Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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SOLE STRUCTURES AND ARTICLES OF FOOTWEAR HAVING
LIGHTWEIGHT MIDSOLE MEMBERS WITHPROTECTIVE ELEMENTS
Related Application Data
[01] This application claims priority to: (a) U.S. Patent Application No.
13/835,715, titled
"Sole Structures and Articles of Footwear Having a Lightweight Midsole Member
with Protective Elements" and filed March 15, 2013; (b) U.S. Patent
Application No.
13/838,051, titled "Sole Structures and Articles of Footwear Having a
Lightweight
Midsole Member with Protective Elements" and filed March 15, 2013, and (c)
U.S.
Patent Application No. 13/837,967, titled "Sole Structures and Articles of
Footwear
Having a Lightweight Midsole Member with Protective Elements" and filed March
15, 2013.
Field of the Invention
[02] 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.
Background
[03] 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. In
addition, the
upper may have a configuration that protects the foot and provides
ventilation,
thereby cooling the foot and removing perspiration. The sole structure is
secured to a
lower surface of the upper and generally is positioned between the foot and
any
contact surface. In addition to attenuating ground reaction forces and
absorbing
energy, the sole structure may provide traction and control potentially
harmful foot
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motion, such as over pronation. The general features and configurations of the
upper
and the sole structure are discussed in greater detail below.
[04] 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. In addition,
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.
[05] 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.
[06] The primary element of a conventional midsole is a resilient, polymer
foam material,
such as polyurethane foam or ethylvinylacetate ("EVA") foam, that extends
throughout the length of the footwear. The properties of the polymer foam
material in
the midsole are primarily dependent upon factors that include the dimensional
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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 ground 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.
[07] Despite the numerous available footwear models and characteristics, new
footwear
models and constructions continue to develop and are a welcome advance in the
art.
Summary of the Invention
[08] This Summary is provided to introduce some general concepts relating to
this
invention in a simplified form that are further described below in the
Detailed
Description. This Summary is not intended to identify key features or
essential
features of the invention.
[09] While potentially useful for any desired types or styles of shoes,
aspects of this
invention may be of particular interest for sole structures used in articles
of athletic
footwear, including basketball shoes, running shoes, cross-training shoes,
cleated
shoes, tennis shoes, golf shoes, etc.
[10] More specific aspects of this invention relate to sole structures for
articles of footwear
that 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, 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.
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[11] 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/cm3) 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) 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
(b) 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 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.
[12] Another sole structure according to some examples of this invention
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
wall, (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
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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.
[13] 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/cm3, 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.
[13a] Some aspects relate to an article of footwear, comprising: an upper; and
a sole
structure engaged with the upper, wherein the sole structure includes: 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/cm3, and 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, wherein at least a portion of the
plurality of
traction elements include a plurality of nubs arranged in a matrix pattern,
and wherein
the web base surface is perforated in a forefoot and midfootarea between some
of the
plurality of nubs, leaving a heel area of the web base surface free of
perforations.
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[13b] Some aspects relate to an article of footwear, comprising: an upper; and
a sole
structure engaged with the upper, wherein, exterior to the sole structure, the
sole
structure consists essentially of: 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/cm3, and a protective
member
engaged with the polymeric foam member to cover at least 60% 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, and wherein at least a portion of the plurality of traction elements
include a
plurality of nubs arranged in a matrix pattern and wherein the web base
surface is
perforated in a forefoot and midfootarea between some of the plurality of
nubs, leaving
a heel area of the web base surface free of perforations.
[14] Additional aspects of this invention relate to articles of footwear
including sole
structures of the various types described above engaged with an upper. Still
additional
aspects of this invention relate to methods for making sole structures and/or
articles of
footwear of the various types described above (and described in more detail
below).
More specific aspects of this invention will be described in more detail
below.
Brief Description of the Drawings
[15] The foregoing Summary of the Invention, as well as the following Detailed
Description
of the Invention, will be better understood when considered in
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conjunction with the accompanying drawings in which like reference numerals
refer
to the same or similar elements in all of the various views in which that
reference
number appears.
[16] Figs. 1A-1F illustrate a sole structure according to one example of this
invention;
[17] Figs. 2A-2F illustrate a sole structure according to another example of
this invention;
[18] Figs. 3A and 3B illustrate features of a sole structure according to
another example of
this invention;
[19] 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;
[20] Fig. 5 illustrates a basketball shoe according to one example of this
invention;
[21] Fig. 6 illustrates a running shoe according to one example of this
invention;
[22] Fig. 7 illustrates a training shoe according to one example of this
invention;
[23] Figs. 8A-8F illustrate a sole structure according to another example of
this invention;
[24] Fig. 9 is an exploded view of a sole structure according to another
example of this
invention;
[25] Figs. 10A and 10B illustrate features of a sole structure according to
another example
of this invention;
[26] Figs. 11A-11C provide various views of an article of footwear according
to another
example of this invention; and
[27] Figs. 12A-12C provide various views of an article of footwear according
to another
example of this invention
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Detailed Description of the Invention
[28] In the following description of various examples of footwear structures
and
components according to the present invention, reference is made to the
accompanying drawings, which form a part hereof, and in which are shown by way
of
illustration various example structures and environments in which aspects of
the
invention may be practiced. It is to be understood that other structures and
environments may be utilized and that structural and functional modifications
may be
made from the specifically described structures and functions without
departing from
the scope of the present invention.
I. General Description of Aspects of this Invention
[29] 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.
A. Features of Sole Structures and Articles of Footwear According to
Examples of this Invention
[30] Some aspects of this invention relate to sole structures for articles of
footwear and
articles of footwear (or other foot-receiving devices), including athletic
footwear,
having such sole structures. Sole structures for articles of footwear
according to at
least some examples of this invention 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.
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[31] Sole structures in accordance with at least some examples of this
invention may
include outsole components (e.g., made of rubber, phylon, phylite,
thermoplastic
polyurethane, or the like) on the bottom surface(s) of one or more of the foam
protective components and/or the foam midsole component (e.g., in one of the
exposed spaces). The outsole component(s) 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). In
some
example structures according to this invention, 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.
[32] If desired, in accordance with at least some examples of this invention,
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
(optionally made from a heavier weight or more dense polymeric foam material),
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). While any number of
individual billow structures are possible on the various components without
departing
from this invention, in some examples, in a top-to-bottom direction, an
individual sole
structure may include from 2 to 8 billows, and in some examples, from 3-6
billows.
[33] 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/cm3) 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:
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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.
[34] Another example sole structure according to some examples of this
invention
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 wall, (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
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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.
[35] 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/cm3, 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.
[36] Still 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).
[37] 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.
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[38] Given the general description of features, aspects, structures, and
arrangements
according to the invention provided above, a more detailed description of
specific
example sole structures, articles of footwear, and methods in accordance with
this
invention follows.
II. Detailed Description of Example Sole Structures and Articles of
Footwear
According to this Invention
[39] Referring to the figures and following discussion, various sole
structures, articles of
footwear, and features thereof in accordance with the present invention are
disclosed.
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, cleated shoes, golf shoes, etc. In addition, 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.
[40] Figs. lA through 1F 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.
For purposes of this disclosure, and as shown in Fig. 1A, portions of an
article of
footwear (and the various component parts thereof) 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. For example, as shown in Fig. 1A,
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
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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). These regions
(although
separated by dividing lines in Fig. 1A) and sides are not intended to
demarcate precise
areas of footwear. Rather, the terms "forefoot region," "midfoot region,"
"heel
region," "lateral side," and "medial side" are intended to represent general
areas of an
article of footwear and the various components thereof to aid the in
discussion that
follows.
[41] Fig. lA shows a top view of the sole structure 100, Fig. 1B shows a
lateral side view,
Fig. 1C shows a medial side view, Fig. 1D shows a bottom view, Fig. lE shows a
heel
or rear view, and Fig. 1F shows a toe or front side view. As shown in Figs. lA
through 1F, 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. While other midsole constructions are possible, in accordance with some
examples of this invention, the midsole component 102 may constitute a foam
material (such as ethylvinylacetate ("EVA") foam, polyurethane foam, phylon
foam,
and the like). 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.
[42] In some examples of this invention, the midsole component 102 will be at
least
partially made from a foam material having a density of less than 0.25 g/cm3
(and in
some examples, a density of less than 0.2 g/cm3, within the range of 0.075 to
0.2
g/cm3, and even within the range of 0.1 to 0.18 g/cm3). If desired, the foam
material
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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. In certain embodiments of
this
invention, 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). In the
example
structure 100 as illustrated in Figs. lA through 1F, 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 hi=hlight the
change in
locations between materials 102/104 in these figures). In this illustrated
example, 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.
[43] As some even more specific examples, at least some of the midsole
component 102
may be made from a foam material as described, for example,
in U.S. Patent No. 7,941,938. In at least some example sole
structures 100 according to this invention, 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
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0.25 g/cm3, less than 0.20 g/cm3, less than 18 g/cm3, less than 0.15 g/cm3,
less than
0.12 g/cm3, and in some examples, about 0.10 g/cm3. As example ranges, the
lightweight foam density may fall within the range, for example, of 0.05 to
0.25 g/cm3
or within the various ranges noted above.
[44] Also, in accordance with at least some examples of this invention, 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/cm2, and typically 15 to 40 kg/cm2. The elongation % is 150
to 500,
typically above 250. The tear strength is 6-15 kg/cm, typically above 7. In at
least
some example constructions according to the invention, 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%. As additional
examples,
if desired, 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.
[45] While the above paragraphs describe potential properties and features of
foam
materials for midsole components 102 in accordance with some examples of this
invention, those skilled in the art will recognize that the 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
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hardness, durability, and/or abrasion resistance to directly contact the
ground in use
(at least not at some higher impact ground contact locations).
[46] The protective component 104 in this example sole structure 100 may be
made from
any desired materials without departing from the invention. For example, the
protective component 104 may be made from conventional outsole material, such
as
rubber, thermoplastic polyurethane (TPU), or the like. As another example, 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.
[47] 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.). In this illustrated example, 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. As additional
examples, 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.
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[48] As further illustrated in Fig. 1D, 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. 1D, the breaks or gaps in the protective
component
104 may be provided along desired lines of flex of the protective component
104
(e.g., elongated slots or gaps in the forefoot area, as shown in Fig. 1D),
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. One skilled in the art,
given the
benefit of this disclosure, will understand that 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.
Preferably,
however, 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.
[49] As best shown in Figs. 1C and 1D, 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. In Figs. 1C and 1D, the support plate 108 is shown
separated
from the midsole component 102 and/or the protective component 104 by junction
line 110. This junction line 110 is provided as an illustrative aid in the
drawings to
highlight the change in locations between support plate 108 and materials
102/104 in
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these figures. In this illustrated example, 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 108 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.
Some more specific examples of 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.
[50] Figs. lA through 1F show another feature that may be included in sole
structures 100
in accordance with at least some examples of this invention. As shown in these
figures, 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 terms "billowed structure" or "billows structure," as used
herein,
mean that the exterior surface shape of the element has the exterior surface
shape of a
billow, e.g., a wave like structure with a series of wave peaks (the outermost
portion
or ridge) and valleys between the wave peaks. In a sole structure, a "billowed
structure" need not expand and compress in the same manner of a conventional
bellow, but rather, the term relates more generally to the shape of the
exterior surface
of the structure. In the illustrated example sole structure 100, 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
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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). As some more
specific
examples, the outer shell of the midsole component 102 (with the billows
structure
120 formed in it) 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.
[51] 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. 1C) to a
lateral
midfoot or forefoot area of the midsole component 102 (see Fig. 1D). This
specific
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overall billows structure 120 includes five billow outer ridges connected by
four
billow interstitial areas located between adjacent billow outer ridges of the
five billow
outer ridges.
[52] The billows structures may take on a variety of forms without departing
from this
invention. For example, Figs. 1B, 1C, 1E, and 1F 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.
As additional examples, if desired, 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. Also, while 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).
[53] Also, in this illustrated example sole structure 100, at the rear heel
area of the midsole
component 102, 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 100 is oriented on a horizontal
surface.
Additionally or alternatively, in this sole structure 100, at the rear heel
area of the
midsole component 102, 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. These features can be best seen, for example, in Figs. 1B
and 1C.
[54] Also, as best shown in Figs. 1B, 1C, and 1F, 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 structure 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.
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As shown, the billows structure 140 of the protective component 104 of this
example
sole structure 100 is not continuous with the billows structure 120 of the
midsole
component 102. Rather, 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 structure 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. Also, 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.
[55] The sole structure 100 shown in Figs. lA through 1F 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 structure 100 of Figs. lA through
1F, but
with a different billows configuration.
[56] For the sake of brevity, the similar parts between Figs lA - 1F and those
in Figs. 2A -
2F, will not be described in detail in this specification. Rather, the
discussion to
follow will focus on the differences between the structures shown in Figs. 2A -
2F as
compared to those shown in Figs. lA - 1F. As those skilled in the art can
understand,
the parts not described in detail below with respect to Figs. 2A ¨ 2F may have
the
same or similar structures and/or the same or similar features and/or options
to those
similar parts and structures described above with respect to Figs. lA ¨ 1F.
[57] Unlike the billows configuration 120 shown in Figs. lA - 1F, 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
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side end to their medial side end, the billows configuration 220 of Figs. 2A ¨
2F
includes intermixed or interwoven billows. As best seen from Figs. 2B, 2C, and
2E,
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. lA ¨ 1F (e.g.,
with five
billow outer ridges and four billow interstitial areas). However, as also best
seen from
Figs. 2B, 2C, and 2E, 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. From their origin points 252, 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. Also, the interstitial billows 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).
Additionally, while not a requirement, in the example sole structure 200 shown
in Fig.
2B, the outer ridges 254 of the new billows series 220b taper downward in size
moving forward from their peak areas to end points 256. 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. Thus, at least on the lateral heel side
shown in Fig.
2B, the new billows series 220b may constitute a central billows configuration
with a
rearward billows configuration extending toward the heel (from origination
points
220f) and a forward billows configuration extending to the midfoot area (from
origination points 258).
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[58] At the medial side of this sole structure 200, as illustrated in 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 billows 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).
[59] The example billows configuration of Figs. 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.
[60] 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.
1D). 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. lA ¨ 1F) 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. 10A and 10B.
[61] Another example alternative sole structure 300 in accordance with some
examples of
this invention is shown in conjunction with Figs. 3A and 3B. Like the other
sole
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structures 100, 200 described above, 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 structures and functions are possible without
departing from the invention. For the sake of brevity, the similar parts
between Figs
2A - 2F and those in Figs. 3A ¨ 3B, will not be described in detail in this
specification. Rather, the discussion to follow will focus on the differences
between
the structures shown in Figs. 3A ¨ 3B as compared to those shown in Figs. 2A -
2F.
As those skilled in the art can understand, the parts not described in detail
below with
respect to Figs. 3A ¨ 3B may have the same or similar structures and/or the
same or
similar features and/or options to those similar parts and structures
described above
with respect to Figs. lA ¨ 2F.
[62] In the example sole structures 100, 200 described above, 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 structure 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
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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.
[63] The cut away area 310 of this example sole structure 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 structure 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. Additional or other alternative
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). For example, cut away areas 310
along the
lateral and/or medial sides of the sole structure 300 (e.g., in the forefoot
area) 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).
[64] At the cut away area 310 of this example sole structure 300, the exposed
edge of the
foam midsole material 302 is covered by 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
material 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 structure 300
and/or
footwear structure in any desired manner without departing from the invention.
As
some more specific examples, these components may be engaged together using
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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
structure 300.
[65] As further shown in Fig. 3B, 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.
[66] While described above as a "cut out" or "cut away" area 312, this area
312 need not
be provided in any part of the sole structure 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 component(s) (e.g.,
components 302 and/or 304) during its manufacturing process, such as by being
molded directly into the structure of foam midsole component 302 and/or a
protective
component 304. Therefore, the term "cut away area" as used herein in this
context
and/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.
[67] 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. In the illustrated example 300, the windows 362 extend along edges of the
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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).
[68] 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.
[69] While the sole structures 100, 200, 300 of Figs. lA through 3B all show
billows
structures having three to five individual billows structures over various
areas that are
relatively uniformly shaped, this is not a requirement. As another example,
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 billow 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. 4 (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. lA through 3B. Also, while only the heel area of the sole component
400
is shown in Fig. 4, those skilled in the art, given the benefit of this
disclosure, would
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readily understand that 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.
[70] The billows structure 402 of Fig. 4 differs from some of the other
billows structures
described above with respect to Figs. lA ¨ 3B in the shape of the billows.
More
specifically, as shown in Fig. 4, the central billows 402b of this example
billows
structure 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. Similarly,
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. Because of this configuration,
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. Similarly, 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. lA through 3B.
[71] Notably, the billows construction 402 has smoother side walls (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. Also, 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.
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[72] 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, and 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. As some more specific
examples, 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.
[73] In further describing the 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. 1A-4. Because 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.
[74] 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
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through fusing techniques (e.g., melt or fuse bonding of a hot melt material,
etc.).
Non-limiting examples of some construction techniques will be described in
more
detail below.
[75] The upper 552, 652, 752 may be made from any desired materials and/or
combinations of materials without departing from this invention. For example,
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. In some more specific
examples, 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.). None
of the interior fabric or textile layer, the mesh layer, and/or the skin layer
needs to
extend to cover an entire surface of the upper 552, 652, 752. Rather, 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 breathability, 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
material), etc. Also, as is known in the art, 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.
[76] The multi-layered upper construction may be produced in any desired
manner without
departing from this invention, including in conventional manners as are known
and
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used in the footwear art. For example, if desired, 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. As additional examples, if desired, the
skin layer
may be engaged with the underlying mesh layer (or other layer) by cements or
adhesives and/or by sewn seams_ As yet additional examples, if desired, the
upper
552, 652, 752 (or portions thereof) 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.
[77] 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. For
example, 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.). If necessary or desired, 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.
[781 Other potential materials that may be used in uppers 552, 652, 752 in
accordance with
at least some examples of this invention 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. As another
potential feature, if desired, at least some portion of the upper 552, 652,
752 may be
formed by a knitting procedure. Optionally, at least a majority (or even all)
of the
upper 552, 652, 752 may be formed using knitting procedures, in at least some
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examples of this invention. Knitted textile components can be used to provide
lightweight, breathable, and comfortable upper constructions.
[79] Returning now to Fig. 5, additional details of this example footwear
structure 550 will
be described. This example footwear structure 550 is a basketball shoe. The
upper
552 may have a construction like that of any conventional basketball shoe,
including
constructions made from leathers, multi-layered fuse-bonded materials, or
other
materials and/or constructions 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. lA through 1F 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.
[80] While similar in billows appearance, however, 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
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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.
[81] Turning now to Fig. 6, additional details of this example footwear
structure 650 will
be described. This example footwear structure 650 is a running shoe. The upper
652
may have a construction like that of any conventional running shoe, including
constructions 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. 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 structure 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.
[82] 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. Notably, 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
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would not be required, this reduced number of billows provides somewhat less
vertical height in the heel area of the sole structure 600.
[83] Also, like the sole structure 500 of Fig. 5, the exposed rear portion 604
of the sole
structure 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). While 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. In this manner, at the
rear of
the footwear structure 650, 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.
[84] With respect to the vertical direction shown in Fig. 6 (e.g., with the
shoe 650 oriented
on a horizontal contact surface), the heel and/or midfoot area includes
interwoven
billows from the rear heel billows series 610 and the forward series of
billows 612. In
other words, as one moves in the vertical direction in at least some portions
of the
heel and/or midfoot area of the sole structure 600 (e.g., shown by line 614),
one will
encounter surfaces of individual billows of the forward series of billows 612
located
between surfaces of individual billows of the rear heel series of billows 610.
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.
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[85] 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. Like
the sole structure 500 of Fig. 5, 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.
[86] In this example sole structure 700, 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). Moving
in the
vertical direction in Fig. 7, a first support rib or element 710 is provided
along the
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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. At
least a
majority (and potentially all) of 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.
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[87] Accordingly, the 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 710, 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.
[88] While other specific structures are possible, in this illustrated
example, 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.
Notably, the outward extending peaks of support ribs or elements 712, 716, and
718
substantially align in a top forward-to-bottom rearward direction. Also, the
outward
extending peaks of support ribs or elements 710, 714, and 718 substantially
align in a
vertical direction from top to bottom.
[89] 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. Also, if desired, simple gaps
between
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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.
[90] One example construction of the sole structures 500, 600, and 700 of
Figs. 5 to 7 is
described in more detail in conjunction with Figs. 8A through 8F. 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, and Fig. 8C shows top views of
these two
parts separated from one another. As can be seen from these figures, 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). In
addition to
extending out the free, forward end of the protective component 804, 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.
[91] In this example 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. Optionally, if desired, 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
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attenuation embedded or included therein. In this illustrated example,
however, 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.
[92] 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. As
some
more specific examples, the protective component 804 may be made from
polyurethane foam, ethylvinylacetate ("EVA") foams, phylon, or other known
midsole foams or materials. In some examples structures in accordance with
this
invention, 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.
[93] As further shown in Figs. 8A-8C, the polymeric foam material of the
protective
component 804 may include billows structures formed around at least portion(s)
of its
perimeter edge. More specifically, 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
wall 804a, and the rear heel wall 804c. In at least some examples of this
invention,
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.
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[94] 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 wall 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 wall 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.
[95] As described above at least with respect to Fig. 7, 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. For example, 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.
Additionally or alternatively, the foam midsole component 802 may include a
billows
structure that extends around a front toe area of the sole structure 800. In
this specific
illustrated example, the billows structure of the foam midsole component 802
includes
three billow outer ridges connected by two billow interstitial areas.
[96] When both components 802 and 804 have billows structures, the billows
structure of
the foam midsole component 802 may or may not extend continuous with the
billows
structure 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 structure 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
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or turning actions), and/or at other desired locations (e.g., to provide
desired support
and/or flexibility, including natural motion flexibility characteristics).
[97] The bottom surfaces of either or both of the foam midsole component 802
and/or the
protective component 804 may be provided with additional components. For
example, for at least some portions of the sole structure 800 that will
contact the
ground in use, abrasion resistant or wear resistant material may be applied to
at least
portions of the bottom surfaces of these components, in order to improve their
wear
resistance and durability features. 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. 8E illustrates example 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.
[98] Fig. 9 provides an exploded view of another example sole structure 900 in
accordance
with some examples of this invention. In this sole structure 900, a
lightweight foam
midsole component 902 (e.g., of the types described above) includes a support
surface
902a for supporting all or substantially all of the planter surface of a
wearer's foot. A
foam protective component 904 (optionally including any desired type of
billows
structures) 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). A plurality of outsole protective components
906a,
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906b, 906c, and 906d 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). In this illustrated example, 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), and 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 manner, 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.
[99] While Figs. 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. For example,
if
desired, 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.
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[100] Figs. 10A and 10B show additional features that may be included in sole
structures in
accordance with at least some examples of this invention. Fig. 10A 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.
More specifically, 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).
[101] The bulbous areas 1004a-1004d 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. During a typical step cycle, 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. As the step continues, the
foot rolls
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 midsole
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
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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 midsole component 1002
to provide
additional impact force attenuation and/or a comfortable, soft feel at these
times in the
step cycle.
[102] 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. As shown in this figure, 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. Additionally or
alternatively, if the foam material of the midsole component 1002 is
sufficiently
responsive, at least some of 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).
[103] While four distinct bulbous areas are described and spaced apart in the
manner
described above with respect Fig. 10A, this is not a requirement. Rather, 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
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of the sole structures shown in Figs. 2B-2F, 3A, 3B, and 7, and may be
included in
any desired sole structure.
[104] Figs. 11A-11C show another example basketball shoe 1150 that includes a
sole
structure 1100 in accordance with at least some examples of this invention.
Fig. 11A
is lateral side view of the shoe 1150, Fig. 11B is a medial side view of the
shoe 1150,
and Fig. 11C is a rear heel view of the shoe 1150. This shoe 1150 includes an
upper
1152 having a multi-layered, fuse bonded type of upper construction, although
other
constructions may be used without departing from this invention. The upper
1152 is
engaged with a sole structure 1100 that includes features in accordance with
at least
some examples of this invention. The upper 1152 may be engaged with the sole
structure 1100 in any desired manner without departing from the invention,
including
in conventional manners as are known and used in the art. As some more
specific
examples, the upper 1152 and sole structure 1100 may be engaged with one
another,
for example, by cements or adhesives, by mechanical connectors, by stitching
or
sewing, or the like.
[105] The sole structure 1100 of this illustrated example includes three main
component
parts. The first part constitutes a lightweight (and low density) midsole
component
1102, for example, of the various types described above. This foam midsole
component 1102 may extend to support all or substantially all of the plantar
surface of
a wearer's foot. Portions of the midsole component 1102 are exposed at the
outer
surface of the footwear structure 1150 at various locations in this
illustrated example,
including: (a) along the lateral side edge, at least at the midfoot area (see
Fig. 11A);
(b) at a forward toe area (optionally, at least at the lateral side; see Fig.
11A); (c)
along all or substantially all of the medial side edge (see Fig. 11B); and (d)
at a
portion of the upper rear heel area on the medial side (see Fig. 11C). This
foam
midsole component 1102 provides a soft and comfortable feel for the wearer's
foot, as
generally described above with respect to the other lightweight foam midsole
structures.
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[106] The second part of this example sole structure 1100 is a protective
component 1104
that at least partially contains the foam midsole component 1102. The
protective
component 1104 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 1102. In this
illustrated
example, one portion of the protective component 1104 extends from a lateral
midfoot
and/or heel area of the sole structure 1100, around the rear heel area of the
sole
structure 1100, and over to a medial heel area sole structure 1100. As best
shown in
Fig. 11C, the foam midsole component 1102 extends outward from behind the
protective component 1104 and is exposed at the exterior surface of the shoe
1150 at
the rear heel area of this sole structure 1100. Another portion of the
protective
component 1104 is provided at the lateral forefoot area of the shoe 1150, as
shown in
Fig. 11A. This lateral forefoot portion of the protective component 1104 may
be
integrally formed with the protective component part 1104 at the rear heel
area as a
unitary, one-piece construction, or it may be a separate part. Another portion
of the
protective component 1104 of this example is provided at the extreme forward
toe
area of the sole structure 1100, extending around the forward toe area from
the medial
side to the lateral side. This forward toe lateral forefoot portion of the
protective
component 1104 may be integrally formed with one or more of the other
protective
component parts 1104 described above (as a unitary, one-piece construction),
or it
may be a separate part.
[107] The third part of this example sole structure 1100 is an outsole element
1106, which
also may function as a protective component, that is engaged with the bottom
side of
the midsole foam component 1102 and/or one or more of the polymeric foam
protective components 1104. The outsole element 1106 of this example sole
structure
1100 covers a major portion of the bottom surface of the shoe 1150. It may
include
traction elements, such as grooves, ridges, nubs, herringbone, and/or other
traction
enhancing components. One or more outsole nubs, such as nub 1108, may cover
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directly contact a bulbous area of the bottom surface of the foam midsole
component
1102 (like the bulbous areas described above in conjunction with Fig. 10A to
provide
a soft contact area of the sole structure 1100. As also shown in Fig. 11B,
this example
outsole component 1106 includes an opening defined through it at which a
bottom
surface of midsole member 1102 is exposed.
[108] The outsole element 1106 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 outsole element
1106 may
be formed 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 1106 to flex significantly
between
adjacent lugs 1108 and/or other structural components. In some sole
structures,
portions of outsole element 1106 may be formed from a rubber compound that is
harder and more durable than other portions of the outsole element 1106. The
higher
durability rubber could be used, e.g., in a crash pad located within the heel
region
and/or on the bottoms of lugs located in certain other high pressure regions
that
typically wear more quickly.
[109] As shown in Fig. 11A, the protective component 1104 of this example sole
structure
1100 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. As shown in Fig. 11A, the central billow of the protective element
1104 that
extends around the heel area terminates between billow ridges of a two-billows
structure provided in the foam midsole component 1102 at the lateral midfoot
area (at
termination point 1110). A portion of another, forward billows structure for
the
lateral forefoot protective component 1104 originates in the interstitial area
between
the two billow ridges of the foam midsole component 1102 at point 1112. The
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billows structure of the foam midsole component 1102 originates in
interstitial areas
between billows of the protective elements 1104 located forward and rearward
of that
billows structure of the foam midsole component 1102 (see points 1114).
[110] As shown in Fig. 11C, the three billow structure at the lateral side of
the protective
component 1104 reduces down to a two billow structure at the bottom medial
heel
side of the protective component 1104. As the foam midsole component 1102
emerges from beneath the protective component 1104 at the rear heel area, the
foam
midsole component 1102 forms a two billows structure that overlies the two
billows
structure of the protective component 1104 at the medial side of the sole
structure
1100. Therefore, in this example sole structure 1100, the billows structure
extending
around the heel morphs from a three billows structure on one side to a four
billows
structure on the other side. At the medial side of the sole structure 1100, as
shown in
Fig. 11B, the billows structure of the protective component 1104 terminates at
the
low, medial heel region of the sole structure 1100. The billows structure of
the foam
midsole component 1102 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. 11A and 11B.
[111] While several of the example sole structures described above included:
(a) a foam
midsole component, e.g., made of a lightweight foam material, and (b) another
foam
polymeric material as a protective element, optionally made from a heavier and
denser polymeric foam material, it is not a requirement that a sole structure
in
accordance with this invention have two different polymeric foam materials.
Rather,
as described above with respect to, for example, Figs. 1A-2F, if desired, 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-
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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.
[112] Fig. 12A illustrates a lateral side view, Fig. 12B illustrates a medial
side view, and
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. As some more
specific
examples, 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.
[113] While not required to have any billows structure, 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. As
shown in Fig. 12A, 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
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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.
[114] The single forefoot raised rib 1218 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 billows 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, however,
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.
[115] 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. In this example structure 1200, notably 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. At
this location, 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
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big toe area of the wearer, 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.
[116] 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.
In this
illustrated example, the support ribs 1230 are angled in a top rear-to-bottom
forward
direction. The ribs 1230, however, 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. As additional examples, 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).
[117] These 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.
[118] Also, 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. When
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more than one rib is present in a series on a sole structure 1200, 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.
[119] Turning now to Fig. 12C, the outsole structure 1206 (or protective
element) of this
example article of footwear 1250 will be described in more detail. 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_ If desired, 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.
[120] This outsole element 1206 is made from a thin, higlhly 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. 12C shows the nubs 1240 as generally square or rectangular
and
substantially arranged in rows or cohimns (as a matrix), any desired nub
shape(s)
and/or nub arrangement(s) and/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 Appin. No. 13/693,596
filed
December 4, 2012, published as U.S. Patent Appin. Publication No.
2014/0150297,
and entitled "Article of Footwear".
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[121] 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. In some sole structures, 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. The
higher
durability or thicker rubber could be used, e.g., in a crash pad area 1244
located
within the heel region, on the bottoms of lugs located in certain other high
pressure
regions that typically wear more quickly, along the lateral edge of the
outsole 1206,
etc. 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.
[122] 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
1202, 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.
III. Conclusion
[123] The present invention is disclosed above and in the accompanying
drawings with
reference to a variety of examples. The purpose served by the disclosure,
however, is
to provide examples of the various features and concepts related to the
invention, not
to limit the scope of the invention. Features of one example structure may be
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provided, used, and/or interchanged in some of the other structures, even
though that
specific combination of structures and/features is not described. One skilled
in the
relevant art will recognize that numerous variations and modifications may be
made
to the structures- described above without departing from the scope of the
present
invention, as defined by the appended claims.
53
