Sole assembly with gas and viscous fluid-filled bladder assembly

A bladder assembly for an article of footwear includes a main body. The main body defines a first chamber and a second chamber, and the second chamber includes a first inner surface and a second inner surface. The bladder assembly also includes a viscous fluid contained in the first or second chamber and a gas contained in the other of the first or second chamber. Furthermore, the bladder assembly includes a fabric member that is fixed to both the first and second inner surfaces. The fabric member limits movement of the first and second inner surfaces away from each other.

FIELD

The present disclosure relates generally to a sole assembly and, more particularly, to a sole assembly with a gas and viscous fluid-filled bladder assembly.

BACKGROUND

Articles of footwear usually include an upper and a sole assembly. The upper can include sections of thin material, straps, laces, and the like for covering the wearer's foot and securing the footwear to the wearer. The sole assembly can include an outsole that is typically a unitary piece of relatively durable, high-friction material that provides traction for the footwear. Also, the sole assembly can include a midsole that resiliently deforms to provide cushioned support for the wearer.

In some cases, the midsole can include a single, unitary foam member that conforms to the curvatures of the foot and that resiliently deforms for cushioning the wearer. In other cases, the midsole can include one or more bladders that are fluid filled.

SUMMARY

A bladder assembly for an article of footwear is disclosed that includes a main body. The main body defines a first chamber and a second chamber, and the second chamber includes a first inner surface and a second inner surface. The bladder assembly also includes a viscous fluid contained in the first or second chamber and a gas contained in the other of the first or second chamber. Furthermore, the bladder assembly includes a fabric member that is fixed to both the first and second inner surfaces. The fabric member limits movement of the first and second inner surfaces away from each other.

Furthermore, an article of footwear is disclosed that includes an upper and a sole assembly that is operably coupled to the upper. The sole assembly includes a bladder assembly with a main body. The main body defines a first chamber and a second chamber, and the second chamber includes a first inner surface and a second inner surface. The bladder assembly also includes a viscous fluid contained in the first or second chamber and a gas contained in the other of the first or second chamber. Furthermore, the bladder assembly includes a fabric member that is fixed to both the first and second inner surfaces. The fabric member limits movement of the first and second inner surfaces away from each other.

Still further, an article of footwear is disclosed that includes an upper, an outsole, and a midsole assembly operably coupled to both the upper and the outsole. The midsole includes a bladder assembly, which includes a first sheet and a second sheet. The first and second sheets overlap each other and are sealed together at a substantially continuous peripheral seal to define a first chamber. The first and second sheets are additionally sealed at a plurality of internal seals surrounded by the peripheral seal to define a plurality of second chambers and a plurality of channels that fluidly connect respective ones of the second chambers. Furthermore, the footwear includes a viscous fluid contained within the first chamber. The viscous fluid includes gel and/or a flowable clay. The footwear additionally includes a gas contained within each of the plurality of second chambers and the plurality of channels. Moreover, the footwear includes a plurality of compressible fabric members, each contained within respective ones of the second chambers, and each including a first fabric layer and a second fabric layer and a plurality of connecting filaments extending between the first and second fabric layers. The first fabric layer is fixed to the first sheet, and the second fabric layer is fixed to the second sheet. The plurality of connecting filaments limit movement of the respective first and second fabric layers away from each other to maintain at least a portion of the respective second chamber substantially flat.

DETAILED DESCRIPTION

Referring initially toFIGS. 1-3, an exemplary embodiment of an article of footwear10is illustrated according to various teachings of the present disclosure. Generally, the article of footwear10includes an upper12and a sole assembly14. The sole assembly14is operatively coupled to the upper12and can include an outsole16and a midsole assembly18. Although the article of footwear10is illustrated as an athletic shoe, it will be appreciated that the footwear10could be a boot, a sandal, or any other type without departing from the scope of the present disclosure.

In some embodiments, the upper12can include various thin sheets of material that partially overlap each other and that are operably secured to each other, for example, by stitching, adhesives, and the like. The upper12can also include a fastening structure, such as laces, buckles, pile tape, and/or other features for tightly securing the upper12to a wearer's foot13(shown in phantom inFIG. 2). It will also be appreciated that the upper12can include various decorative features for aesthetically enhancing the footwear10.

Also, the outsole16can include a layer of high-friction material (e.g., rubber, etc.) for providing traction. Moreover, the midsole assembly18can be disposed between and operably coupled to both the outsole16and the upper12. The midsole assembly18can provide cushioned support for the wearer's foot13as will be discussed in greater detail below.

As shown inFIG. 3, the midsole assembly18can include a first portion20, a second portion22, and a bladder assembly24, which is disposed between the first and second portions20,22. The bladder assembly24can be overlapped on opposite sides by the first and second portions20,22. Also, in some embodiments, the bladder assembly24can be operably coupled to (e.g., fixed to) the first portion20and/or the second portion22. For instance, the bladder assembly24can be embedded in the first portion20and/or the second portion22, for instance, using a molding process, via adhesives, and the like. Also, in some embodiments, the bladder assembly24can be separate (i.e., unattached) from the first portion20and/or the second portion22.

The first and second portions20,22can be made of or include a layer of polymer (e.g., foam, etc.) that is resiliently flexible and resiliently compressible. The first and/or second portions20,22can be contoured in a manner that conforms to the foot13.

Also, the bladder assembly can define a first chamber26and one or more second chambers28a-28j. The first chamber26can contain a viscous fluid30, such as a gel or flowable clay. The second chambers28a-28jcan contain a gas32, such as air. In additional embodiments, the first chamber26contains the gas32while the second chambers28a-28jcontain the fluid30. Moreover, one or more fabric members34can be encapsulated within respective second chambers28a-28j. In some embodiments, the fabric members34are cylindrically shaped with a diameter D and a thickness T that is less than the diameter D (FIG. 5). Accordingly, different portions of the bladder assembly24can provide different types and different levels of support of the wearer's foot13as will be discussed in greater detail below.

Referring now toFIGS. 1-5, the bladder assembly24will be discussed in greater detail. The bladder assembly24can include a main body36that defines the first and second chambers26,28a-28j. More specifically, the bladder assembly24can include a first sheet38and a second sheet40(seeFIG. 2). The first and second sheets38,40can each be made of or include a polymeric material. As shown inFIG. 2, the first and second sheets38,40can overlap each other and can be coupled together at various locations to define the first and second chambers26,28a-28j. More specifically, the first and second sheets38,40can be sealed or bonded together (e.g., hermetically sealed) by a known plastic welding process to define various seals42,44or weldments. Also, in some embodiments, the first and second sheets38,40can be joined and sealed together by other suitable means, such as adhesives.

In the embodiments shown inFIGS. 1-5, the first and second sheets38,40can be sealed together at a peripheral seal42. The peripheral seal42can extend continuously about the periphery of the main body36of the bladder assembly24. Also, the first and second sheets38,40can be sealed together at an internal seal44. The internal seal44can extend continuously, and can be surrounded and spaced apart from the peripheral seal42. Accordingly, the first chamber26can be defined between the peripheral seal42and the internal seal44(i.e., between the peripheral seal42and the second chambers28a-28j).

The internal seal44can define the plurality of second chambers28a-28j, which are substantially circular in some embodiments. The internal seal44can also define a plurality of channels46a-46i, which are elongate and fluidly connected at both ends to respective pairs of second chambers28a-28j. The channels46a-46ican provide fluid communication between the plurality of second chambers28a-28j.

It will be appreciated that the first chamber26, the second chambers28a-28j, and the channels46a-46ican be disposed, positioned, and arranged in any suitable location in the article of footwear10. Also, it will be appreciated that the bladder assembly24can include a plurality of first chambers26. Moreover, it will be appreciated that the bladder assembly24can include any suitable number of second chambers28a-28jand channels46a-46j.

In the embodiments illustrated inFIGS. 1-5, the footwear10can include ten second chambers28a-28jthat are linked in a “chain” by respective channels46a-46j. The “chain” of second chambers28a-28jand channels46a-46jcan extend over a forefoot region50of the bladder assembly24, across a midfoot region54of the bladder assembly24, and over a rearfoot region52of the bladder assembly24. More specifically, one end of the “chain” (i.e., the second chamber28a) can be disposed in the forefoot region50to be disposed generally underneath the big toe of the foot13. The “chain” can extend anteriorly toward the second chambers28c. Then, the “chain” can extend posteriorly along the lateral side of the foot13to the rearfoot region52such that the second chamber28iis disposed generally underneath the heel of the foot13. Then, the “chain” can extend anteriorly and can end at the second chamber28j.

The first chamber26can also extend across each of the forefoot, rearfoot, and midfoot regions50,52,54. In the embodiments shown, the first chamber26is disposed primarily on the periphery and other areas that correspond to lower stress points of the foot13.

As mentioned above, the first chamber26can contain a viscous fluid30(FIGS. 2 and 5). The viscous fluid30can be of any suitable type and can have any suitable viscosity. In some embodiments, the viscous fluid30can be a gel or a flowable clay. Accordingly, the fluid30can flow within the first chamber26to allow the first chamber26to deflect (e.g., due to compression loads from the foot13). Thus, the first chamber26can closely conform to the shape of the foot and provide a high level of cushioned support.

Moreover, as mentioned above, the gas32can be contained in and can flow through the second chambers28a-28jand the channels46a-46j. The gas32can be of any suitable type (e.g., oxygen, nitrogen, helium, etc.). Also, the gas32can be at any suitable pressure.

In addition, as mentioned above, the second chambers28a-28jcan each encapsulate a respective fabric member34. The fabric member34and/or the bladder assembly24can incorporate any of the features disclosed in U.S. Pat. No. 4,906,502, issued Mar. 6, 1990 to Rudy and U.S. Pat. No. 5,083,361, issued Jan. 28, 1992, to Rudy, which are hereby incorporated by reference in their entireties.

Thus, as shown inFIG. 5, each fabric member34can include a first fabric layer60and a second fabric layer62. The first and second fabric layers60,62can have any suitable shape. In some embodiments, the first and second fabric layers60,62can be flat and rounded (e.g., substantially circular with a diameter D). Also, the fabric members34can each include a plurality of connecting filaments64that are connected to and that extend transversely between the respective first and second fabric layers60,62. The filaments64can be flexible, but non-elastic when in tension.

Moreover, the first fabric layer60can be operably coupled (e.g., fixed) to an inner surface66of the first sheet38of the bladder assembly24within the respective second chamber28a-28j. Likewise, the second fabric layer62can be operably coupled (e.g., fixed) to an inner surface68of the second sheet40of the bladder assembly24within the respective second chamber28a-28j. The first and second fabric layers60,62can be coupled to the first and second sheets38,40, respectively, in any suitable manner, such as adhesives.

Accordingly, the gas32within the second chambers28a-28jcan inflate the second chambers28a-28jand also place the filaments64in tension. The length of the filaments64can be such that the fabric member34can have a thickness T (FIG. 5). In some embodiments, each fabric members34can occupy the majority of the volume V of the respective second chamber28a-28j. More specifically, the peripheral volume of each fabric member34(peripheral volume=π(D/2)2(T)) occupies a majority of the volume V of the respective second chamber28a-28j.

Thus, because the first and second fabric layers60,62are operably coupled to the first and second sheets38,40, respectively, the filaments64can limit movement of the first and second fabric layers60,62(and, thus, the first and second sheets38,40) away from each other. More specifically, when the second chambers28a-28jare subject to a compressive load, the second chamber28a-28jcan compress and reduce the thickness T of the respective fabric member34. In some embodiments, the filaments64do not resist this compression. The second chambers28a-28jcan resiliently recover such that the fabric member34regains its total thickness T, limited by the length of the filaments64. As shown inFIG. 5, the fabric member34can maintain at least a portion of the respective second chamber28a-28jin a substantially flat state. More specifically, as shown inFIG. 5, the first sheet38and the second sheet40of the second chamber28hcan be substantially flat. This feature can improve the fit and feel of the footwear10and the second chambers28a-28jcan better support the foot13.

In some embodiments, the second chambers28a-28jcan be pressurized such that the second chambers28a-28jare more stiff (e.g., more resistant to compressive deformation) than the first chamber26. As mentioned above, the second chambers28a-28jcan be positioned in areas corresponding to higher-stress portions of the foot13as compared to the first chamber26. Thus, the second chambers28a-28jcan support these higher-stress areas and provide resiliency, whereas the first chamber26can readily deform to conform to the lower-stress areas of the foot13. Accordingly, the bladder assembly24can provide a high degree of comfort and cushioned support for the wearer, across a wide range of activities.