ARTICLE OF FOOTWEAR WITH SOLE PLATE

A sole assembly for an article of footwear. The sole assembly includes a top midsole layer, a bottom midsole layer and a plate disposed between the top midsole layer and the bottom midsole layer. The plate includes a forefoot portion with lateral, medial and central longitudinal extensions, and a heel portion with a heel cup and a heel flange extending outwardly from the heel cup. The central and lateral longitudinal extensions are joined by a bridge. The top midsole layer is seated within the heel cup and does not cover the upper surface of the heel flange. The bottom midsole layer underlies and supports the heel flange.

BACKGROUND OF THE INVENTION

The present invention relates to footwear, and more particularly to footwear incorporating a sole assembly have a plate.

A typical article of footwear includes an upper joined to a sole or sole assembly. The sole underlies the wearer's foot and provides a ground-engaging surface that protects the wearer's foot. In addition to protecting the wearer's foot, soles are often designed to provide the desired support, cushioning and energy return. To achieve these objectives, footwear is available with a wide variety of different soles or sole assemblies. In many articles of footwear, the sole assembly incorporates a plate that is substantially more rigid than the cushioning materials incorporated into the sole assembly. The plate is designed to bend under load during an initial portion of the wearer's stride to store energy and then to return to its original shape as the load is reduced during a later portion of the wearer's stride, for example, during toe off.

The properties of a sole assembly are complex and depend greatly on a variety of factors, most notably the design and configuration of the plate and the cushioning materials with which the plate is combined. As a result, a wide range of plated sole assemblies have been developed for a variety of different applications, such as hiking, walking, running and leisure activities. For example, the rigidity of the plate, the position of the plate within the sole assembly, the shape of the plate, the material from which the plate is manufactured, the cushioning properties of the cushioning materials (e.g. midsole), the position of the cushioning material relative to the plate and the wearer's foot are all factors that contribute to the overall properties of the sole assembly. More rigid plates can be used to provide enhanced support when desired, but they can increase weight and make the sole assembly less comfortable and overly stiff for a range of applications. By changing the size, shape and configuration of the plate, the support and energy return properties provided by the plate can be localized or otherwise controlled to contribute to the overall characteristics of the sole assembly. Similarly, the cushioning materials can be designed to accommodate the plate and to give the sole assembly the cushioning, comfort and energy return characteristics desired. Too little cushioning material may not provide adequate cushioning and may reduce the comfort level of the sole assembly. On the other hand, too much cushioning material may make the sole assembly excessively thick and may reduce the effectiveness of the plate by absorbing too much of the energy returned by the plate.

As can be seen, a variety of properties can be deliberately adjusted to tune a plated sole assembly for the intended application. Despite this general understanding within the footwear industry, ideal plated sole assemblies have not been developed for many different footwear applications. As a result, there remains a need for a plated sole assembly that provides an optimized combination of support, cushioning and energy return for use in an article of footwear intended for use in the field of running and other athletic activities.

SUMMARY OF THE INVENTION

An article of footwear includes a sole assembly have a plate disposed between top and bottom midsole layers. The plate includes a heel portion, an arch portion and a forefoot portion. The forefoot portion includes a medial extension that extends generally longitudinally along the medial edge of the forefoot region, a central extension that extends longitudinally through the approximate center of the forefoot region and a lateral extension that extends longitudinally along the lateral edge of the forefoot region. The central and lateral longitudinal extensions are joined to one another at their forward ends.

In one embodiment, the heel portion of the plate includes a peripheral region that is curved upwardly to provide a somewhat concave seat for the heel of the wearer's foot. In one embodiment, the arch portion also includes a peripheral region that extends upwardly in concert with the peripheral region of the heel portion, whereby the arch region and heel region cooperatively define a heel cradle that begins in the arch portion and extends to the rearmost end of the plate. The heel cradle receives the heel portion of the top midsole layer and, when worn, receives the heel of the wearer's foot. The complex curvature of the plate in the heel region also enhances the rigidity of the plate in the heel region where the force of heel strike is primarily focused.

In one embodiment, an opening is defined through the approximate center of the heel region of the plate. The opening may be generally oval being extended in the longitudinal direction. The heel opening allows communication between the upper midsole layer and the bottom midsole layer in the approximate center of the heel region, thereby providing enhanced centering and cushioning of the wearer's foot while also reducing the weight of the plate.

In one embodiment, the medial extension is curved and extends along the medial peripheral edge of the sole beginning at the forward end of the arch region and extending forwardly to at least a point under the great toe. The medial extension may be offset inwardly from an extend parallel to the medial edge of the sole assembly.

In one embodiment, the lateral extension is curved and extends along the lateral peripheral edge of the sole beginning at the forward end of the arch region and extending forwardly to at least a point under the small toes. The lateral extension may be offset inwardly from and extend parallel to the lateral edge of the sole assembly.

In one embodiment, the central longitudinal extension is generally straight beginning at the forward end of the arch region and extending forwardly to a point between the end of the medial longitudinal extension and the lateral longitudinal extension.

In another embodiment, the plate includes a lateral bridge extending somewhat laterally between the forward ends of the central extension and the lateral extension. The bridge may have approximately the same width as the central extension and the lateral extension. In one embodiment, the central extension, lateral extension and lateral bridge cooperatively define a closed opening in the forefoot region.

In still another embodiment, the heel region of the upper midsole layer is disposed in the heel cradle. The upper midsole layer may be supported upon the plate with its peripheral edge remaining separate from the lower midsole layer. In one embodiment, the peripheral edges of the upper midsole layer and the lower midsole layer are separated through the heel portion or separated through both the arch portion and the heel portion.

In one embodiment, the peripheral edge of the plate flares outwardly to define a heel flange extending around at least a portion of the heel region of the plate. The heel flange may extend along a plane. The heel flange may include an upwardly facing surface that is exposed around at least a portion of the heel portion. In one embodiment, the upper midsole layer terminates short of the heel flange on the lateral side, the medial side and the rear end of the sole assembly. In such embodiments, the upper midsole layer may be adhesively joined to the upper surface of the plate, excluding the upper face of the flange.

In one embodiment, the lower midsole layer is wider than the upper midsole layer in at least a portion of the heel region. In one embodiment, the lower midsole layer extends beneath the heel flange of the plate and is in direct contact therewith. As a result, the portions of the lower midsole layer beneath the heel flange provide additional cushioning and support for the wearer's foot, especially during heel strike.

In yet another embodiment, an outsole is disposed on the undersurface of the bottom midsole layer. If included, the outsole may cover all of the undersurface or it may cover one or more portions of the undersurface. The outsole may be formed by a single continuous section of outsole material or it may be formed by a plurality of separate segments of outsole material that cooperate to cover different portions of the undersurface. In some embodiments, the outsole (whether continuous or in separate parts) is secured to the undersurface of the bottom midsole layer by adhesive

In one embodiment, the peripheral edges of the bottom surface of plate are exposed in the arch region. For example, the bottom midsole layer may include medial and lateral recesses that expose portions of the bottom surface of the plate. In some application, the size and shape of the recesses may be selected to tune the cushioning, support and energy return characteristics of the plate, particularly in the arch region.

In yet another embodiment, the upper, top midsole layer, plate and bottom midsole layer may have a stepped arrangement in the heel portion that is configured to provide the sole with the desired cushioning, support and energy return characteristics. In one embodiment, the top midsole layer extends outwardly beyond the lateral, medial and rear extents of the upper in the heel region. In one embodiment, the plate extends outwardly beyond the lateral, medial and rear extents of the top midsole layer. In one embodiment, the bottom midsole layer extends outwardly beyond the lateral, medial and rear extents of the top midsole layer and/or the plate in the heel region. The stepped arrangement provides the sole assembly with broad support for the heel on the lateral side, the medial side and the rear while reducing the breadth of the top midsole layer to enhance the cushioning feel above the plate.

The current embodiments relate to a sole construction having a unique arrangement of a top midsole layer, a plate and a bottom midsole layer that provide optimal support, cushioning and energy return through the gait cycle from heel strike to toe off. Among other things, the plate provides the forefoot with substantial longitudinal support while still allowing a desirable amount of lateral flexibility. The use of a separate medial extension and joined central and lateral extensions gives the great toe enhanced, independent flexibility while helping to maintain a greater level of lateral support for the remaining toes. The heel cradle helps to center and support the wearer's foot, as well as to provide optimized energy return following heel strike. The incorporation of a stepped configuration broadens the ground engaging surface to provide enhanced support and cushioning. The heel flange extends outwardly over the broadened bottom midsole layer, thereby receiving support and cushioning from the additional cushioning material disposed thereunder.

DETAILED DESCRIPTION OF THE CURRENT EMBODIMENTS

An article of footwear in accordance with a current embodiment of the present invention is shown inFIG.1and generally designated10. The article of footwear10includes a sole assembly12that incorporates a top midsole layer14, a plate16and a bottom midsole layer18. The sole assembly106may also include an outsole50that is joined to the bottom surface of the bottom midsole layer18. The top midsole layer14, the plate16and the bottom midsole layer18are configured to provide enhanced support, cushioning and energy return. In this embodiment, the plate16includes a forefoot portion20with a medial extension22, a central extension24and a lateral extension26. The central extension24and the lateral extension26of this embodiment are joined to one another by a bridge28at their forward ends. The plate16also includes a heel portion30that includes a heel cup32and a peripheral heel flange34. In this embodiment, the top midsole layer14is secured within the heel cup32and does not extend over the heel flange34, while the bottom midsole layer18is broader than the top midsole layer14and extends beneath and supports the heel flange34.

Although a current embodiment is illustrated in the context of a running shoe, the sole assembly thereof can be incorporated into any type or style of footwear, including performance shoes, trail shoes and boots, work boots, all-terrain shoes, hiking shoes, athletic shoes, running shoes, sneakers, conventional tennis shoes, walking shoes, multisport footwear, casual shoes, dress shoes or any other type of footwear or footwear components. It also should be noted that directional terms, such as “vertical,” “horizontal,” “top,” “bottom,” “upper,” “lower,” “inner,” “inwardly,” “outer” and “outwardly,” are used to assist in describing the invention based on the orientation of the embodiments shown in the illustrations. Further, the terms “medial,” “lateral” and “longitudinal” are used in the manner commonly used in connection with footwear. For example, when used in referring to a side of the shoe, the term “medial” refers to the inward side (that is, the side facing the other shoe) and “lateral” refers to the outward side. When used in referring to a direction, the term “longitudinal direction” refers to a direction generally extending along the length of the shoe between toe and heel, and the term “lateral direction” refers to a direction generally extending across the width of the shoe between the medial and lateral sides of the shoe.

The use of directional terms should not be interpreted to limit the invention to any specific orientation. Further, as used herein, the term “arch region” (or arch or midfoot) refers generally to the portion of the footwear or sole assembly corresponding to the arch or midfoot of the wearer's foot; the term “forefoot region” (or forefoot) refers generally to the portion of the footwear forward of the arch region corresponding to the forefoot (for example, including the ball and the toes) of a wearer's foot; and the term “heel region” (or heel) refers generally to that portion of the footwear rearward of the arch region corresponding to the heel of the wearer's foot. The forefoot region100, arch region or mid-foot region102, and heel region104generally are identified inFIG.1; however, delineation of these regions may vary depending upon the configuration of the sole assembly and/or footwear.

The footwear10can include a textile upper106joined with the sole assembly12. The upper106can be formed from a variety of material elements joined together to cover at least a portion of the wearer's foot. The material elements can be selected based on the intended uses of the article of footwear10, and can include synthetic textiles, mesh textiles, polymers or leather, for example. The upper106can be constructed to improve the rigidity of the sole assembly12. For example, the upper can be constructed from leather, plastic, canvas or other materials. The upper106can include one or more closure elements, including, for example, shoelaces. The upper106additionally includes an upper opening for receiving the wearer's foot. The upper106may be affixed to sole assembly12using essentially any form of attachment. For example, the bottom of the upper106may be closed by a Strobel board (not shown) in a conventional manner, and the bottom edge of the sidewall of the upper106and the bottom surface of the Strobel board may be secured to the sole assembly106by an adhesive. The joining of the sole assembly12and the upper106can be accomplished using adhesives, cement, injection molding, pour molding or any other technique used to join an upper and sole assembly.

An insole, inner sole or footbed (not shown) can be positioned within the void defined by the upper106. The insole can be constructed from a sheet of material, such as foam, EVA, PU, latex, gel or other materials, and by virtue of its compressibility, provide cushioning, and may also conform to the foot in order to provide comfort, support, and stability. The insole (not shown) need not be constructed from a sheet material, but may instead be formed by other techniques, such as injection molding, compression molding or additive manufacturing.

The sole assembly12will now be described in further detail with reference toFIGS.2-12.FIGS.2,3and5show the sole assembly12separated from the upper106. As mentioned above, the sole assembly12of the illustrated embodiment includes a top midsole layer14, a plate16, a bottom midsole layer18and an outsole50(as perhaps best shown in the exploded view ofFIG.4). The plate16is disposed between the top midsole layer14and the bottom midsole layer18.

The top midsole layer14is configured to generally extend the full length and width of the sole assembly12to provide a platform to receive and support (directly or indirectly) the wearer's foot. In the illustrated embodiment, the upper surface40of the top midsole layer14is curved to provide a three-dimensional recess configured to receive the bottom of the upper106and to provide a comfortable seat for the wearer's foot. The curvature may be selected to correspond anatomically with the shape of the bottom surface of the wearer's foot. In this embodiment the peripheral margin42of the top midsole layer14is raised above the bottom extent of the upper106. This allows the top midsole layer14to extend up around the bottom of the upper106to facilitate a durable and aesthetically pleasing connection. The raised peripheral margin42helps to center and retain the wearer's foot on the sole assembly12. The thickness of the top midsole layer14may vary to provide the desired support, cushioning and energy return profile. For example, in the illustrated embodiment, the top midsole layer14is thinner in the heel region104and gradually thickens through the arch region102into the forefoot region100with its maximum thickness in the approximate center of the forefoot region100so that the top midsole layer14provides the greatest degree of cushioning below the metatarsal heads of the wearer's foot (seeFIG.11).

In the illustrated embodiment, the sole assembly12is configured to provide a support platform that is broader than the extents of the upper106. As shown inFIGS.1,5,10and11, the top midsole layer14extends outwardly beyond the periphery of the upper106in the heel region104on the lateral side, the medial side and the rear of the footwear10. Additionally, the bottom midsole layer18extends beyond the periphery the top midsole layer14in the heel region on the lateral side, the medial side and the rear of the footwear10.

As noted above, the plate16is disposed between the top midsole layer14and the bottom midsole layer18and is configured to provide the sole assembly12with the desired support, cushioning and energy return characteristics. Referring now toFIG.6, the plate16generally includes a forefoot portion20extending through the forefoot region100of the sole assembly12, an arch portion36extending through the arch region102of the sole assembly12and a heel portion30extending through the heel region104of the sole assembly. As shown, the plate16may begin close to the rearmost extend of the sole assembly12and continue forwardly into the forefoot region100terminating somewhat short of the forwardmost end of the sole assembly12. The plate14includes a plurality of longitudinal extensions running through the forefoot region100. The forefoot portion20of the plate14of the illustrated embodiment includes a medial extension22that extends generally longitudinally along the medial edge of the sole assembly12through the forefoot region100, a central extension24that extends longitudinally through the approximate center of the forefoot region100and a lateral extension26that extends longitudinally along the lateral edge of the sole assembly12in the forefoot region100. In this embodiment, the central and lateral longitudinal extensions are joined to one another at their forward ends by bridge28.

In the illustrated embodiment, the medial longitudinal extension22is curved and extends along the medial peripheral edge of the sole assembly12beginning at the forward end of the arch region and extending forwardly at least to a point underlying a portion of the distal phalanx of the great toe (seeFIGS.8,12and13). The medial longitudinal extension22may in one embodiment extend to a point below the phalanges, the proximal phalanx or below the distal phalanx of the great toe. The configuration of the medial longitudinal extension22may vary from application to application. For example, the length, width, curvature and thickness of the medial longitudinal extension22, as well as the offset from the medial edge of the sole assembly12, may vary.

The lateral longitudinal extension26of the illustrated embodiment is also curved in a manner similar to the medial longitudinal extension22. As shown inFIGS.8,12and13, the lateral longitudinal extension26extends along the lateral peripheral edge of the sole assembly12beginning at the forward end of the arch region102and extending forwardly at least to a point underlying a portion of the middle phalanx of the 4thand/or 5thtoes. The lateral longitudinal extension26may in one embodiment extend to a point below the phalanges, the proximal phalanges, the intermediate phalanges or the distal phalanges of the 4thand/or 5thtoes. The configuration of the lateral longitudinal extension26may vary from application to application. For example, the length, width, curvature and thickness of the lateral longitudinal extension26, as well as the offset from the lateral edge of the sole assembly12, may vary.

The central longitudinal extension24of the illustrated embodiment is generally straight beginning at the forward end of the arch region102and extending forwardly at least to a point underlying a portion of the middle phalanx of the 2ndand/or 3rd toes (seeFIGS.8,12and13). In this embodiment, a lateral bridge28extends between the forward ends of the central extension24and the lateral extension26. The central longitudinal extension24may in one embodiment extend to a point below the phalanges, the proximal phalanges, the intermediate phalanges or the distal phalanges of the 2ndand/or 3rd toes. The central longitudinal extension24may vary from application to application. For example, the length, width, curvature and thickness of the central longitudinal extension24may vary.

As discussed above, the illustrated plate16includes a bridge28that joins the central longitudinal extension24and the lateral longitudinal extension26to provide enhanced stability and support for the 2nd-5thtoes. The bridge28may in one embodiment extend beneath the phalanges, the proximal phalanges, the intermediate phalanges or the distal phalanges of the 2nd-5thtoes. As shown, the central longitudinal extension24, the lateral longitudinal extension26and the lateral bridge28cooperatively define a closed opening44in the forefoot region100. The central and lateral longitudinal extensions may be varied to alter the size, shape and/or configuration of the closed opening44.

Referring now toFIGS.6and9-11, the heel portion30of the illustrated plate16is shaped to provide a heel cup32. More specifically, the heel portion includes a gradual upwardly opening curve that helps to seat and center the wearer's foot on the sole assembly12. In this embodiment, the arch portion36is also curved upwardly in concert with the peripheral region of the heel portion30, such that the heel portion30and the arch portion36cooperatively define an extended heel cup32that begins at the back of the heel and extends well into the arch region102. The extents of the heel cup32may vary from application to application.

Referring now toFIGS.6,10and11, an opening46is defined through the approximate center of the heel portion30. The opening46may be generally oval being extended in the longitudinal direction. The heel opening46allows communication between the top midsole layer14and the bottom midsole layer18in the approximate center of the heel region104, thereby providing enhanced centering and cushioning of the wearer's foot while also reducing the weight of the plate16. The size, shape and configuration of the heel opening46may vary from application to application to tune the support, cushioning and energy return characteristics of the sole assembly12. In some applications, the heel opening46may be eliminated.

In the illustrated embodiment, the peripheral edge of the plate16flares outwardly in the heel region104to define a heel flange34extending around at least a portion of the heel region30of the plate16. As perhaps best shown inFIGS.6,10and11, the heel flange34of the illustrated embodiment extends along a plane and is generally crescent-shaped, but it may in alternative embodiments be nonplanar and have different shapes. In the illustrated embodiment, the heel portion of the top midsole layer14terminates short of the heel flange34, thereby leaving the top surface of the heel flange34exposed. More specifically, as shown inFIGS.5,10and11, the illustrated heel flange34includes an upwardly facing surface that is exposed around at least a portion of the heel region30and a downwardly facing surface that is in direct contact with the bottom midsole layer18as discussed in more detail below.

In this embodiment, the top midsole layer14is adhesively joined to the upper face of the plate16, excluding the upper face of the heel flange34(which, as noted above, is exposed and not covered by the top midsole layer16). The top midsole layer14may also be adhesively joined to the upper face of the bottom midsole layer14in those regions in which the bottom surface of the top midsole layer14and the surface of the bottom midsole layer18come into contact, such as through the heel opening46, around the periphery of the forefoot region and through the spaces between the longitudinal extensions22,24and26. The top midsole layer14and/or the bottom midsole layer18may be recessed to accommodate the plate16. For example, the bottom surface of the top midsole layer14may define a recess70that corresponds with the plate16. In this embodiment, the recess70is essentially coextensive with the plate16and is essentially the same thickness as the plate16so that the bottom surface of the plate16is essentially flush with the bottom surface of the top midsole layer14surrounding the recess70. In alternative applications, the plate16may be recessed into the bottom midsole layer18or into both the top midsole layer14and the bottom midsole layer18. In alternative applications, the recess may be eliminated in its entirety.

In the illustrated embodiment, the bottom midsole layer18provides the sole assembly12with a cushioning, support and energy return layer disposed generally below the plate16. Referring now toFIGS.5and8-11, the bottom midsole layer18is positioned immediately below the plate16. The bottom midsole layer18of the illustrated embodiment is wider than the top midsole layer14in at least a portion of the heel region. As shown, the illustrated bottom midsole layer18extends beneath and in direct contact with the heel flange34of the plate16. As a result, the portions of the bottom midsole layer18beneath the heel flange34provide additional cushioning, support and energy return that is generally communicated through the plate16.

As noted above, the sole assembly12of the illustrated embodiment includes a stepped arrangement in the heel region104. More specifically, the upper106, top midsole layer14, plate16and bottom midsole layer18ofFIG.1are arranged in a stepped configuration with each component being somewhat wider than the component disposed above. The stepped heel configuration helps to provide the sole with the desired cushioning, support and energy return characteristics. Referring now toFIG.1, the top midsole layer14extends outwardly beyond the lateral, medial and rear extremes of the upper100in the heel region104. Similarly, the plate16of this embodiment extends outwardly beyond the lateral, medial and rear extremes of the top midsole layer14in the heel region104. Further, the bottom midsole layer18of this embodiment extends outwardly beyond the lateral, medial and rear extremes of the top midsole layer14and/or the plate16in the heel region104. The degree of offset between the various layers of the sole assembly12may vary from application to application to provide the desired cushioning, support and energy return characteristics.

In the illustrated embodiment, the peripheral edges of the bottom surface of plate16are exposed on both lateral and medial sides in the arch region102. For example, the bottom midsole layer18may include medial and lateral recesses48that expose portions of the bottom surface of the plate18. The size, shape and configuration of the recesses48may be selected to tune the cushioning, support and energy return characteristics of the plate16, particularly in the arch region102. More specifically, the characteristics of the recesses48may be varied to tune the amount of cushioning material that is engaged with and supports the plate in the arch region102.

In the illustrated embodiment, the bottom midsole layer18may define a forefoot opening60disposed that extends through the bottom midsole layer18from the bottom surface to the top surface. The forefoot opening60may be aligned with and extend along at least a portion of the central longitudinal extension24. The forefoot opening60may reduce the support provided to the central longitudinal extension24by the bottom midsole layer18, thereby giving the central longitudinal extension24additional flexibility along its length. The size, shape and configuration of the forefoot opening60may vary from application to application as desired to tune the characteristics of the sole assembly12.

Similarly, the bottom midsole layer18may define an arch opening62that extends through the bottom midsole layer18in the arch region102. The arch opening62of the illustrated embodiment is generally triangular in shape and extends entirely through the bottom midsole layer18from bottom surface to top surface, such that the plate16is visible through the arch opening62. In some applications, the arch opening62helps to control the amount of support and cushioning in the arch region102and also provides a degree of decoupling between the forefoot and heel portions of the bottom midsole layer18. The size, shape and configuration of the arch opening62may vary from application to application as desired to tune the characteristics of the sole assembly12.

In the illustrated embodiment, the bottom midsole layer18also defines a heel recess64that extends into the bottom of the bottom midsole layer18in the heel region104. The size, shape, depth and configuration of the heel recess64may vary from application to application to tune the properties of the bottom midsole layer18in the heel region104.

In this embodiment, the bottom midsole layer18is adhesively joined to the bottom surface of the plate16and the bottom surface of the top midsole layer14. However, the bottom midsole layer18may be joined to the sole assembly12using other methods. For example, the plate16may be placed in a mold and the top midsole layer14and/or bottom midsole layer18may be molded in place on the plate16as an integral part of the molding process.

As noted above, an outsole50is disposed on the undersurface of the bottom midsole layer18in the illustrated sole assembly12. When included, the outsole50may cover all of the undersurface of the bottom midsole layer18or it may cover one or more different portions of the undersurface of bottom the midsole layer18. The outsole may be formed by a single continuous section of outsole material or it may be formed by a plurality of separate segments of outsole material that cooperate to cover all or different portions of the undersurface. Referring now toFIGS.2,3,8,10and11, the outsole50include a forefoot segment52and a heel segment54. The illustrated forefoot segment52defines a central opening56that is aligned with the forefoot opening60in the bottom midsole layer18, such that the central longitudinal extension24is visible from the bottom of the sole assembly12.

In the illustrated embodiment, the outsole50(whether continuous or in separate parts) is secured to the undersurface of the bottom midsole layer18by adhesive. However, the outsole50may be joined to the undersurface using other methods. For example, the outsole50may be positioned in the mold when the bottom midsole layer18is formed and therefore become joined as an integral part of the molding process.

The top midsole layer14and the bottom midsole layer18may be manufactured from essentially any desirable cushioning material. For example, the two midsole layers may be manufactured from ethyl vinyl acetate (EVA), polyurethane (PU), expanded thermoplastic polyurethane (eTPU) foam, polyether block amide (PEBA/PEBAX) foam, other bead and non-bead foams, a gel or other cushioning materials. In the illustrated embodiment, the top midsole layer14and the bottom midsole layer18are manufactured from eTPU or PEBA bead foams. While the top midsole layer14and the bottom midsole layer18are manufactured from the same material in the illustrated embodiment, the two midsole layers may be manufactured from different materials or from the same material, but with different cushion properties (such as different durometers).

The plate16may be manufactured from essentially any material and will typically be manufactured from a material that is more rigid than the material used to manufacture the midsole layers14and18. In the illustrated embodiment, the plate16is manufactured from nylon. For example, the plate16may be molded from nylon stock or formed from a sheet of nylon. Although the plate16of the illustrated embodiment is manufactured from a single layer of material, the plate16may in alternative embodiments be constructed from multiple layers. For example, the plate16can be constructed from a composite material, such as layers of carbon fabric that are each weaved from carbon strands. It also will be appreciated that the plate can be constructed from other polymer materials, such as polymers, metals, composited and combinations thereof.

The outsole50can be manufactured from one or more materials, for example, natural or synthetic rubber, thermoplastic polyurethane elastomers (TPU), nylon, polymer blends, wear resistant polymers, elastomers and/or other materials. Other materials, such as fiber-reinforced polymers can be used, which can include epoxy, polyethylene or thermosetting plastic reinforced with carbon, glass and/or aramid fibers for enhanced protection. The outsole50can include multiple lugs and/or treads that extend downward or that are defined by recesses into the bottom surface of the outsole, or alternatively can be relatively featureless, forming a smooth surface. Where present, the lugs and treads can be arranged as desired, and alternatively in a repeating pattern. The lugs and treads can include one or more geometric shapes.

Although the different elements and assemblies of the embodiments are described herein as having certain functional characteristics, each element and/or its relation to other elements can be depicted or oriented in a variety of different aesthetic configurations, which support the ornamental and aesthetic aspects of the same. Simply because an apparatus, element or assembly of one or more of elements is described herein as having a function does not mean its orientation, layout or configuration is not purely aesthetic and ornamental in nature.

In addition, when a component, part or layer is referred to as being “joined with,” “on,” “engaged with,” “adhered to,” “secured to,” or “coupled to” another component, part or layer, it may be directly joined with, on, engaged with, adhered to, secured to, or coupled to the other component, part or layer, or any number of intervening components, parts or layers may be present. In contrast, when an element is referred to as being “directly joined with,” “directly on,” “directly engaged with,” “directly adhered to,” “directly secured to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between components, layers and parts should be interpreted in a like manner, such as “adjacent” versus “directly adjacent” and similar words. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.