Abstract:
A method of forming a sole assembly of an article of footwear that includes an interior space that receives a foot of a wearer is disclosed. The article of footwear also includes an exterior surface. The method includes providing a first portion of the sole assembly. The first portion includes a first surface that at least partially defines the interior space. The first portion also includes a first chamber surface that opposes the first surface. Moreover, the method includes providing a second portion of the sole assembly. The second portion includes a second surface that at least partially defines the exterior surface of the article of footwear. The second portion also includes a second chamber surface that opposes the second surface. The method further includes operably securing the first portion to the second portion such that the first chamber surface and the second chamber surface cooperate to at least partially define a substantially sealed chamber within the sole assembly.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This application is a divisional of co-pending application Ser. No. 13/756,189, filed Jan. 31, 2013, the disclosure of which is hereby incorporated by reference in its entirety. 
     
    
     FIELD 
       [0002]    The present disclosure relates to a sole assembly for an article of footwear and, more particularly, relates to a sole assembly having plural portions that cooperatively define a chamber. 
       BACKGROUND 
       [0003]    Articles of footwear can include an upper, a midsole, and an outsole. The upper can include layers or sections of material that wrap about a substantial portion of the superior, anterior, posterior, medial and lateral portions of the wearer&#39;s foot. The upper can also include laces, straps, or the like for securing the footwear to the wearer&#39;s foot. The outsole can be a unitary piece of relatively high-friction material that provides traction for the footwear. Also, the midsole can include foam that is disposed between the outsole and the upper for providing cushioned support for the wearer. 
         [0004]    In some cases, footwear can additionally include a bladder that contains a fluid, such as a gas or gel. The bladder can be embedded within the midsole, and weight of the wearer and other loading on the bladder can cause the fluid to displace within the bladder. As such, the bladder can resiliently deform and conform to the wearer&#39;s foot in order to provide better support and comfort than some midsoles made entirely out of foam. Also, the bladder can dampen or attenuate shock loads or other loads during jumping, running, and other activities to provide better cushioning. 
         [0005]    Although conventional footwear with bladders have been adequate for their intended purposes, they do suffer from certain disadvantages. For instance, manufacturing of the footwear can be significantly expensive and complicated. For instance, the bladder itself increases the part count of the footwear. Also, the bladder is typically manufactured separately from the rest of the sole assembly, and then the bladder is assembled into the sole assembly. As such, the bladder can increase part costs and manufacturing costs. 
         [0006]    Furthermore, sole assemblies that include fluid-filled bladders can significantly increase the weight of the sole structure, which can hinder the wearer&#39;s running, jumping, or other movements. Even further, such sole assemblies can be difficult to recycle because the assembly includes multiple parts as discussed above. 
       SUMMARY 
       [0007]    The present disclosure overcomes these and other shortfalls of conventional sole assemblies. 
         [0008]    A method of forming a sole assembly of an article of footwear that includes an interior space that receives a foot of a wearer is disclosed. The article of footwear also includes an exterior surface. The method includes providing a first portion of the sole assembly. The first portion includes a first surface that at least partially defines the interior space. The first portion also includes a first chamber surface that opposes the first surface. Moreover, the method includes providing a second portion of the sole assembly. The second portion includes a second surface that at least partially defines the exterior surface of the article of footwear. The second portion also includes a second chamber surface that opposes the second surface. The method further includes operably securing the first portion to the second portion such that the first chamber surface and the second chamber surface cooperate to at least partially define a substantially sealed chamber within the sole assembly. 
         [0009]    Also, a sole assembly is disclosed for an article of footwear that includes an interior space that receives a foot of a wearer and an exterior surface. The sole assembly includes a first portion that includes a first surface that at least partially defines the interior space. The first portion also includes a first chamber surface that opposes the first surface. The first portion further includes a first mating surface. Also, the sole assembly includes a second portion that includes a second surface that at least partially defines the exterior surface of the article of footwear. The second portion also includes a second chamber surface that opposes the second surface. The second portion further includes a second mating surface that is mated to the first mating surface such that the first chamber surface and the second chamber surface cooperate to at least partially define a substantially sealed chamber within the sole assembly. 
         [0010]    Furthermore, a method of manufacturing is disclosed for a sole assembly for an article of footwear that includes an interior space that receives a foot of a wearer. The article of footwear also includes an exterior surface. The method includes molding a first portion of the sole assembly. The first portion includes a first surface that at least partially defines the interior space. The first portion also includes a first chamber surface that opposes the first surface. The first portion also includes a first rail member that projects from the first chamber surface. The method additionally includes molding a second portion of the sole assembly. The second portion includes a second surface that at least partially defines the exterior surface of the article of footwear. The second portion also includes a second chamber surface that opposes the second surface. The second portion also includes a second rail member that projects from the second chamber surface. Also, the method includes compressing and molding the first portion to the second portion such that the first chamber surface and the second chamber surface cooperate to at least partially define a substantially sealed chamber within the sole assembly and such that the first rail member attaches to the second rail member. Moreover, the method includes changing a pressure inside the chamber via a valve included in the first portion. Molding the first portion and molding the second portion includes molding the first portion and the second portion together within a single mold assembly. Also, the mold assembly includes a first mold member, a middle mold member, and a second mold member. Furthermore, molding both the first portion and the second portion together includes molding the first portion between the first mold member and the middle mold member and molding the second portion between the middle mold member and the second mold member, and further comprising removing the middle mold member from between the first portion and the second portion and subsequently securing the first portion to the second portion by moving at least one of the first mold member and the second mold member toward the other. The first portion is made of a different material from the second portion. 
         [0011]    This section provides a general summary of the disclosed sole assembly and is not a comprehensive disclosure of the full scope or all of the features of the present disclosure. Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]    The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure. 
           [0013]      FIGS. 1A and 1B  illustrate a top and bottom perspective view, respectively, of a sole assembly according to exemplary embodiments of the present disclosure; 
           [0014]      FIGS. 2A and 2B  illustrate top and bottom exploded perspective views, respectively, of the sole assembly of  FIGS. 1A and 1B ; 
           [0015]      FIG. 3  is a bottom perspective view of a first mold member used to form the sole assembly of  FIGS. 1A and 1B ; 
           [0016]      FIGS. 4A and 4B  illustrate a middle mold member used to form the sole assembly of  FIGS. 1A and 1B , wherein  FIG. 4A  is a top perspective view of the middle mold member, and wherein  FIG. 4B  is a bottom perspective view of the middle mold member; 
           [0017]      FIG. 5  is a top perspective view of a second mold member used to form the sole assembly of  FIGS. 1A and 1B ; and 
           [0018]      FIGS. 6A and 6B  is a section view of a mold assembly of the mold members of  FIGS. 3-5 , wherein  FIG. 6A  is a section view of the first, middle, and second mold members during use, and wherein  FIG. 6B  is a section view of the first and second mold members during use. 
       
    
    
       [0019]    Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings. 
       DETAILED DESCRIPTION 
       [0020]    Example embodiments will now be described more fully with reference to the accompanying drawings. 
         [0021]    Referring initially to  FIGS. 1A and 1B , a sole assembly  100  is illustrated according to exemplary embodiments of the present disclosure. The sole assembly  100  includes various features that will be discussed in detail below. Although a sole assembly  100  for a right foot is illustrated, it will be appreciated that the sole assembly  100  can be configured for a left foot without departing from the scope of the present disclosure. 
         [0022]    The sole assembly  100  can be relatively flat and can include an anterior region  101 , a posterior region  103 , a medial region  105 , and a lateral region  107 . The sole assembly  100  can also include a first surface  104  and a second surface  110  that are opposite each other (i.e., face away from each other) in a superior/inferior direction Z. The first and second surfaces  104 ,  110  can extend generally in lateral directions X, Y between the anterior, posterior, medial, and lateral regions  101 ,  103 ,  105 ,  107 . It will be appreciated that the sole assembly  100  can extend along any suitable portion of the length of the wearer&#39;s foot. For instance, the sole assembly  100  can extend only along the heel region portion of the wearer&#39;s foot without extending to the forefoot region of the wearer&#39;s foot, or vice versa. 
         [0023]    The sole assembly  100  can be operably coupled (e.g., lasted, etc.) to an upper  113  (shown in phantom in  FIG. 1A ) to form an article of footwear  115 , such as a shoe, a boot, a sandal, etc. Once attached to the upper  113 , the first surface  104  and the upper  113  can cooperate to define an interior space  117  of the footwear  115 . The wearer&#39;s foot (not shown) can be received within the space  117  such that the upper  113  extends over (superior to) the wearer&#39;s foot and the sole assembly  100  extends below (inferior to) the wearer&#39;s foot. The first surface  104  can be disposed directly beneath and can abut the wearer&#39;s foot or can abut a sock that is worn on the wearer&#39;s foot. Also, a separate insole (not shown) can cover the first surface  104  in some embodiments to be disposed between the first surface  104  and the wearer&#39;s foot. As shown, the first surface  104  can be contoured (e.g., three-dimensionally contoured) to conform to the anatomical contours of the wearer&#39;s foot. For instance, the first surface  104  can contour superiorly at the periphery or lip  116  to substantially cup the wearer&#39;s foot. 
         [0024]    The second surface  110  can at least partially define an exterior surface  119  (e.g., an outsole surface) of the footwear  115 . Specifically, the exterior surface  119  can contact the ground (e.g., pavement, grass, dirt, etc.) during running, walking, or other movement. The second surface  110  can also include treads, projections, spikes, cleats, or other features that increase traction on the ground. 
         [0025]    Referring now to  FIGS. 2A and 2B , the sole assembly  100  is illustrated in exploded perspective views. As shown, the sole assembly  100  can include a plurality of portions  102 ,  108 . There can be any number of portions  102 ,  108 , but in the illustrated embodiments, there is a first portion  102  and a second portion  108 . The first portion  102  and the second portion  108  can each be monolithic (uni-body construction), can be formed in any suitable manner (e.g., molding), and can be formed out of any suitable material. The first and second portion  102 ,  108  can both extend in the lateral directions X, Y between the anterior, posterior, medial, and lateral regions  101 ,  103 ,  105 ,  107  ( FIGS. 1A and 1B ). Also, the first and second portions  102 ,  108  can be layered over each other in the inferior/superior direction Z. 
         [0026]    As shown in  FIGS. 2A and 2B , the first portion  102  can include the first surface  104 , and the first portion  102  can also include a first chamber surface  106  ( FIG. 2B ) that is opposite the first surface  104 . Furthermore, the second portion  108  can include the second surface  110 , and the second portion  108  can also include a second chamber surface  112  ( FIG. 2A ) that is opposite the second surface  110 . The first and second chamber surfaces  106 ,  112  can be substantially flat and can extend in the lateral directions X, Y between the anterior, posterior, medial, and lateral regions  101 ,  103 ,  105 ,  107 . Also, the first portion  102  can include an inferiorly extending peripheral wall  121  that terminates at a first mating surface  125 , and the second portion  108  can include a superiorly extending peripheral wall  123  that terminates at a second mating surface  127 . 
         [0027]    The first and second mating surfaces  125 ,  127  can be layered over each other and attached together (mated together) in any suitable means (e.g., plastic molding, adhesives, fasteners, etc.) to secure the first and second portions  102 ,  108  together. Once attached, a substantially sealed chamber  114  ( FIG. 1A ) can be defined between the first and second portions  102 ,  108 . The first chamber surface  106  and the second chamber surface  112  can at least partially define the boundaries of the chamber  114 . In the illustrated embodiments, the chamber  114  extends transversely along substantially the entire length of the sole assembly  100  between the anterior, posterior, medial, and lateral regions  101 ,  103 ,  105 ,  107 ; however, the chamber  114  can extend across any portion of the sole assembly  100 . As will be discussed, the chamber  114  can deflect to attenuate shock loads in the sole assembly  100 , provide greater comfort, etc. 
         [0028]    The chamber  114  can contain a fluid, such as air, another gas, a gel, etc. The fluid can be supplied into the chamber  114  to increase pressure therein, or fluid can be removed to decrease pressure in the chamber  114 . For instance, the sole assembly  100  can further include a valve assembly  129  that provides a selectively open fluid flow path between the chamber  114  and an area outside the chamber  114 . Thus, pressure can be changed in the chamber  114  via the valve assembly  129 . In some embodiments, the valve assembly  129  is operably supported only by the first portion  102  and extends between the first surface  104  and the first chamber surface  106 . In additional embodiments, the valve assembly  129  is operably supported by the second portion  108 . The valve assembly  129  can be a one-way valve such that fluid only flows in one direction therethrough. For instance, the valve assembly  129  can be used only to introduce additional fluid into the chamber  114  to increase pressure therein, or vice versa. However, the valve assembly  129  could be a two-way valve in additional embodiments such that fluid can be selectively and alternately moved into and out of the chamber  114 . 
         [0029]    In some embodiments, the first portion  102  can include one or more first rails  131  ( FIG. 2B ), and the second portion  108  can include one or more second rails  135  ( FIG. 2A ). The rails  131 ,  135  can extend longitudinally in one or both transverse directions X, Y or be configured in any angle or shape with respect to each other such as a hexagonal pattern, herring bone pattern, or the like. Also, the first rails  131  can extend inferiorly from the first chamber surface  106 , and the second rails  135  can extend superiorly from the second chamber surface  112 . In the embodiments illustrated in  FIG. 2B , there are three first rails  131  that extend substantially parallel to the Y-axis between opposing sides of the peripheral wall  121  and one first rail  131  that extends substantially parallel to the X-axis between two other first rails  131 . As shown in the embodiments of  FIG. 2A , the number and position of the second rails  135  can correspond to that of the first rails  131 . In some embodiments, the first rails  131  can be integrally connected to the first chamber surface  106  so as to be monolithic, and the second rails  135  can be integrally connected to the second chamber surface  112  so as to be monolithic. 
         [0030]    As shown in  FIG. 1A , when the first and second portions  102 ,  108  are joined together, the first rails  131  can abut and attach to the second rails  135  such that the rails  131 ,  135  collectively divide the chamber  114  into a plurality of areas  137   a,    137   b.  There can be any suitable number of areas  137   a,    137   b,  and the areas can be included in the forefoot, midfoot, medial, lateral, and/or rearfoot areas). In some embodiments, the rails  131 ,  135  can be sealed together such that these areas  137   a,    137   b  within the chamber  114  are fluidly disconnected from others. However, in additional embodiments, one or both of the rails  131 ,  129  can include an opening  133  extending laterally therethrough to provide fluid communication between the areas  137   a,    137   b  of the chamber  114 . For instance, as shown in  FIG. 2B , the first rails  131  can include one or more notch-like openings  133  that provide fluid communication between the areas  137   a,    137   b  of the chamber  114 . 
         [0031]    It will be appreciated that the rails  131 ,  135  can support the first and second portions  102 ,  108  relative to each other. For instance, the rails  131 ,  135  can prop the first chamber surface  106  above the second chamber surface  112  to substantially inhibit the chamber  114  from collapsing. Also, it will be appreciated that the sole assembly  100  could include a single rail that extends from only one of the first and second chamber surfaces  106 ,  112  to abut the other of the first and second chamber surfaces  106 ,  112 . Moreover, the sole assembly  100  could include another type of support member other than the rails  106 ,  112  for supporting the first and second portions  102 ,  108  relative to each other. For instance, the sole assembly  100  could include biasing members or tensile elements that bias the portions  102 ,  108  away from each other, cylindrical columns, posts, or other types of support members that extend between the first and second chamber surfaces  106 ,  112  and keep the surfaces  106 ,  112  separated from each other. 
         [0032]    The first and second portions  102 ,  108  can be made out of foam, rubber, a combination of foam and rubber, or any other suitable material. Furthermore, the first and second portions  102 ,  108  can be made out of different materials from each other. For instance, the first portion  102  can be made out of foam while the second portion  108  can be made out of rubber. Additionally, the first portion  102  and second portion  108  can be made out of different foams. Moreover, the first portion  102  and the second portion  108  can be made out of different rubbers. 
         [0033]    Also, in some embodiments, the material characteristics of the first and second portions  102 ,  108  can be different from each other. For instance, the first portion  102  and the second portion  108  can have a different durometer, a different resistance to resilient deformation, a different coefficient of friction, different durabilities, and/or other material characteristic difference. In some examples, the material of the second portion  108  is more durable and has a higher coefficient of friction than the material of the first portion  102  such that the second portion  108  performs similar to a traditional outsole. In an additional example, the material of the first portion  102  is softer than the material of the second portion  108  such that the first portion  102  performs similar to a traditional midsole. The softer properties of the first portion  102  can help make the contact between the wearer&#39;s foot and the surface  104  of the first portion  102  more comfortable for the wearer during wear. In further examples, the first portion  102  and the second portion  108  differ in impact-attenuating properties. For instance, the first portion  102  can be less resistant to resilient deformation than the second portion  108 . It will be appreciated that the first portion  102  and the second portion  108  can have any suitable differences. 
         [0034]    Referring now to  FIGS. 3 ,  4 A,  4 B,  5 ,  6 A, and  6 B, various methods of manufacturing the sole assembly  100  will be discussed. In some embodiments, the first and second portions  102 ,  108  of the sole assembly  100  can be formed via molding (e.g., injection molding, etc.) in a mold assembly  151  ( FIGS. 6A and 6B ). Also, the first and second portions  102 ,  108  can be joined together via molding (e.g., compressive molding, etc.) within the same mold assembly  151 . However, it will be appreciated that the first and second portions  102 ,  108  can be formed in any suitable fashion, and it will be appreciated that the first and second portions  102 ,  108  can be joined in any suitable fashion. 
         [0035]    The mold assembly  151  can generally include a first mold member  153  ( FIG. 3 ), a second mold member  155  ( FIG. 5 ), and a middle mold member  157  ( FIGS. 4A and 4B ). In the embodiments illustrated, the mold members  153 ,  155 ,  157  can be used to form two sole assemblies  100  at once (e.g., a left and a right sole assembly  100 ); however, any number of sole assemblies  100  and any shape of sole assemblies  100  can be formed in the mold assembly  151 . 
         [0036]    The first mold member  153  can be a plate that includes one or more (e.g., two) first mold surfaces  159  as shown in  FIG. 3 . The first mold surfaces  159  can correspond in shape to the first surface  104  of the first portion  102  of the sole assembly  100 . 
         [0037]    The second mold member  155  can be a plate that includes one or more (e.g., two) second mold surfaces  161  as shown in  FIG. 5 . The second mold surfaces  161  can correspond in shape to the second surface  110  of the second portion  108  of the sole assembly  100 . 
         [0038]    The middle mold member  157  can be a plate that includes an upper mold surface  163  ( FIG. 4A ) and a lower mold surface  165  ( FIG. 4B ). The upper and lower mold surfaces  163 ,  165  can be disposed on opposite sides of the middle mold member  157 . The upper mold surface  163  can correspond in shape to the first chamber surface  106  of the first portion  102  of the sole assembly  100 , and the lower mold surface  165  can correspond in shape to the second chamber surface  112  of the second portion  108  of the sole assembly  100 . 
         [0039]    As shown in  FIG. 6A , the molding process can include positioning and layering the mold members  153 ,  155 ,  157  over each other such that the middle mold member  157  is disposed between the first and second mold members  153 ,  155 . As such, a first mold cavity  171  can be defined between the first mold surface  159  and the corresponding upper mold surface  163 , and a second mold cavity  173  can be defined between the lower mold surface  165  and the corresponding second mold surface  161 . 
         [0040]    Then, material can flow into the first mold cavity  171  and the second mold cavity  173  to form the first portion  102  and the second portion  108 . The injection of the material for making the first and second portions  102 ,  108  can occur substantially simultaneously. In some embodiments, the valve member  129  can be insert molded within the first mold cavity  171  with the first portion  102 . 
         [0041]    Subsequently, as shown in  FIG. 6B , the middle mold member  157  can be removed from between the first and second mold members  153 ,  155 . A vacuum source (not shown) can provide suction into the cavities  171 ,  173  to retain the first and second portions  102 ,  108  therein. Then, the first and/or second mold members  153 ,  155  can be moved toward the other, and the first and second portions  102 ,  108  can be secured together via compressive molding. The mold members  153 ,  155  can be heated to mold and cure the first and second portions  102 ,  108  together. In some embodiments, an adhesive can be introduced between the first and second portions  102 ,  108  within the mold assembly  151  before the first and second portions  102 ,  108  are compressed together. In additional embodiments, the first and second portions  102 ,  108  can also be vulcanized together. It will be appreciated that the chamber  114  can be pressurized to a predetermined pressure as a direct result of joining the first and second portions  102 ,  108  together. 
         [0042]    It will be appreciated that the mold assembly  151  can include an actuator that actuates the first, second, and/or middle mold members  153 ,  155 ,  157  as discussed above. The actuator can actuate the mold members  153 ,  155 ,  157  pneumatically, hydraulically, via electric motors, etc. 
         [0043]    Once the first and second portions  102 ,  108  are joined together, the resulting sole assembly  100  can be removed from the mold assembly  151 . In some embodiments, additional outsole material (e.g., high friction material, etc.) is attached to portions of the second surface  110 . Then, in some embodiments, the pressure inside the chamber  114  can be pressurized. Subsequently, the sole assembly  100  can be lasted to the upper  113  to substantially finish the article of footwear  115 . 
         [0044]    The sealed chamber  114  can be pressurized by any suitable source (e.g., a mechanical and/or electrical pump or any other source of fluid). The chamber  114  can be pressurized either manually or automatically. In additional examples, the pressurizing is performed at a retail location at which the articles of footwear  115 . In yet another example, the pressurizing is performed by the wearer when desired. For instance the footwear  115  can be sold to the wearer with a pump (not shown), and the wearer can use the pump to pressurize the chamber  114  to a desired pressure and to re-pressurize the chamber  114  if fluid leaks from the chamber  114 . 
         [0045]    Accordingly, the sole assembly  100  can provide cushioned support and impact-attenuating properties because the chamber  114  is included therein. The sole assembly  100  can include fewer parts than sole assemblies having a midsole, an outsole, and a separate and independent bladder. Also, the sole assembly  100  can be manufactured more efficiently than existing sole assemblies with bladders. 
         [0046]    Optional features may be additionally added to any of the aspects of the sole assemblies  100  described above. For example, the exemplary sole assembly  100  can include more than one valve assembly  129 . The materials that comprise the sole assembly  100  may have any suitable color or appearance. Also, in some examples, the materials of the sole assembly are opaque and the sealed chamber  114  is hidden from view. In other examples, the materials of the sole assembly  100  or a portion thereof is transparent and the sealed chamber  114  is viewable from the exterior of the sole assembly  100 . 
         [0047]    Also, manufacturing of the sole assembly  100  can vary. In the embodiments discussed above, the first portion  102  and the second portion  108  are substantially simultaneously formed. In other examples, the first portion  102  and the second portion  108  are formed at different times in separate mold assemblies. 
         [0048]    Similarly, individual elements or features of a particular aspect of the sole assembly  100  and article of footwear  115  are generally not limited to that particular aspect, but, where applicable, are interchangeable and can be used in a selected aspect, even if not specifically shown or described. The same also may be varied in many ways. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are intended to be included within the scope of the present disclosure.