresponding with the arch area of the foot.
  • the heel region generally corresponds with the rear portions of the foot, including the calcaneus bone.
  • the lateral and medial sides of the footwear extend through the forefoot, midfoot, and heel regions and generally correspond with opposite sides of the footwear (and may be considered as being separated by a central longitudinal axis).
  • Fig. 1 A shows a top view of the sole structure 100
  • Fig. IB shows a lateral side view
  • Fig. 1C shows a medial side view
  • Fig. ID shows a bottom view
  • Fig. I E shows a heel or rear view
  • Fig. IF shows a toe or front side view.
  • this example sole structure 100 includes a single midsole component 102 that extends continuously in this particular structure 100 to support a complete plantar surface of a wearer's foot, i.e., from the rear heel area of the sole 100 to the front toe area of the sole 100 and from the lateral side edge to the medial side edge of the sole 100.
  • the midsole component 102 may constitute a foam material (such as efhylvinyiacetate (“EVA”) foam, polyurethane foam, phylon foam, and the like).
  • EVA efhylvinyiacetate
  • the top surface 102a of the midsole component 102 may be contoured, e.g., to comfortably support and/or help position a plantar surface of a wearer's foot.
  • the midsole component 102 will be at least partially made from a foam material having a density of less than 0.25 g/cm J (and in some examples, a density of less than 0.2 g/ ' cm', within the range of 0.075 to 0.2 g/cm and even within the range of 0.1 to 0.18 g/cm J ).
  • the foam material of midsole component 102 may include one or more openings defined therein and/or another impact- force attenuating component included with it, such as a fluid-filled bladder, a mechanical shock absorbing member, etc.
  • the entire midsole component 102 will constitute this lightweight foam material (e.g., with a density feature as described above) and will extend to support the complete foot of the wearer (e.g., the complete plantar surface).
  • the foam midsole component 102 is shown as a separate part from a protective component 104 (e.g., one or more of: another, more dense or harder midsole material (e.g., polymeric foam material); an outsole material; a "cage" or “carrier member; etc.) by junction line 106 (this junction line 106 is provided as an illustrative aid in the drawings to highlight the change locations between materials 102/104 in these figures).
  • the midsole component 102 generally lies above the protective component 104 (and may be at least partially contained by the protective component 104), As other options, the midsole component 102 may be made from multiple component midsole (e.g., foam) parts, if desired, and/or the sole structure 100 may include multiple protective component parts 104.
  • the midsole component 102 may be made from multiple component midsole (e.g., foam) parts, if desired, and/or the sole structure 100 may include multiple protective component parts 104.
  • the midsole component 102 may be made from a foam material as described, for example, in U.S. Patent No. 7,941,938, which patent is entirely incorporated herein by reference.
  • all, substantially all, or at least some portion of the midsole component 102 may include a foam material comprising a reaction product of about 10 to about, 100 parts per hundred hydrogenated or non-hydrogenated acrylonitrile butadiene copolymer, 0 to about 40 parts per hundred modified hydrogenated acrylonitrile butadiene copolymer, and 0 to about 90 parts per hundred alpha olefin copolymer, and at least one additive in an amount suitable to form the foam material.
  • This foam material may have a lightweight, spongy feel.
  • the density of the foam material may be generally less than 0.25 g/cm 3 , less than 0.20 g/cm 3 , less than 18 g/cm 3 , less than 0.15 g/cnr', less than 0.12 g/cm 3 , and in some examples, about 0.10 g/cm 3 .
  • the lightweight foam density may fall within the range, for example, of 0.05 to 0.25 g/cm' or within the various ranges noted above.
  • the resiliency of the foam material for the midsole component 102 may be greater than 40%, greater than 45%, at least 50%, and in one aspect from 50-70%. Compression set may be 60% or less, 50% or less, 45% or less, and in some instances, within the range of 20 to 60%.
  • the hardness (Durometer Asker C) of the foam material for this example midsole component 102 may be, for example, 25 to 50, 25 to 45, 25 to 35, or 35 to 45, e.g., depending on the type of footwear.
  • the tensile strength of the foam material 102 may be at least 15 kg/cm 2 , and typically 15 to 40 kg/cm .
  • the elongation % is 150 to 500, typically above 250.
  • the tear strength is 6-55 kg/cm, typically above 7.
  • the foam material of at least some portion of the midsole component 102 may have lower energy loss and may be more lightweight than traditional EVA foams.
  • the energy loss may be less than 30%, and optionally within the range of about 20% to about 30%.
  • at least some portion of the midsole component 102 may be made from foam materials used in the LUNAR family of footwear products available from NIKE, Inc. of Beaverton, Oregon.
  • midsole component 102 may have other desired properties, features, and/or combinations of features without departing from this invention.
  • Other lightweight and/or low density foams also may be used. Because of the protective components 104 described in more detail below, the lightweight foam midsole component 102 need not necessarily have sufficient hardness, durability, and/or abrasion resistance to directly contact the ground in use (at least not at some higher impact ground contact locations).
  • the protective component 104 in this example sole structure 100 may be made from any desired materials without departing from the invention.
  • the protective component 104 may be made from conventional outsoie material, such as rubber, thermoplastic polyurethane (TPU), or the like.
  • the protective component 104 may be made, at least in part, from a polymeric foam cage or carrier material, like those described in U.S. Patent No. 7,941 ,938 identified above.
  • Other conventional polymer foam, materials also may be used for protective component 104.
  • the foam midsole component 102 and the protective component 104 may be engaged together in any desired manner without departing from the invention, including in conventional manners as are known and used in the art (e.g., via cements or adhesives, via mechanical connectors, etc.).
  • the protective component 104 fits within one or more recesses formed in the bottom and/or side surfaces of the polymeric foam, component 102.
  • the recess(es) when present, may be formed during the molding process (or other formation process) in which the lightweight foam component 102 is formed. Alternatively, the recesses may be produced after the lightweight foam component 102 is formed, e.g., by a cutting or grinding action.
  • the protective component 104 may include traction elements or other features for engaging the ground or other contact surface in use, such as herringbone structures, raised ribs or ridges, recessed grooves, etc., including conventional traction elements as are known and used in the art.
  • the bottom surface of the protective component 104 may be formed to include receptacles for receiving removable cleats and/or may be formed to include actual cleat elements extending from the bottom surface thereof.
  • the bottom surface of the protective component 104 does not need to completely cover the bottom surface of the midsole component 102. Rather, some spaces or holes may be provided in the protective component 104 through which the bottom surface of the lightweight foam material 102 is exposed.
  • This feature can provide several potential advantages. For example, eliminating some of the protective component 104 may lighten the weight of the sole structure 100. Additionally, as illustrated in Fig. ID, the breaks or gaps in the protective component 104 may be pro vided along desired lines of flex of the protecti ve component 104 (e.g., elongated slots or gaps in the forefoot area, as shown in Fig. ID), thereby helping maintain the overall flexibility (and optionally a more natural flexibility) of the overall sole structure 100.
  • the large opening in the protective component 104 at the heel area of this example sole structure 100 provides a relatively large and soft "crash pad" for the heel, e.g., to provide better comfort and feel as the wearer's heel strikes the ground, e.g., when landing a step or jump.
  • the openings in the protective component 104 are optional, and, when present, they may be provided in any desired sizes, shapes, and/or numbers without departing from the invention.
  • areas of high wear on the bottom surface of the sole structure 100 will include some layer of a protective component 104 overlying the lightweight (and more fragile) polymeric midsole component 102, to help protect the structural integrity of the midsole component 102.
  • this example sole structure 100 includes a further element, namely, support plate 108 provided in the central or midfoot area, of the sole structure 100.
  • This support plate 108 provides additional support for the arch area of this sole structure 100.
  • the support plate 108 is shown separated from the midsole component 102 and'Or the protective component 104 by junction line 1 10.
  • This junction line 1 10 is provided as an illustrative aid in the drawings to highlight the change locations between support plate 108 and materials 102/104 in these figures.
  • the support plate 108 may be at least partially sandwiched or layered between midsole component 102 and protective component 104 in at least the arch area of the sole structure 100.
  • the support plate 108 may be engaged with one or more of the midsole component 102 and/or protective component 104 by adhesives or cements, by mechanical connectors, and/or by any other desired manner, including conventional manners known or used in this art.
  • the support, plate 08 may be made from, any desired number of pieces or parts and'Or from any desired materials without departing from the invention, including conventional arch support materials and'Or parts as are known and used in the art.
  • materials include: thermoplastic polyurethanes, nylon based polymer materials (e.g., PEBAX), carbon fiber reinforced polymeric materials, glass fiber reinforced polymeric materials, other composite materials, and the like.
  • Figs. 1A through IF show another feature that may be included in sole structures 100 in accordance with at least some examples of this invention.
  • at least some portion of the outer edges or sides of the midsole foam component 102 and/or the protective component 104 may include a "billowed structure” 120.
  • the lightweight midsole foam component 102 has a series of 41 ⁇ 2 billows 122 (e.g., appearing like four stacked disks around the rear heel area), and the protective component 104 includes 1 ⁇ 2 billow 124 (which joins with the bottom 1 ⁇ 2 billow 122 of the midsole foam component 102 to complete the bottommost billow in this sole structure 100).
  • At least some portion of the billowed structure 120 may be provided on side walls of the midsole component 102 (and its billowed structure 120) that are raised up from the top surface 102a of the midsole component 102, e.g., so that the midsole component 102 at least partially wraps around the wearer's foot (e.g., at least at the heel area).
  • the outer shell of the midsole component 102 may include a lateral side wall 130, a medial side wall 132, a rear heel wall 134 connecting the medial side wall 132 and the lateral side wall 130, and the top plantar support surface 102a connecting the medial side wall 132, the lateral side wall 130, and the rear heel wall 134.
  • the top plantar support surface 102a may constitute a layer of polymeric foam, (optionally with one or more fluid-filled bladders contained therein) that extends downward from the top surface 102a by, for example, about 10-20 mm in the central heel area and'or by about 8-16 mm in the forefoot (e.g., metatarsal head support) area.
  • the walls 130, 132, and 134 may extend upward from the top surface 102a and may be tapered or of varying height, e.g., from 0-5 mm at the forefoot area to 25-50 mm (or even more) at the rear heel area. At least some portions of the 41 ⁇ 2 billows of the billows structure 120 may extend continuously around an exterior surface of the lateral side wall 130, the rear heel wall 134, and the medial side wall 132.
  • the size, number, shape, and/or other features of the billowed structure 120 may be selected to control the feel of the article of footwear. Typically, a deeper billow (i.e., a greater dimension from a wave crest to the bottom of an adjacent trough) will provide a more responsive feel (e.g., quicker return to original shape).
  • the size, density, and/or hardness of the midsole component(s) 102 and'or the protective component(s) 104 also may be controlled so as to enable control over the feel of the sole structure 100 to a wearer's foot.
  • the billows structure 120 of this illustrated example sole structure 100 extends continuously and uninterrupted from a medial midfoot or forefoot area of the midsole component 102 (see Fig.
  • This specific overall billows structure 120 includes five billow outer ridges connected by four billow interstitial areas located between adjacent billow outer ridges of the five bi llow outer ridges.
  • the billows structures may take on a variety of forms without departing from this invention.
  • Figs. IB, 1 C, IE, and IF show that the walls of the individual billows have a "stepped" configuration and the outermost ridge of each individual billow constitutes a relatively sharp corner. These are not requirements.
  • the billows side walls may be smooth, straight, and/or curved. Additionally, the outermost edge or ridge of each billow may be made as a less sharp corner, smoothly curved, boxed off, etc., without departing from, the invention.
  • the billows structures may appear similar on the opposite interior side of walls 130, 132, and 134 (e.g., with the billow peaks "hollowed" out; e.g., see Fig. 9), in this illustrated example, the interior surfaces of walls 130, 132, and 134 are smooth (i.e., these billows are solid and not hollowed out).
  • a highest billow outer ridge (the topmost billow ridge) is vertically separated from a lowest billow outer ridge (at the bottom) by a vertical distance of at least 1.5 inches when the sole structure 1 00 is oriented on a horizontal surface.
  • a central billow outer ridge (the third billow in this example) extends rearward a greatest distance when the sole structure 100 is oriented on the horizontal surface.
  • an exposed outer edge of the protective component 104 of this example sole structure 100 includes a billows structure 140 that, extends around a front toe area of the sole stracture 100.
  • This example billows structure 140 includes three billow outer ridges connected by two billow interstitial areas located between adjacent billow outer ridges of the three billow outer ridges. As shown, the billows structure 140 of the protective component 104 of this example sole structure 100 is not continuous with the billows stracture 120 of the midsole component 102.
  • the billows structure 140 of the protective component 104 is separated from the billows structure 120 of the midsole component 102 by transition areas 142, 144 provided at a lateral forefoot area and at a medial forefoot area, respectively, of the sole stracture 100.
  • the transition areas 142 and/or 144 may be made from the midsole component 102, the protective component 104, and/or another sole component.
  • the transition areas 142 and/or 144 may have any desired structure, including another billows structure, one or more raised ribs or other support components, etc.
  • the sole structure 100 shown in Figs. 1A through IF has a billows configuration 120 in which at least some of the individual billows 122, 124 extend continuously and uninterrupted around the midsole component(s) 102 and/or the protective component(s) 104 from their lateral side end to their medial side end. This is not a requirement. Rather Figs 2A through 2F show a similar sole structure 200, having similar parts and construction to the sole stracture 100 of Figs. 1A through IF, but with a different billows configuration.
  • the billows configuration 220 of Figs. 2A - 2F includes intermixed or interwoven billows.
  • the billows configuration 220a at the rear heel area of this sole structure 200 has a similar billows construction as that in the rear heel area of the billows configuration 120 at the rear heel area of the sole structure 100 of Figs.
  • the billows configuration 220 in this example sole structure 200 has a different configuration extending along and forward from the lateral heel and medial heel areas. More specifically, as illustrated in Fig. 2B, a new billows series 220b originates at the heel area within the interstitial areas 250 provided between the top three billows of the rear billows configuration 220a. The origins of the new billows of the new billows series 220b are shown in Fig. 2B at points 252 in interstitial areas 250.
  • the three interstitial billows taper to larger widths and heights so as to form the outermost billow ridges to either side of their outer most points 254.
  • the interstitial bil lows of the new billows series 220b taper to a sufficiently large size so as to completely overtake the rear heel billows series 220a (note, for example, that the rear heel billows 220a have origin points 220f at locations within the interstitial areas of the new billows series 220b).
  • the outer ridges 254 of the new billows series 220b taper downward in size moving forward from their peak areas to end points 256.
  • FIG. 2B Other support structures, including another billows series configuration as shown in Fig. 2B, can originate from the interstitial areas between the new billows configuration 220b and/or from the outside of the new billows configuration 220b (e.g., from points 258) and moving forward in the sole structure 200.
  • the new billows series 220b may constitute a central billows configuration with a rearward billows configuration extending toward the heel (from origination points 22 Of) and a forward billows configuration extending to the midfoot area (from origination points 258).
  • FIG. 2C another new billows series 220c originates at the heel area within the interstitial areas 250 provided between the top three billows of the rear bil lows configuration 220a.
  • the origins of the new billows of the new billows series 220c are shown in Fig. 2C at points 260 in interstitial areas 250. From their origin points 260, the three interstitial billows taper to larger widths and heights so as to completely overtake the rear heel billows series 220a (note, for example, that the rear heel billows 220a have origin points 220f at locations within the interstitial area of the new billows series 220c).
  • FIG. 2A - 2F shows different interstitial billows constructions on the medial side v. the lateral side. This is not a requirement. Rather, if desired, a billows configuration like that of Fig. 2B may be provided on the medial side and/or a billows configuration like that of Fig. 2C may be provided on the lateral side, without departing from the invention.
  • Fig. 2D further shows that this sole structure 200 has a somewhat differently configured bottom surface on the protective component 204 as compared to the bottom surface of the protective component 104 of sole structure 100 (shown in Fig. I D), This leads to a different pattern of exposed midsole material 102 at the bottom surface of the sole structure 200.
  • the junction areas between the protective component 204 and the lightweight midsole material 202 are highlighted in Figs. 2A - 2F by line 206. Also, the junction areas between a midfoot support element 208 (e.g., akin to support element 108 of Figs. 1A - IF) and the lightweight midsole material 202 and/or the protective component 204 are highlighted in Figs. 2A -- 2F by line 210.
  • the bottom surface of the protective component 204 also includes traction elements and the like, as well as some features described in more detail below with respect to Figs. 1 OA and 10B.
  • FIG. 3A and 3B Another example alternative sole structure 300 in accordance with some examples of this invention is shown in conjunction with Figs. 3A and 3B.
  • the sole structure 300 includes a lightweight foam midsole material 302 engaged, e.g., by adhesives or cements, with a protective component 304.
  • the protective component 304 which may be made from a more dense or durable polymer foam and/or outsole material, provides at least a portion of the bottom surface of the sole structure 300.
  • the sole structure 300 of Figs. 3A and 3B may be generally similar in structure and function to the sole structure 200 shown in Figs. 2A - 2F, although other stmctures and functions are possible without departing from the invention.
  • the billows structure ran uninterrupted around the entire heel area of the lightweight midsole components 102, 202. This is not a requirement. Rather, as shown in Figs. 3A and 3B, the rear heel area of this example lightweight midsole component, 302 includes a cut out or cut away area 310 at its top side. This cut away area 310 may extend any desired vertical distance in the midsole component 302 without departing from the invention. As illustrated in Fig. 3B, in this example stracture 300, the cut away area 310 extends down through at least two (and optionally more) of the individual billows structures, although other arrangements are possible without departing from the invention.
  • the cut away area 310 also may extend downward from 25% to 65% of a total vertical height (H) of the sole structure 300 (and/or the midsole component 302) immediately adjacent the cut away areas 310. Also, while Figs. 3A and 3B show the cut away area 310 only in the midsole component 302, the cut away area 310 also could be provided in the protective component 304, especially for sole structures in which the protective component 304 has a greater presence in the vertical dimension at the location of the cut away area 310.
  • the cut away area 310 of this example sole stracture 300 is somewhat V-shaped so as to provide an open V-shaped area at the rear edge of the midsole component 302.
  • Other shapes for the cut away area 310 are possible without departing from this invention, such as, U-shaped, rectangular or square shaped, circular shaped, star shaped, logo shape, and/or any other desired configuration.
  • This example cutaway area 310 helps provide flexibility to the overall sole stracture 300, and particularly to the midsole component 302, in the lateral side -to-medial side direction. This can provide a more natural motion or feel as a user engages in walking or other activities, such as running, landing a jump, or the like.
  • cut away areas of these type may be provided at other locations around the sole structure 300 (i.e., not limited to the rear heel area).
  • cut away areas 310 along the lateral and/or medial sides of the sole structure 300 may help provide and establish lines of flex for the sole structures (optionally to enhance the flexibility of the sole structure 300 to more closely correspond to or support natural foot flexion tendencies).
  • an edge element 312 e.g., a molded thermoplastic polyurethane member, another plastic member, etc.
  • This edge element 312 formed as a heel clip, helps protect the exposed edges of the foam midsole materia] 302 and helps provide interesting aesthetic or design opportunities.
  • Edge elements 312 of this type also allow one to change the shape of the cutaway area 310, if desired.
  • the edge elements 312, when present, may be secured to the foam midsole component 302 and/or to another portion of the overall sole stracture 300 and/or footwear stracture in any desired manner without departing from the invention. As some more specific examples, these components may be engaged together using adhesives or cements, mechanical connectors, or the like.
  • the edge element, 312 also can be used to affect the flex or stiffness characteristics of the sole stracture 300. ] As further shown in Fig.
  • some of the various billows areas of the foam midsole component 302 of this structure 300 have origination points 360 located at or near the edge of the cut away area 310. While the individual billows interrupted by the cutaway area 310 may have their origination points 360 at the edge of the cutaway area 310, in this illustrated example sole structure 300, additional billows areas located below the cut away area 310 also have their origination points 360 located at the rear heel area. Alternatively, if desired, the lower billows areas could extend continuously around the rear heel area uninterrupted (although optionally changing in size) without departing from the invention. Other billows configurations above and/or below the cut away area 310 also may used without departing from this invention.
  • this area 312 need not be provided in any part of the sole stracture 300 by a cutting action. Rather, area 312 could be provided in the desired component(s) of the sole structure 300 in any desired manner without departing from, the intervention, including through the use of a cutting action, e.g., by a laser, knife, blade, die, or other cutting system. Alternatively, the area 312 could be formed directly in the sole structure components) (e.g., components 302 and/or 304) during its manufacturing process, such as by being molded directly into the stracture of foam midsole component 302 and/or a protective component 304. Therefore, the term "cut away area” as used herein in this context a.nd/or for this type of component or structure should be construed to include an area of this type of structure regardless of how the area is provided in the component,
  • Figs. 3A and 3B also show that in this example structure 300, some of the areas between the billows at the rear heel area, adjacent the cut away area 310, have windows 362 that extend completely through the side wall of the midsole component 302.
  • the windows 362 extend along edges of the billows located above and below them (as the billows taper to their origination points 360), although other shapes for the windows 362 may be used without departing from the invention.
  • the windows 362 may affect the flexibility of the midsole component 302 at the rear heel area of this example sole structure 300. More or fewer windows 362 may be provided in the sole structure 300 without departing from the invention, including more or less windows 362 on either side of the cut away area 310 (including no windows 362 on one or both sides).
  • the windows 362 may be provided in the desired component(s) of the sole structure 300 in any desired manner without, departing from the intervention, including through the use of a cutting action (e.g., by a laser, knife, blade, die, or other cutting system), by integrally forming the windows 362 directly in the sole structure component(s) (e.g., components 302 and/or 304) during its manufacturing process (such as by molding the windows 362 directly into the structure of foam midsole component 302 and/or a protective component 304), etc.
  • a cutting action e.g., by a laser, knife, blade, die, or other cutting system
  • integrally forming the windows 362 directly in the sole structure component(s) e.g., components 302 and/or 304
  • the sole structures 100, 200, 300 of Figs. 1A through 3B all show billows s tinctures having three to five individual billows structures over various areas that are relatively uniformly shaped, this is not a requirement.
  • Fig. 4 illustrates a portion of another example sole component 400 in which the billows structure 402 includes three billows oriented in the vertical or top-to-bottom direction.
  • the view of Fig. 4 shows a lateral side view of this example billo w structure 402, but a similar structure could be provided, for example, on the medial side of the sole component 400 and/or at the rear heel area of the sole component 400.
  • This example billow structure 402 may be provided in a foam midsole component as illustrated in Fig.
  • a sole component 400 (e.g., akin to components 102, 202, and/or 302 discussed above), or it may be provided in a protective component, such as polymeric foam protective component and/or components like components 104, 204, 304 discussed above in conjunction with Figs. 1A through 3B.
  • a sole component for supporting an entire plantar surface of a wearer's foot (or any portion thereof) could be provided, without departing from this invention.
  • the billows structure 402 of Fig. 4 differs from some of the other billows structures described above with respect to Figs, 1A - 3B in the shape of the billows. More specifically, as sho wn in Fig. 4, the central billows 402b of this example bil lows stnicture 402 is concave (or expands outward) both in the upward and downward directions. As shown in Fig. 4, the bottom valley of the interstitial area 404a between the central billows 402b and the top billows 402a curves in a concave upward direction so that the high point of that curve is at the central side heel area.
  • the bottom valley of the interstitial area 404b between the central billows 402b and the bottom billows 402c curves in a concave downward direction so that the low point of that curve is at the central side heel area.
  • the top billows 402a is shaped to curve in an upward direction with the upper maximum point of that curve located in the central area of the top billows 402a in the arrangement shown in Fig. 4.
  • the bottoms billows 402c is shaped so as to curve in a downward direction with the lower minimum point of that curve located in the central area of the bottom billows 402c in the arrangement shown in Fig. 4. This gives the overall billow structure 402 somewhat of a more bulbous shape as compared to at least some of the billow structures shown in Figs. 1A through 3B.
  • the billows construction 402 has smoother side w r alls (as do the billows structures of Figs. 2A-3B) as compared to the more stepped side walls in the billows structures shown in Figs. 1A-1F,
  • the billows constructions of Figs. 2A-4 have outer ridges of the individual billows formed as sharp corners. Other structural options for these side walls and/or corners are possible, however, without departing from this invention.
  • Figs. 5, 6, and 7 show side views of various different examples of articles of footwear 550, 650, and 750 that include sole structures 500, 600, and 700 in accordance with other examples of this invention.
  • Fig, 5 illustrates a basketball shoe 650
  • Fig. 6 illustrates a running shoe 650
  • Fig. 7 illustrates a cross training shoe 750.
  • the sole structures 500, 600, and 700 are engaged with uppers 552, 652, and 752, respectively, to provide the overall footwear structures 550, 650, and 750.
  • the uppers 552, 652, and 752 may be engaged with their respective sole structures 500, 600, and 700 in any desired manner without departing from this invention, including in conventional manners as are known and used in this art.
  • the uppers 552, 652, and 752 and the sole structures 500, 600, and 700 may be engaged together by adhesives or cement, by mechanical connectors, by stitching or sewing, and/or by other connection techniques.
  • footwear structures 500, 600, and 700 of Figs. 5-7 various features of example uppers (including potential features of uppers 552, 652, and 752) will be described.
  • This description includes examples of features of uppers that may be included in footwear structures in accordance with at least some examples of this invention, including examples of uppers that may be engaged with the sole structures 100, 200, 300, and 400 of Figs. 1 A-4.
  • the sole structures 500, 600, and 700 of Figs. 5-7 have generally similar structures, some differences between these sole structures 500, 600, and 700 will be described in conjunction with Figs. 5-7. Thereafter, more detailed features of the construction and parts of the sole structures 500, 600, and 700 of Figs. 5-7 will be described in more detail in conjunction with Figs. 8A-8F.
  • the uppers 552, 652, and 752 for article of footwear structures 550, 650, and 750 in accordance with this invention may constitute one or multiple component part constructions that may be engaged together in any desired manner, including in conventional manners as are known and used in the footwear art, including through the use of cements or adhesives, through the use of mechanical connectors, and/or through fusing techniques (e.g., melt or fuse bonding of a hot melt material, etc.). N on-limiting examples of some construction techniques will be described in more detail below.
  • the upper 552, 652, 752 may be made from any desired materials and/or combinations of materials without departing from this invention.
  • the upper 552, 652, 752 may include a multi-layered construction, with the various layers covering all or some portion of the overall upper area.
  • the upper 552, 652, 752 may include an intermediate mesh layer covered and/or sandwiched in at least some areas by an interior fabric or textile layer (e.g., for comfortable contact with the foot) and an exterior "skin" layer (e.g., made from a thermoplastic polyurethane film, to provide better support at certain areas, to provide wear or abrasion resistance in certain areas, to provide desired aesthetics, etc.).
  • the location(s) of the various layers may be selected to control the properties of the upper 552, 652, 752, e.g., by omitting the skin layer at certain areas to improve hreathability, to improve flexibility, to provide a different aesthetic appearance (such as openings in the skin layer to produce a "LOGO" or other design feature from the underlying mesh materia]), etc.
  • the upper 552, 652, 752 may define an ankle opening, around which a comfort-enhancing foam or fabric ring may be provided, if desired.
  • the bottom surface of the upper 552, 652, 752 may include an interior strobel member that connects the medial and lateral sides of the upper material (e.g., the strobel member may be sewn to the medial and lateral side edges of the upper) to thereby close off the upper 552, 652, 752.
  • the sole structure 500, 600, 700 may be engaged with the upper 552, 652, 752 at its bottom edges and the strobel, e.g., using cements or adhesives, stitching or sewing, mechanical connectors, etc.
  • the multi-layered upper constmction may be produced in any desired manner without departing from this invention, including in conventional manners as are known and used in the footwear art.
  • the skin layer may be made from a "no-sew" type material that may be adhered to the underlying mesh layer (or other layer) using an adhesive or hot melt material in a conventional manner, e.g., by application of heat and/or pressure.
  • the skin layer may be engaged with the underlying mesh layer (or other layer) by cements or adhesives and/or by sewn seams.
  • the upper 552, 652, 752 may ⁇ be constructed by bonding various layers of materials using fusing techniques, e.g., as described in U.S. Patent Application Publication No. 2011/0088282 and U.S. Patent Application Publication No. 2011/0088285, each of which is entirely incorporated herein by reference.
  • the upper 552, 652, 752 may include other support elements at desired locations, e.g., sandwiched between the exterior skin layer and the underlying mesh layer.
  • a heel counter may be provided in the heel area to provide more support for the wearer's heel.
  • the heel counter when present, may be made from a rigid, thin plastic material, such as PEBAX, TPU, or other polymeric material, and it may include one or more openings (e.g., to control flexibility, breathability, support characteristics; to reduce weight; etc.).
  • additional supports may be provided in other areas of the shoe 550, 650, 750, such as in the forefoot or toe area (to provide protection and wear resistance, etc.), at the lateral side area near the fifth metatarsal head, etc.
  • uppers 552, 652, 752 include one or more of: synthetic leather, natural leather, textiles, any combination of these materials, and/or any combinations of these materials with any of the other materials described above.
  • at least some portion of the upper 552, 652, 752 may be formed by a knitting procedure.
  • at least a majority (or even all) of the upper 552, 652, 752 may be formed using knitting procedures, in at least, some examples of this invention. Knitted textile components can be used to provide lightweight, breathable, and comfortable upper constructions.
  • This example footwear structure 550 is a basketball shoe.
  • the upper 552 may have a construction like that of any conventional basketball shoe, including constractions made from leathers, multi-layered fuse-bonded materials, or other materials and/or constractions as are known and used in the art.
  • the sole structure 500 of this example has a similar general appearance to the sole structure 100 shown in Figs. 1 A through I F as described in detail above, e.g., including a series of five stacked billows extending continuously around the sole structure 500 from the forefoot lateral side area, around the rear heel area, to the forefoot medial side area of the sole structure 500.
  • the five billow construction of this example sole structure 500 is well suited for a basketball shoe because it creates a somewhat taller heel structure, as is common in modern day basketball shoes.
  • the sole structure 500 of Fig. 5 differs considerably in construction from the sole structure 100 of Figs. 1A-1F. While a detailed description of the construction of this sole structure 500 will be saved for the discussion of Figs. 8A-8F below, at this juncture it is adequate to say that the exposed rear portion 504 of the sole structure 500 constitutes a protective element that at least partially holds and contains a portion of midsole component 502,
  • the rear protective component 504 may be made from materials like the various protective components 104, 204, 304 described above (e.g., including a polymeric foam material with one or more billows structures formed on its outside wall edge).
  • the forward portion 502 of sole structure 500 in this example constitutes an exposed portion of a lightweight foam midsole material 502, which may be akin to the lightweight midsole components 102, 202, 302, as described above (including the same or similar materials). While the midsole component 502 still may extend to support all or substantially all of the plantar surface of a wearer's foot, in this illustrated example structure 500, at least some, and optionally a majority, of the lightweight midsole component 502 is contained within the protective component 504. In this manner, at the rear of the footwear structure 550, the protective component 504 acts as a cage or carrier for the lightweight foam component 502, The foam midsole component 502 extends out of the forward (open) end of the protective component 504, as will be described in more detail below.
  • This example footwear structure 650 is a running shoe.
  • the upper 652 may have a construction like that of any conventional running shoe, including constractions made from multi-layer fuse-bonded materials, textiles, meshes, knit materials, or other materials and/or constructions as are known and used in the art.
  • the sole structure 600 of this example has a similar general appearance to the sole structure 200 shown in Figs.
  • FIG. 2A through 2F as described in detail above, e.g., including a first series of stacked billows 610 extending around the rear heel area of the sole stmcture 600 and a staggered, forward series of billows 612 extending forward from the heel area toward the midfoot and forefoot areas of the sole structure 600.
  • the forward series of billows 612 originate in the interstitial areas between billows of the rear heel billows series 610.
  • the top billow of the forward series of billows 612 originates above the top billow of the rear heel billows series 610.
  • the rear heel series of billows 610 terminates in the heel to midfoot area, e.g., in interstitial areas between or along individual billows of the forward series of billows 612. While Fig. 6 shows only the lateral side view, the medial side view of this shoe structure 650 may have a similar interstitial billows configuration.
  • the sole structure 600 for this running shoe 650 example is somewhat shorter and more low profile than the sole structure 200 of Figs. 2A-2F and the sole structure 500 of Fig. 5.
  • the sole structure 600 includes three vertically stacked billows 610 at the rear heel area (instead of the five billows shown in Figs. 2A-2F) and three vertically stacked forward billows 612 staggered from the heel billows 610. While it would not be required, this reduced number of billows provides somewhat less vertical height in the heel area of the sole structure 600.
  • the exposed rear portion 604 of the sole stmcture 600 constitutes a protective element that at least partially holds and contains a portion of a lightweight foam midsole component 602.
  • the rear protective component 604 may be made from materials like the various protective components 104, 204, 304 described above (e.g., including a polymeric foam material with one or more billows structures formed on its outside wall edge).
  • the forward portion 602 of sole structure 600 in this example constitutes an exposed portion of a lightweight foam midsole material 602, which may be akin to the lightweight midsole components 102, 202, 302, as described above (including the same or similar materials).
  • the midsole component 602 may still extend to support all or substantially all of the plantar surface of a wearer's foot, in this example structure 600, at least some, and optionally a majority, of the lightweight midsole component 602 is contained within the protective component 604.
  • the protective component 604 acts as a cage or carrier for the lightweight foam midsole component 602.
  • the foam midsole component 602 extends out of the forward (open) end of the protective component 604 as will be described in more detail below.
  • the heel and/or midfoot area includes interwoven billows from the rear heel billows series 610 and the forward series of billows 612,
  • the sole structure 600 e.g., shown by line 614
  • these stacked and/or interwoven series of billows provide added support in this heel/midfoot area and provide good support for a running shoe sole.
  • Fig. 7 illustrates a training shoe 750.
  • the upper 752 may have a construction like that of any conventional training shoe, including constructions made from fuse-bonded materials, textiles, meshes, knit materials, or other materials and/or constructions as are known and used in the art.
  • the sole structure 700 of this example has a configuration with interstitial billows as will be described in more detail below.
  • the exposed rear portion 704 of the sole structure 700 constitutes a protective element that at least partially holds and contains a portion of midsole component 702.
  • the rear protective component 704 may be made from materials like the various protective components 104, 204, 304 described above (e.g., including a polymeric foam material with billows structures formed on its outside wall edge).
  • the forward portion 702 of sole structure 700 in this example constitutes an exposed portion of a lightweight foam midsole material 702, which may be akin to the lightweight midsole components 102, 202, 302, as described above (including the same or similar materials). While the midsole component 702 may still extend to support all or substantially all of the plantar surface of a wearer's foot, in this example structure 700, at least some, and optionally a majority, of the lightweight midsole component 702 is contained within the protective component 704. in this manner, at the rear of the footwear structure 750, the protective component, 704 acts as a cage or carrier for the lightweight foam midsole component 702. The foam midsole component 702 extends out, of the forward (open) end of the protective component 704 as will be described in more detail below.
  • both the rear heel area of the protective component 704 and the forward toe area of the midsole foam component 702 include a vertically stacked three billows structure (with the heel billows somewhat deeper than the forefoot, billows).
  • Various different types of support features are provided, however, in the midfoot to forefoot area, at least along the lateral side of the shoe 750 (although similar structures could be provided on the medial side, if desired).
  • a first support rib or element 710 is provided along the bottom of the lateral side of the sole structure 700 (in the foam midsole component 702, in this example).
  • This first support rib or element 710 is located vertically downward from and proximate to a fifth metatarsal head support area of the sole structure 700.
  • a second support rib or element 712 is provided somewhat rearward and upward from the first support rib or element, 710. This second support rib or element 712 bridges the junction between the foam midsole component 702 and the protective component 704 in this example structure 700 and peaks more in the midfoot or arch region of the sole structure 700.
  • the second support rib or element 712 may have an overall longer longitudinal dimension from, end-to-end. than that of the first support rib or element 710.
  • a third support rib or element 714 is provided somewhat forward and upward from the second support rib or element 712.
  • this third support rib or element 714 is formed in the foam midsole component 702.
  • the third support rib or element 714 vertically overlaps the first support rib or element 710 and is located vertically downward from and proximate to the fifth metatarsal head support area, of the sole structure 700.
  • This third support rib or element 714 may have a shorter longitudinal dimension (end-to-end) than the first support rib or element 710.
  • a fourth support rib or element 716 is provided somewhat rearward and upward from the third support rib or element 714.
  • This fourth support rib or element 716 also bridges the junction between the foam midsole component 702 and the protective component 704, but a majority of it is located in the midsole component 702 and forward of the second support rib or element 712.
  • a fifth support rib or element 718 is provided somewhat forward and upward from the fourth support rib or element 716. At least a majority (and potentially all) of this fifth support rib or element 718 is formed in the foam midsole component 702.
  • the fifth support rib or element 718 vertically overlaps the first support rib or element 710 and the third support rib or element 714, and it is located proximate to the fifth metatarsal head support area of the sole structure 700.
  • the fifth support rib or element 718 may have a shorter longitudinal dimension than the first support, rib or element 710 and/or the third support rib or element 714.
  • first support rib or element 710, second support rib or element 712, third support rib or element 714, fourth support rib or element 716, and fifth support rib or element 718 produce a discontinuity in the billows structures between the billows structures in the rear heel protective component 704 and the forward foam midsole component 702.
  • These support ribs or elements 7.10, 712, 714, 716, and/or 718 provide additional support for the lateral midfoot and/ ' or forefoot areas of this sole structure 700, e.g., in the area near the fifth metatarsal head of the wearer's foot. This provides additional support for the wearer during training activities, such as when pushing off the outside of the foot, e.g., when making a sharp turn or cut action.
  • the support rib or elements 710, 712, 714, 716, 718 are shaped as raised pyramid-like structures that extend outward from the side surface of the sole structure 700.
  • the support ribs or elements 710, 712, 714, 716, 718 may be oriented somewhat like the interwoven billows structures that are shown in various other figures described above. More specifically, as shown in Fig. 7, the support ribs or elements 712 and 716 originate in interstitial areas between the support ribs or elements 710, 714, and 718.
  • the support ribs or elements 710, 712, 714, 716, 718 also may originate in interstitial areas between billows located forward and/or rearward of the support rib or element.
  • the outward extending peaks of support ribs or elements 712, 716, and 71 8 substantially align in a top forward- to-bottom rearward direction.
  • the outward extending peaks of support ribs or elements 710, 714, and 718 substantially align in a vertical direction from top to bottom.
  • the support rib or element structures of Fig. 7 constitute merely examples of structures for providing lateral and/or medial side support (and/'or for altering or controlling support features of the sole 700).
  • Other support changing configurations including different, numbers of ribs, different arrangements of ribs, different shapes of ribs, and/or different relative orientation of the ribs with respect to one another may be used without departing from this invention.
  • simple gaps between adjacent billows structures could be provided, e.g., to change the support or feel at the gaps.
  • the "gaps" may include actual spacings in the foam material or smooth foam material between billows structures.
  • Figure 8A shows a bottom perspective view of an example sole structure 800 including a rear protective component 804 and a foam midsole component 802 extending forward and out of the free end of the protective component 804,
  • Figure 8A shows the protective component 804 and the foam component 802 fit together, but prior to being secured to one another, for example, using adhesives or cements.
  • Fig. 8B shows bottom views of these two parts separated from one another
  • Fig. 8C shows fop views of these two parts separated from one another.
  • the protective component 804 acts as a cage or carrier that contains the rear part of the foam midsole component 802.
  • the foam midsole component 802 has an upper support surface 802a for supporting all or substantially all of a plantar surface of a wearer's foot (although if desired, the protective component 804 also could provide a surface for directly supporting at least some portion of a plantar surface of a wearer's foot).
  • the foam midsole component 802 is exposed through a heel opening 806 defined in the bottom surface of the protective component 804. Providing this bottom opening 806 can both lighten the weight and allow one to control and alter the flexibility characteristics of the overall sole structure 800.
  • the foam midsole component 802 may be made from any desired foam material (or combinations of foam materials) without departing from this invention, including lightweight foam materials of the types described above in conjunction with components 102, 202, 302.
  • the foam midsole component 802 may include one or more fluid filled bladders, mechanical shock absorbing structures, and/or other structures for providing impact force attenuation embedded or included therein.
  • the foam midsole component 802 constitutes a single, solid piece of foam material, preferably one of the lightweight, and/or less dense foam materials described above.
  • the protective component 804 of this illustrated example sole structure 800 also may constitute a polymeric foam material, including conventional polymeric foam materials as are known and used as midsole materials in the footwear art.
  • the protective component 804 may be made from polyurethane foam, ethylvinylacetate (“EVA”) foams, phylon, or other known midsole foams or materials.
  • EVA ethylvinylacetate
  • the polymeric foam material used for the protective component 804 will be a heavier, more dense, and/or more durable foam material (e.g., more wear resistant, more abrasion resistant, etc.) than the foam material used in the foam midsole component 802.
  • the polymeric foam material of the protective component 804 may include billows structures formed around at least portion(s) of its perimeter edge.
  • Figs, 8A-8C show that the protective component 804 may constitute an outer shell including the billows structure (like those of Figs. 5-7), wherein the outer shell includes: a lateral side wall 804a; a medial side wall 804b; a rear heel wall 804c connecting the medial side wall 804b and the lateral side wall 804a; and a bottom wall 804d connecting the medial side wall 804b, the lateral side wail 804a, and the rear heel wall 804c.
  • the outer shell includes: a lateral side wall 804a; a medial side wall 804b; a rear heel wall 804c connecting the medial side wall 804b and the lateral side wall 804a; and a bottom wall 804d connecting the medial side wall 804b, the lateral side wail 804a, and the rear heel wall 804c.
  • the billows structure of the polymeric foam material of the protective component 804 will extend continuously around an exterior surface of at least a portion of the lateral side wall 804a, the rear heel wall 804c, and at least a portion of the medial side wall 804b.
  • the billows structure of the polymeric foam material of the protective component 804 also may include interwoven billows, support ribs or elements, vertical ribs, gaps, and/or any of the other billows structures, features, and/or options described above.
  • FIGS. 8A-8C further show that at least a heel portion of the foam midsole component 802 is received in a space defined between the lateral side wall 804a, the medial side wall 804b, the rear heel wail 804c, and the bottom wall 804d of the protective component 804.
  • a forefoot end of foam midsole component 802 extends beyond a forward end of the lateral side wail 804a and a forward end of the medial side wall 804b in this example structure 800. This forefoot end of foam midsole component 802 may be at least partially exposed in the finished sole structure 800.
  • both the exterior side edge surface of the protective component 804 and the exterior side edge surface of the foam midsole component 802 may include billows structures.
  • the billows structure of the protective component 804 may extend (continuously or discontinuously (e.g., due to interwoven billows, other supports, and/or other features)) around a lateral side -to-rear heel-to-medial side of the sole structure.
  • the foam midsole component 802 may include a billows stmcture that extends around a front toe area of the sole structure 800.
  • the billows structure of the foam midsole component 802 includes three billow outer ridges connected by two billow interstitial areas.
  • the billows stracture of the foam midsole component 802 may or may not, extend continuous with the billows stmcture of the protective component 804.
  • These billows structures may be interrupted, e.g., by support ribs or other elements, by interstitial billows, by gaps in the sole structure, by smooth foam material, by external plastic or composite supports, by transition areas, or the like, without departing from the invention.
  • Such “interruptions" in the billows structures may be provided at any desired locations, such as at a lateral forefoot area of the sole stracture and at a medial forefoot area of the sole structure (e.g., to provide locations that support more natural motion flex), at a lateral forefoot area of the sole structure (e.g., to provide added support for cutting or turning actions), and/or at other desired locations (e.g., to provide desired support and/or flexibility, including natural motion flexibility characteristics).
  • Fig. 8D illustrates example outsole components 820 that may be applied to the bottom surface of the protective component 804, optionally, in receptacles 822 formed (e.g., molded or cut) in the heel area of the protective component 804. Fig.
  • outsole components 824 that may be applied to the bottom surface of the foam midsole component 802, optionally, in receptacles or other areas formed (e.g., molded or cut) in the forefoot area (area 826) of the foam midsole component 802.
  • Fig. 8F illustrates these parts and how they fit together.
  • These outsole components 820 and 824 may be made from any desired outsole material (or combinations of outsole materials) without departing from this invention, including rubbers, thermoplastic polyurethanes, and the like. Additionally or alternatively, one or more of the outsole components 820, 824 may constitute cleat structures or receptacles for receiving detachable cleat structures.
  • Fig. 9 provides an exploded view of another example sole structure 900 in accordance with some examples of this invention.
  • a lightweight foam midsole component 902 e.g., of the types described above
  • a foam protective component 904 extends around at, least the sides of the midsole component 902 and acts as a cage or carrier for that portion of foam midsole component 902 it contains (from the lateral midfoot or forefoot area, around the rear heel area, to the medial midfoot or forefoot area, in this example).
  • outsole protective components 906a, 906b, 906c, and 9()6d are provided to protect various areas of the bottom of the foam midsole component 902 (and/or the bottom of the protective component 904, should the protective component 904 be exposed at the exterior bottom surface of the sole structure 900).
  • outsole component 906a protects one heel side of the foam midsole component 902 (and/or the protective component 904)
  • outsole component 906b protects a rear heel area of the foam midsole component 902 (and/or the protective component 904)
  • outsole component 906c protects the other heel side of the foam midsole component 902 (and/or the protective component, 904).
  • a relatively large outsole protective component 906d at the forefoot area covers much, if not all, of the forefoot area of the bottom of the foam midsole component 902 (and/or the protective component 904).
  • These various components may be engaged with one another in any desirable ma ner, for example by cements or adhesives, by mechanical connectors, or any other manner as is known and used in the art. These components may be made, for example, from any of the materials described above for the corresponding parts. Also, any of the individual components shown or described above in Fig. 9 may be made from one or more separate parts without departing from the invention. While Figs.
  • FIG. 5-9 show sole structures in which the lightweight midsole component is at least partially covered by a protective component in the heel and/or midfoot areas (and extending out to be exposed at the forefoot area of the sole structure), other configurations are possible without departing from the invention.
  • exposed portions of the lightweight midsole component and the protective component could essentially "flip-flop" ends in the structures of Figs. 5-9 such that the lightweight midsole component is covered by the protective component, in the forefoot and'or midfoot areas (and extends out to be exposed at the heel area of the sole structure ).
  • Modifications to the sizes, shapes, and/or junction areas between the lightweight midsole component and the protective component also may be varied widely without departing from the invention. 100] Figs.
  • FIG. 5 OA shows the bottom surface 1002a of a lightweight midsole component 1002, like those described in detail above.
  • the bottom surface 1002a of this example lightweight midsole component 1002 includes a plurality of extended out or "bulbous" areas at various locations of the midsole component 1002.
  • One bulbous area 1004a is provided in the rear heel area of the midsole component 1002 and provides additional impact force attenuation and/or a comfortable, soft feel, e.g., for when the wearer lands a step or a jump. Additional bulbous areas are provided in the forefoot area of the sole structure 1000.
  • a bulbous area 1004b is provided, e.g., under the fifth metatarsal head region on the lateral side of the midsole component 1002.
  • a third bulbous region 1004c is located centered somewhat, forward and medial with respect to a center of bulbous area 1004b (e.g., at the lateral side located under the first metatarsal head support area of the sole (i.e., beneath the metatarsal head area of the big toe),
  • a fourth bulbous region 1004d is located forward of the third bulbous region 1004c (e.g., at the lateral side located under the big toe and/or adjacent toe).
  • the bulbous areas l()04a-l()04d in this example structure 1002 are arranged so as to provide additional impact force attenuation and/or a comfortable, soft feel under the wearer's foot during certain activities, such as running (or walking), landing a step or jump, launching a jump, etc.
  • a runner lands a step toward the lateral heel side of the foot.
  • Bulbous area 1004a is provided in the rear heel area of this midsole component 1002 to provide additional impact force attenuation and/or a comfortable, soft feel at this heel strike time.
  • the foot roils forward and the lateral side edge of the sole contacts the ground.
  • Bulbous area 1004b is provided at the lateral side area (beneath the little toe) of this niidsole component 1002 to provide additional impact force attenuation and/or a comfortable, soft feel at this time in the step cycle. As the foot continues to roll forward, it also begins to roll inward, toward the medial side, and eventually the runner pushes off from the ground using the first metatarsal head area and/or the big toe (and possibly the adjacent toe).
  • Bulbous areas 1004c and 1004d are provided at the medial forefoot side area (beneath the ball of the foot and/or the big toe area) of this niidsole component 1002 to provide additional impact force attenuation and/or a comfortable, soft feel at these times in the step cycle.
  • Fig. 10B shows an illustration of the bottom surface 1000a of a sole structure 1000 that incorporates a midsole component 1002 of the type described above with respect to Fig. 10A included therein.
  • the bottom of the sole structure 1000 includes traction elements and/or other features that underlie the bulbous areas 1004a- 1004d (e.g., formed as part, of a thin web type protective component as will be described in more detail below).
  • the bulbous nature of the sole structure 1000 at the various locations and the foam material above those locations help provide good impact force attenuation at the bulbous areas 1004a- 1004d.
  • these bulbous areas 1004a-1004d may provide return energy to the foot (e.g., apply a foot lifting force to the wearer's plantar surface as the impact force is lessened (as the foot lifts for the next step) and the foam midsole component 1002 returns to its original shape).
  • any desired pattern of bulbous areas including more or fewer bulbous areas, may be provided in a midsole component without departing from this invention.
  • Sole structures in accordance with examples of this invention may include any number of bulbous areas, including no bulbous areas; one, two, or more bulbous areas (arranged in any desired manner).
  • Bulbous area(s) may be arranged to provide impact force attenuation, a soft feel, and/or return energy at any desired location(s), optionally depending on the intended use of the shoe. Bulbous areas of these types also are visible at the bottom of the sole structures shown in Figs. 2B-2F, 3A, 3B, and 7, and may be included in any desired sole structure.
  • FIGs. 1 lA-1 5 C show another example basketball shoe 1 150 that includes a sole structure 1 100 in accordance with at least some examples of this invention.
  • Fig, 1 1 A is lateral side view of the shoe 1 150
  • Fig. 1 IB is a medial side view of the shoe 1 150
  • Fig, 1 1 C is a rear heel view of the shoe 1 150.
  • This shoe 1 150 includes an upper 1 152 having a multi- layered, fuse bonded type of upper construction, although other constructions may be used without departing from this invention.
  • the upper 1 152 is engaged with a sole structure 1 100 that includes features in accordance with at least some examples of this invention.
  • the upper 52 may be engaged with the sole structure 1 100 in any desired manner without departing from the invention, including in conventional manners as are know n and used in the art.
  • the upper 1 152 and sole structure 1 100 may be engaged with one another, for example, by cements or adhesives, by mechanical connectors, by stitching or sewing, or the like.
  • flOSj The sole structure 1 100 of this illustrated example includes three main components parts.
  • the first part constitutes a lightweight (and low density) midsole component 1 102, for example, of the various types described above.
  • This foam midsole component 1 102 may extend to support all or substantially all of the plantar surface of a wearer's foot. Portions of the midsole component 1 102 are exposed at the outer surface of the footwear structure 1 150 at various locations in this illustrated example, including: (a) along the lateral side edge, at, least at the midfoot area (see Fig. 1 1 A); (b) at a forward toe area (optionally, at least at the lateral side; see Fig.
  • This foam midsole component 1 102 provides a soft and comfortable feel for the wearer's foot, as generally described above with respect to the other lightweight foam midsole structures.
  • the second part of this example sole structure 1 100 is a protective component 1 104 that at least partially contains the foam midsole component 1 102.
  • the protective component 1 104 of this illustrated example constitutes a polymeric foam type protective component that may have a denser or heavier foam construction than the foam material of the lightweight foam midsole component 1 102.
  • one portion of the protective component 1 104 extends from a lateral midfoot and/or heel area of the sole stmcture 1 100, around the rear heel area of the sole structure 1 100, and over to a medial heel area sole structure 1 100. As best shown in Fig.
  • the foam midsole component 1 102 extends outward from behind the protective component 1 104 and is exposed at the exterior surface of the shoe 1 150 at the rear heel area of this sole structure 1 100.
  • Another portion of the protective component 1 104 is provided at the lateral forefoot area of the shoe 1 150, as shown in Fig. 1 1 A.
  • This lateral forefoot portion of the protective component 1 104 may be integrally formed with the protective component part 1 104 at the rear heel area as a unitary, one-piece construction, or it may be a separate part.
  • Another portion of the protective component 1 104 of this example is provided at the extreme forward toe area of the sole structure 1 100, extending around the forward toe area from the medial side to the lateral side.
  • This forward toe lateral forefoot portion of the protective component 1 104 may be integrally formed with one or more of the other protective component parts 1 104 described above (as a unitary, one-piece constmction), or it may be a separate part.
  • the third part of this example sole structure 1 100 is an outsoie element 1 106, which also may function as a protective component, that is engaged with the bottom side of the midsole foam component 1 102 and/or one or more of the polymeric foam protective components 1 104.
  • the outsoie element 5 506 of this example sole structure 1 100 co vers a major portion of the bottom surface of the shoe 1 150.
  • outsoie nubs may cover and directly contact a. bulbous area of the bottom surface of the foam midsole component 1 102 (like the bulbous areas described above in conjunction with Fig. 10A to provide a soft contact area of the sole structure 1 100.
  • this example outsoie component 1 106 includes an opening defined through it at which a bottom surface of midsole member 1 102 is exposed.
  • the outsoie element 1 106 may be made from a thin, highly flexible material, which may have a base surface thickness (i.e., a thickness of its base sheet or web surface at locations not through a nub, a raised rib, a traction element, or the like) of less than 3 mm, and in some examples, a base thickness of less than 2 mm, less than 1.5 mm, or even less than 1 mm, in some examples.
  • This thin, flexible outsoie element 1 106 may be formed from synthetic rubber having a hardness and other properties similar to those of synthetic rubber compounds conventionally used for footwear outsoles.
  • outsoie element 1 106 This thin outsoie web structure permits outsoie element 1 106 to flex significantly between adjacent lugs 1 108 and/or other structural components, in some sole structures, portions of outsoie element 1 106 may be formed from a rubber compound that is harder and more durable than other portions of the outsoie element 1 106.
  • the higher durability rubber could be used, e.g., in a crash pad located within the heel region and/or on t e bottoms of lugs located in certain other high pressure regions that typically wear more quickly. ] As shown in Fig.
  • the protective component 1 104 of this example sole structure 1 100 has a billows structure (with three outer billow ridges) that appears similar, at least, in some regards, to the billows structure described above in conjunction with Fig. 4.
  • the central billo w of the protective element 1 104 that extends around the heel area terminates between billow ridges of a two-billows structure provided in the foam midsole component 1 102 at the lateral midfoot area (at termination point 1 1 1 0).
  • a portion of another, forward billows structure for the lateral forefoot protective component 1 104 originates in the interstitial area between the two billow ridges of the foam midsole component 1 02 at point 1 1 12.
  • the billows structure of the foam, midsole component 1 102 originates in interstitial areas between billows of the protective elements 1 104 located forward and rearward of that billows structure of the foam midsole component, 1 102 (see points 1 1 14). ] As shown in Fig. 1 1C, the three billow structure at the lateral side of the protective component 1 104 reduces down to a two billow structure at the bottom medial heel side of the protective component 1 104. As the foam midsole component 1 102 emerges from beneath the protective component 1 104 at the rear heel area, the foam midsole component 1 102 forms a two billows structure that overlies the two billows structure of the protective component 1 104 at the medial side of the sole structure 1 100.
  • sole structure 1 100 the billows structure extending around the heel morpbs from a three billows structure on one side to a four billows structure on the other side.
  • the billows structure of the protective component 1 104 terminates at the low, medial heel region of the sole structure 1 100.
  • the billows structure of the foam midsole component 1 102 extends further forward, and the top outer ridge of this billows structure extends forward in a somewhat wavy or curved manner.
  • An independent and shallower billows structure runs around the forward toe area along the side edge of protective component 1104 and/or exposed foam midsole component 1102, as shown in Figs, 1 1A and 1 IB.
  • a foam midsole component e.g., made of a lightweight foam material
  • another foam polymeric material as a protective element optionally made from a heavier and denser polymeric foam material
  • a protective component in the form of an outsole component may be provided on at least a portion of a bottom of a lightweight and less dense foam midsole component without the need for another polymeric foam protective component in the sole structure.
  • FIGS. 12A-12C illustrate another example sole structure 1200 in which a lightweight and less dense foam midsole component 1202 (e.g., of the types described above) is protected over at least, portions of its bottom surface with an outsole component 1206, without the inclusion of another polymeric foam, protective material at, any other location in the sole structure 1200.
  • a lightweight and less dense foam midsole component 1202 e.g., of the types described above
  • an outsole component 1206 without the inclusion of another polymeric foam, protective material at, any other location in the sole structure 1200.
  • Fig. 12A illustrates a lateral side view
  • Fig. 12B illustrates a medial side view
  • FIG. 12C illustrates a bottom, view of this example sole structure 1200 and article of footwear 1250 in accordance with this example of invention.
  • This example article of footwear 1250 is a running shoe, and it includes an upper 1252 constructed, for example, of any of the various materials described above.
  • the upper 1252 may be made, at least in part, from a textile material, such as a mesh material, a knitted material, or the like.
  • the upper 1252 may be engaged with the sole structure 1200 in any conventional manner, for example, using adhesives or cements.
  • the side surface 1202a of the lightweight midsole component 1202 of this example structure 1200 does include various billows structures, although the overall billows structure of this sole 1200 differs in some regards from the various other billows structures described above.
  • the heel area of this example midsole component 1202 includes a three layered billows structure 1210 extending from the rear heel area around to the lateral side of the shoe 1250.
  • a double layered billows structure 1212 is provided at the midfoot area of this midsole component 1202, and the two layer billows structure 1212 is separated from the rear heel three-layer billows structure 1210 by a segment 1214 of smooth polymeric foam material (a portion of the lightweight midsole component 1202) to thereby provide a gap in the billows structures on the lateral side of the shoe 1200.
  • the midfoot two- layered billows series 1212 terminates at the midfoot/forefoot area of the sole structure 1200.
  • Another smooth segment, 1216 of polymeric material (a portion of the lightweight, midsole component 1202) produces a gap between the midfoot two-layered billows series 1212 and a single billow 1218 (or raised rib structure) that extends around the toe area of the shoe 1250.
  • the single forefoot, raised rib 2 8 of this example structure extends from the lateral side, around the forward toe area, to the medial side of the shoe 1250, as shown in Figs. 12A and 12B. As illustrated therein, the single billow 1218 terminates at the medial forefoot area. After another short gap 1220 with no billows (in which a. smooth polymeric foam segment 1220 of this midsole component 1202 is provided), a two layered billows series 1222 begins and extends rearward through the forefoot area.. The lower billows of the two layered bil lows series 1222 terminates in the midfoot area, at which another smooth segment 1224 of midsole material 1202 is provided.
  • the top billow of the two layer billows series 1222 extends continuously along the upper edge of the midsole component 1202, at the junction between the midsole component 1202 and the upper 1252. After the smooth segment 1224, the heel billows area 1210 begins on the medial side of the sole structure 1200. Notably, the upper billows of the forefoot billow series 1222 forms the upper billows of the rear heel billows series 1210.
  • the segments of smooth polymeric foam material of the midsole component 1202 e.g., segments 1214, 1216, 1220, and 1224, provide areas that are somewhat stiffened in the vertical direction as compared to areas supported by the various billow structures.
  • segments 1214, 1216, 1220, and 1224 provide areas that are somewhat stiffened in the vertical direction as compared to areas supported by the various billow structures.
  • one smooth gap segment 1214 is provided in the lateral heel area of the sole structure 1200. This segment 1214 provides additional support for a runner's foot when landing a step during a running step cycle.
  • the smooth gap segment 1216 also on the lateral side of the sole structure 1200, is located at or near the fifth metatarsal head area of the sole structure 1200.
  • the somewhat stiffened smooth segment 1216 provides additional support under the fifth metatarsal head area as the foot rolls forward during continuation of the step cycle.
  • Smooth gap segment 1220 is located at, the medial forefoot or toe area of the sole structure 1200 and provides additional support for the big toe area of the w r earer, e.g., during the pushoff phase of the step cycle.
  • Smooth gap segment 1224 is provided in the arch area of the shoe 1250 and provides additional arch support for the wearer.
  • the heel billows structure 1210 of this example sole structure 1200 is interrupted in the medial heel side area by a series of angularly oriented support ribs 1230.
  • the support ribs 1230 are angled in a top rear-to-bottom forward direction.
  • the ribs 1230 may be oriented at any desired angle without departing from this invention, including at a vertical angle (90° from horizontal) when the sole 1200 rests on a horizontal surface.
  • the ribs 1230 may be oriented at an angle within the range of 25° to 90°, with respect to the horizontal direction (when the sole 1200 rests on a horizontal surface).
  • the ribs 1230 when angled other than vertical, may be angled in the opposite direction from that shown in Fig. 12B, i.e., in a rear bottom-to-forward top direction. Not all ribs in a series where more than one rib is present need to extend at the same angle as another rib (although all ribs may be parallel, if desired).
  • ribs 1230 provide additional support for the medial side of the foot during the step cycle, for example, to prevent overpronation during a step cycle. While other arrangements are possible, in this illustrated example sole structure 1200, the ribs of area 1230 extend from the top billows element to the bottom billows element of the rear heel billows series 1210. In this manner, the ribs 1230 extend integrally from the top and bottom billows ridges, and the ribs 1230 interrupt the center billows of the three layered billow series 1210. Also, while three support rib elements 1230 are shown in Fig. 12B, one, two, or more rib elements 1230 of this type could be provided as this type of medial heel support without departing from the invention.
  • the ribs 1230 of a series on an individual shoe 1250 may have any desired shape without departing from the invention, including a triangular cross-sectional shape a rounded cross-sectional shape, a flat or rectangular cross sectional shape, etc.
  • the various ribs 1230 of that series need not all have the same identical shape and/or even the same general shapes. Rather, the shapes of the rib elements 1230 may vary widely even in an individual shoe 1250 without departing from the invention.
  • the outsole element 1206 may be engaged with the bottom side of the midsole foam component 1202, e.g., using cements or adhesives.
  • the outsole element 1206 of this example sole structure 1200 covers a major portion of the bottom surface of the shoe 1250. While it may include any desired types of traction elements and/or traction element configuration, in this illustrated example, the traction elements constitute mainly raised nubs (or lugs) 1240 spaced around the bottom of the sole structure 1200 in a generally matrix pattern.
  • one or more outsole nubs 1240 may cover and directly contact a bulbous area of the bottom surface of the foam midsole component 1202 (like the bulbous areas described above in conjunction with Fig. 10A) to provide a soft contact area of the sole structure 1200,
  • This outsole element 5206 is made from a thin, highly flexible material, which may have a base surface thickness (i.e., a thickness of its base sheet or web surface at locations 1242 between nubs 1240) of less than 3 mm, and in some examples, a base sheet or web surface thickness of less than 2 mm, less than 1.5 mm, or even less than 1 mm. While Fig. 52C shows the nubs 1240 as generally square or rectangular and substantially arranged in rows or columns (as a matrix), any desired nub shape(s) and/or nub arrangements) anc [/ or spacing(s) may be provided on a sole structure without departing from the invention.
  • the outsole element 1206 of this example sole structure 1202 also may have any of the structures, features, or characteristics of similar thin sole components as described in U.S. Patent Appln. No. 13/693,596 filed December 4, 2012 and entitled “Article of Footwear,” which application is entirely incorporated herein by reference.
  • This thin, flexible outsole element 1206 may be formed as a sheet like material, e.g., from synthetic rubber having a hardness and other properties similar to those of synthetic rubber compounds conventionally used for footwear outsoles.
  • This thin outsole web structure permits outsole element 1206 to be very lightweight and to flex significantly between adjacent nubs 1242.
  • portions of outsole element 1206 may be formed from a rubber compound that is harder and more durable than other portions of the outsole element 1206, or the outsole component web area 1242 may be made somewhat thicker in some areas than others.
  • Fig. 12C further shows that this example thin web type outsole structure 1206 is perforated at some locations (e.g., in the forefoot and midfoot areas, in this example). Also, as further shown, the nub size (e.g., height, cross sectional dimensions, cross sectional shapes, etc.) may vary over different areas of the outsole structure 1206.
  • the thin web outsole member 1206 is engaged with the polymeric foam member to cover at least 60% of a surface area of a bottom surface of the midsole component 5202, and in some examples at least 80%, at least 90%, or even at least 95% of this surface area. At least a majority of the web base surface (a majority of the surface area between traction elements) will have a thickness that is less than 2 mm thick, and in some examples less than 1.5 mm or even less than 1 mm thick, if desired, at least 75%, at least 85%, at least 90%, or even at least 95% of the web base surface (surface area between traction elements) will have the thickness characteristics noted above.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Footwear And Its Accessory, Manufacturing Method And Apparatuses (AREA)
PCT/US2014/025607 2013-03-15 2014-03-13 Sole structures and articles of footwear having lightweight midsole members with protective elements WO2014151379A2 (en)

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EP14717322.3A EP2967183B1 (en) 2013-03-15 2014-03-13 Article of footwear comprising a sole structure including a billows structure
JP2016501893A JP6430480B2 (ja) 2013-03-15 2014-03-13 ビロー構造を含有するソール構造を含むフットウェア製品
AU2014235049A AU2014235049B2 (en) 2013-03-15 2014-03-13 Article of footwear comprising a sole structure including a billows structure
BR112015023027A BR112015023027A2 (pt) 2013-03-15 2014-03-13 estruturas de solas e artigos de calçado tendo componentes de entressolas leves com elementos de proteção
CN201480015717.1A CN105101829B (zh) 2013-03-15 2014-03-13 包括包含波涛结构的鞋底结构的鞋类物品
KR1020157028639A KR20150132311A (ko) 2013-03-15 2014-03-13 파형부 구조체를 포함한 밑창 구조체를 포함하는 신발류 물품
CA2902810A CA2902810C (en) 2013-03-15 2014-03-13 Sole structures and articles of footwear having lightweight midsole members with protective elements
MX2015012596A MX2015012596A (es) 2013-03-15 2014-03-13 Articulo de calzado que comprende una estructura de suela que incluye una estructura de ondulaciones.
ZA2015/06094A ZA201506094B (en) 2013-03-15 2015-08-21 Article of footwear comprising a sole structure including a billows structure
HK16102099.8A HK1214482A1 (zh) 2013-03-15 2016-02-24 包括包含波濤結構的鞋底結構的鞋類物品

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US13/838,051 US9504289B2 (en) 2013-03-15 2013-03-15 Sole structures and articles of footwear having a lightweight midsole member with protective elements
US13/835,715 2013-03-15
US13/837,967 US9510635B2 (en) 2013-03-15 2013-03-15 Sole structures and articles of footwear having a lightweight midsole member with protective elements
US13/838,051 2013-03-15
US13/837,967 2013-03-15
US13/835,715 US9301566B2 (en) 2013-03-15 2013-03-15 Sole structures and articles of footwear having a lightweight midsole member with protective elements

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JP (3) JP6430480B2 (pt)
KR (4) KR20150132311A (pt)
CN (3) CN105101829B (pt)
AU (3) AU2014235049B2 (pt)
BR (2) BR112015022556B1 (pt)
CA (3) CA2902810C (pt)
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AU2014235049A1 (en) 2015-10-15
MX2015012586A (es) 2016-01-12
BR112015022776B1 (pt) 2021-02-09
CN105050440B (zh) 2017-06-23
HK1214482A1 (zh) 2016-07-29
BR112015022556B1 (pt) 2021-06-15
ZA201505652B (en) 2016-11-30
EP2967185B1 (en) 2018-07-25
CA2900541A1 (en) 2014-09-18
CN105050441B (zh) 2017-10-10
EP2967184A1 (en) 2016-01-20
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JP2016512139A (ja) 2016-04-25
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CA2902810A1 (en) 2014-09-25
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BR112015022776A2 (pt) 2017-07-18
EP2967185A1 (en) 2016-01-20
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HK1214097A1 (zh) 2016-07-22
KR20180021241A (ko) 2018-02-28
KR20150135351A (ko) 2015-12-02
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AU2014235049B2 (en) 2016-10-20
EP3449746B1 (en) 2021-08-11
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