Patent Publication Number: US-9402442-B2

Title: Sole structure and article of footwear including same

Description:
BACKGROUND 
     “Outsole” is a term often used to describe bottom portions of a shoe sole structure. An outsole, or various parts of the outsole, will typically contact the ground when a shoe wearer stands or when the wearer walks or otherwise moves relative to the ground. In sports and other activities, a person&#39;s feet may experience a wide range of motion and/or support that person&#39;s weight during a range of different body motions. A sole structure designed to provide support or otherwise enhance performance during one type of motion may not be ideal for a different type of motion that a shoe wearer might also perform. For instance, some types of outsole elements may help increase traction when a shoe wearer walks or otherwise traverses various types of surfaces. However, that same shoe may also be worn when performing other activities that do not require that same type of propulsive effort. During those other activities it may be more desirable to stabilize the wearer foot during body motions that differ from motions experienced while walking. 
     Golf is one example of an activity in which a person&#39;s feet repeatedly experience different types of motions and body positions. A golfer may spend large amounts of time walking. Much of that walking may be over uneven surfaces and/or surfaces that might be slippery. It may thus be desirable to include outsole elements to increase traction when moving across such surfaces. However, the manner in which a golfer swings a club is an important aspect of golf. Proper foot placement and support are important during a golf swing. Because of differences between walking motions and swing motions, sole structures that increase traction while walking across a golf course may not be the best structures to stabilize a wearer&#39;s feet while swinging a golf club. Thus, there remains a need for structures that can adapt to the changing forces imposed on footwear as a golfer walks, swings a club, etc. 
     Moreover, a golfer may wish to wear the same shoes on and off the golf course. With conventional golf shoe designs, however, this may often not be practical. In many off-course environments (e.g., indoors, on the street, etc.), the wearer may have no need for special outsole structures that increase stability and/or traction while playing golf or while walking on a golf course. Such structures might be disadvantageous in many such off-course environments. When walking on a hard surface, for example, many types of fraction structures found on conventional golf shoes can impose uncomfortable localized pressures on the bottom of the shoe wearer&#39;s foot. Walking significant distances over hard surfaces in shoes having such traction structures is often not practical. As another example, many conventional golf shoe traction structures may snag carpeting or scratch various types of indoor flooring material. Indeed, golf shoes may not be permitted in some locations for this reason. 
     Many golf shoes are thus not suitable for wear in off-course settings. This can be a source of annoyance to golfers who find it inconvenient to change footwear when arriving at or leaving a golf course. Many such persons would find it advantageous to have a single pair of shoes that could provide support and traction while playing golf, but which could also be worn in off-course settings. 
     SUMMARY 
     This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key or essential features of the invention. 
     In at least some embodiments, an article of footwear includes a sole structure having a flexible web. That flexible web is surrounded by a ridge extending downward from a bottom side of the web. Traction elements also extend downward from the web bottom side. When standing or casually walking, a substantial portion of the wearer&#39;s weight is transferred to the ground by the ridge. During golf play, increased downward force of the wearer on the web deforms the web and transfers more of the wearer weight onto various portions of the traction elements, thereby providing increased localized traction in regions of the wearer foot corresponding to the increased downward force. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Some embodiments are illustrated by way of example, and not by way of limitation, in the figures of the accompanying drawings and in which like reference numerals refer to similar elements. 
         FIG. 1A  is a lateral front perspective view of a shoe according to some embodiments. 
         FIG. 1B  is a medial front perspective view of the shoe of  FIG. 1A . 
         FIG. 1C  is a rear view of the shoe of  FIG. 1A . 
         FIG. 2A  is a medial bottom perspective view of the shoe of  FIG. 1A . 
         FIG. 2B  is a lateral bottom perspective view of the shoe of  FIG. 1A . 
         FIG. 2C  is a partial enlarged view taken from the location indicated in  FIG. 2B . 
         FIGS. 3A and 3B  are enlarged, partially schematic, area cross-sectional views taken from the location indicated in  FIG. 4 . 
         FIG. 4  is a bottom plan view of the shoe of  FIG. 1A . 
     
    
    
     DETAILED DESCRIPTION 
       FIG. 1A  is a lateral front perspective view of a shoe  10  according to some embodiments.  FIG. 1B  is a medial front perspective view of shoe  10 .  FIG. 1C  is a rear view of shoe  10 . Shoe  10  is a left shoe and is part of a pair of shoes. For convenience, the right shoe of the pair is not shown in the drawings. However, in at least some embodiments, the right shoe of the pair is a mirror image of left shoe  10 . This need not be the case, however. Shoe  10  and its associated right shoe are intended for wear by a golfer, but can also be worn in non-golf settings. Other embodiments can include footwear for use in other athletic and non-athletic activities. 
     Shoe  10  includes a sole structure  11 . Sole structure  11  includes a sidewall  12  that wraps around the entire perimeter of shoe  10 . As explained in more detail below, an interior portion of sole structure  11  below a top edge  13  of sidewall  12  forms a platform to support a foot of a shoe  10  wearer. That platform, together with regions of sidewall  12  below top edge  13 , are bonded to an upper  14 . Additional features of sole structure  11  are described below in connection with subsequent drawing figures, such description merely providing examples of features according to certain embodiments. 
     Shoes having sole structures according to various embodiments can include various types of uppers. The details of such uppers are not pertinent to understanding sole structures disclosed herein. Accordingly, upper  14  is shown generically in  FIGS. 1A through 1C  using a broken line. Upper  14  may include laces or other means for securing upper  14  (and thus, shoe  10 ) to a wearer&#39;s foot. In some embodiments, and although it is not visible in  FIGS. 1A through 1C , shoe  10  further includes a removable interior midsole structure formed from a foam material. Additional aspects of that removable midsole are described below. 
     The locations of certain regions in sole structure  11 , and in sole structures according to other embodiments, may be described using references to human foot anatomy. Specifically, various regions of a described sole structure may be identified using foot bones of a person wearing a shoe that includes the described sole structure. Identifications in this manner assume that the shoe is properly sized for the wearing foot. 
     When referring to a region or component of a sole structure, a “forefoot” region will generally lie under or near the metatarsal and phalangeal bones of a shoe wearer&#39;s foot and may extend beyond the wearer&#39;s toes to the front most portion of the shoe. A forefoot region may extend beyond the medial or lateral peripheral edge of the wearer&#39;s foot. A “midfoot” region will generally lie under or near the cuboid, navicular, medial cuneiform, intermediate cuneiform and lateral cuneiform bones of the wearer&#39;s foot. A midfoot region may also extend beyond the medial or lateral peripheral edge of the wearer&#39;s foot. A “hindfoot” or heel region of a sole structure extends from the midfoot region and under/near the wearer calcaneus (heel bone), may extend to the rearmost portion of the shoe, and may also extend beyond the medial or lateral peripheral edge of the wearer&#39;s foot. One or more of the above-described regions may overlap, and description of a component by reference to a particular anatomical region does not require that the component cover that entire anatomical region. 
       FIG. 2A  is a medial bottom perspective view of shoe  10 .  FIG. 2B  is a lateral bottom perspective view shoe  10 . Sidewall  12  includes a bottom edge  15 . Although sidewall bottom edge  15  appears at the top of the drawings in  FIGS. 2A and 2B , edge  15  is nonetheless named based on its location when shoe  10  is upright and at rest (e.g., as shown in  FIGS. 1A-1C ). This component naming convention will be applied throughout the remainder of the description. Unless the context clearly indicates otherwise, bottom surfaces of other elements will refer to surfaces that may contact the ground when shoe  10  is in use and/or that may be the lowest portion of an element when shoe  10  is upright and unloaded. 
     For convenience, an outsole region  20  of sole structure  11  can be defined as including edge  15  and exposed regions of sole structure  11  inside of the perimeter of edge  15 . Various portions of outsole region  20  contact the ground when a wearer of shoe  10  stands, walks, swings a golf club, or otherwise performs an activity. 
     Sole structure  11  further includes a flexible web  21  that forms a substantial portion of outsole region  20 . Web  21  is integrally joined to sidewall  12  around the entire inside perimeter of sidewall  12 . As seen in  FIGS. 2A and 2B , web  21  meets sidewall  12  and forms a ridge  23  that extends below an exposed bottom side  24  of web  21 . In other words, ridge  23  is the portion of sidewall  12  below bottom side  24  of web  21 . 
       FIG. 2C  is a partial enlarged view taken from the location indicated in  FIG. 2B . The intersection of web  21  bottom side  24  with side wall  12  forms a base  25  of ridge  23 . A height HR can be defined as a distance between base  25  and sidewall bottom edge  15  at a particular perimeter location (e.g., location P shown in  FIG. 2C ). In some embodiments, HR may not be constant over all of sole structure  11 . Stated differently, a height HR1 at a first location P1 on sole structure  11  may be different from a height HR2 at a second location P2. 
     Sole structure  11  also includes multiple traction elements  30  located in outsole region  20 . For simplicity, traction elements of sole structure  11  will be generically identified by reference character  30 . Specific traction elements of sole structure  11  will be identified by reference character  30  with an appended suffix (e.g., traction element  30   a ). Each traction element is integrally attached to web  21  and extends downward from bottom side  24  of web  21 . As explained in more detail below, a base groove  26  is formed around each traction element  30  in a portion of bottom surface  24  that surrounds that traction element  30 . 
     In the embodiment of shoe  10 , traction elements  30  are simple “lug” traction elements. Traction elements  30  are approximately square in cross-section, but have differing cross-sectional sizes and differing heights relative to surface  24 . In some embodiments, and so as maintain flexibility of web  21 , no traction element has a width dimension in any direction greater than approximately 10 millimeters. In other embodiments, this maximum width dimension could be smaller (e.g., approximately 8 millimeters or smaller). 
     Referring to  FIG. 2C , traction element  30   au  has a bottom surface  32   au . For simplicity and to avoid confusion of the drawings with excess detail, bottom surface  32   au  and bottom surfaces of other traction elements  30  are shown as flat. In some embodiments, however, traction element bottom surfaces may be non-flat. For example, in some embodiments each traction element bottom surface has a slight pyramid with a flattened apex, and with a rounded nub extending from the flattened apex. Each traction element  30  also has a height HT that can be defined as a distance from the adjacent bottom side  24  surface to the bottom most portion of the fraction element bottom surface. In determining HT, depth of the base groove  26  (e.g., depth of base groove  26   au  in this instance) can be ignored. In the case of traction element  30   au , the height HT( 30   au ) is the distance between bottom side  24  and the bottom most portion of bottom surface  32   au.    
     In at least some embodiments, bottom surfaces of the traction elements do not extend significantly beyond a hypothetical surface defined by sidewall bottom edge  15  when shoe  10  is in an unloaded condition. Specifically, the lowest (i.e., bottom-most) points at each perimeter location of bottom edge  15  could be identified. Those points would then define a hypothetical surface. When shoe  10  is not loaded, no significant portion of a traction element  30  would pass through that hypothetical surface. In this context, “no significant portion” means no more than a few percent of the volume of the traction element. In some embodiments, no portion of a traction element would pass through that hypothetical surface. 
     The relationship between ridge and traction element height can be defined in other ways. For example, each of the traction elements  30  in a group of traction elements could have a height HT that is substantially the same as or less than the height HR of ridge  23  at a location that is closest to that traction element. As one illustration thereof, the height HT( 30   au ) of traction element  30   au  is substantially the same or less than the height HR of ridge  23  at a location along ridge  23 , which location is not specifically marked in  FIG. 2C , that is closest to traction element  30   au.    
       FIG. 3A  is an enlarged, partially schematic, area cross-sectional view of sole structure  11  taken from the location indicated in  FIG. 4 .  FIG. 4 , a bottom plan view of shoe  10 , is discussed in detail below. In  FIG. 3A , all elements of shoe  10  other than sole structure  11  have been omitted. A top side  33  of flexible web  21  forms a platform to support the foot of a shoe  10  wearer. An upper part of an interior perimeter of sidewall  12  acts as a support wall  34  to resist medial, lateral, forward and rearward movement of the wearer foot across that platform.  FIG. 3A  only shows a medial and a lateral portion of support wall  34  extending above web  21 . However, and as can be appreciated from  FIGS. 1A-1C , sidewall  12  wraps around the entire perimeter of sole structure  11 . Because web  21  is joined to sidewall  12  at approximately the same level over the entire area of sole structure  11 , the intersection of web  21  and sidewall  12  forms support wall  34  around the entire upper perimeter sole structure  11  in a manner similar to that in which ridge  23  is formed around the entire lower perimeter of sole structure  11 . 
     Sidewall  12  is relatively thick, at least in the lower portions below web  21 . This thickness allows ridge  23  to provide significant support for the weight of a shoe  10  wearer, particularly when the wearer is standing or walking casually on a firm surface. Example thickness of ridge  23 , not including tabs  35  (discussed below), is approximately 6-7 millimeters for a men&#39;s size 10 shoe. Web  21  is relatively thin, however. As discussed in more detail below, this allows increased flexibility of web  21  in response to forces resulting from wearer activity. Although  FIG. 3A  only shows the thickness of web  21  in the location indicated in  FIG. 4 , web  21  is of relatively thin thickness throughout the entire length and width of sole structure  11 . In some embodiments, web  21  has a thickness t of between 1.5 millimeters (mm) and 2.5 mm for a men&#39;s size 10 shoe. 
     As also seen in  FIG. 3A , traction elements  30  are integrally formed with web  21 . In some embodiments, sole structure  11 , which includes sidewall  12 , web  21  and traction elements  30 , is molded as a single unit. Sole structure  11  can be molded from one or more elastomeric materials. Examples of elastomeric materials that can be used include, without limitation, synthetic rubber. In some embodiments, sole structure  11  is molded in a single-shot molding process wherein a single material is used. In alternate embodiments, a multiple shot molding process and multiple materials could be used. For example, a first step could mold the bottom portions of the traction elements and of the sidewall from a first type of synthetic rubber, and a second step could then mold the remainder of the sole structure (e.g., the remainder of the traction elements, the web, the remainder of the sidewall) around the bottoms of the traction elements and sidewall from a second type of synthetic rubber. The first type of synthetic rubber could be harder and more durable, but the second type might be softer and more flexible. Additional variations on a molding process could be employed so as to also obtain a sole structure in which the sidewall, web and traction elements are an integral unit. 
     As previously indicated, a base groove  26  is formed around each traction element  30  in a portion of the bottom side  24  surface that surrounds that traction element  30 . Additional details of these base grooves can be seen with regard to five traction elements in  FIG. 3A . Specifically, a base groove  26   aa  surrounds traction element  30   aa  in the portion of bottom side  24  immediately adjacent to the base of traction element  30   aa . Grooves  26   ab ,  26   ac ,  26   ad  and  26   ae  similarly surround traction elements  30   ab ,  30   ac ,  30   ad  and  30   ae , respectively. Each of the other traction elements  30  of sole structure  11  similarly has a corresponding surrounding groove. These grooves allow increased flexibility of web  21 . Example dimensions for grooves  26  are a groove width w of 1 mm to 1.5 mm and a groove depth d of 0.75 mm to 1.5 mm. 
       FIG. 3B  is an enlarged, partially schematic, area cross-sectional view of shoe  10  taken from the location indicated in  FIG. 4 .  FIG. 3B  is similar to  FIG. 3A , but includes other elements of shoe  10  in addition to sole structure  11 . Upper  14  of shoe  10  includes a lasting element  40  (e.g., a Strobel) that can be stitched or otherwise attached to the top elements of upper  14  around a footbed perimeter  41 . While upper  14  with attached lasting element  40  is on a last, upper  14  is bonded directly onto sole structure  11 . In particular, the bottom surface  42  of lasting element  40  is bonded to top side  33  of web  21 . Interior faces of support wall  34  are then bonded to corresponding faces of upper  14  around the entire perimeter of shoe  10 . 
     Also visible in  FIG. 3B  is a portion of a removable interior midsole structure  46 . Removable midsole  46  is formed from a foam material. Examples of foam materials that can be used for midsole  46  include foam materials used in the LUNAR family of footwear products available from NIKE, Inc. of Beaverton, Oreg. Additional examples of foam materials that can be used for midsole  46  include materials described in U.S. Pat. No. 7,941,938, which patent is hereby incorporated by reference herein. In some embodiments, midsole  46  is relatively flat in the forefoot and heel regions, with the heel region being raised relative to the forefoot. 
       FIG. 4  is a bottom plan view of shoe  10  showing outsole region  20  of sole structure  11 . To avoid confusing  FIG. 4  with unnecessary detail, a portion of base grooves  26  have been omitted. In  FIG. 4 , each of traction elements  30  has been individually numbered  30   a  through  30   da  for purposes of further discussion. Sole structure  11  includes two main clusters of lugs. A first cluster  51  is located in the forefoot region and is slightly weighted toward the medial side. In particular, a more of the larger lugs in cluster  51  are located on the medial side. For example, lugs  30   h ,  30   l ,  30   p ,  30   u  and  30   z  at the far lateral side are substantially smaller than other lugs in cluster  51 . Lugs  30   o ,  30   t ,  30   y ,  30   ae  and  30   aj  are also significantly smaller than other lugs within cluster  51 . Conversely, lugs  30   g ,  30   j ,  30   k ,  30   m ,  30   n ,  30   r ,  30   s ,  30   v - 30   x ,  30   ab - 30   ad ,  30   af - 30   ai ,  30   al - 30   ao , and  30   ap - 30   at  are larger. 
     A second cluster  52  of lugs  30  is located in the heel region. Most of the lugs in cluster  52  are also relatively large. Lugs  30   cl ,  30   cm ,  30   co ,  30   cp ,  30   cq ,  30   cs ,  30   ct  and  30   cw  are generally located under a wearer calcaneus and are the largest lugs in cluster  52 . The remaining lugs in cluster  52  are slightly smaller and surround the lugs under the wearer calcaneus. 
     Lugs are absent from much of the midfoot region of outsole region  20 . Where lugs are included in the midfoot region, many are of relatively small cross-sectional area and/or have a reduced height. For example, lugs  30   bd ,  30   bh ,  30   bl ,  30   bo ,  30   bq ,  30   br ,  30   bs ,  30   bt ,  30   bu ,  30   bv ,  30   bw ,  30   by  and  30   bz  and  30   ca  have minimal height relative to other lugs of sole structure  20 . 
     As also seen in  FIG. 4 , as well as in  FIGS. 2A-2C , sole structure  11  further includes multiple tabs  35 . Tabs  35 , individual ones of which are also identified in  FIG. 4  by appended suffixes (i.e., as tabs  35   a - 35   z ), extend inward from ridge  23 . Each tab  35  is integrally joined to ridge  23  and to web  21 . Each of tabs  35  is relatively narrow, and does not extend significantly toward the interior of outsole region  20 . In particular, none of tabs  35  is wider than any of traction elements  30 . No tab  35  has a height that extends beyond the height of ridge  23  at the perimeter location where that tab  35  joins ridge  23 . In the embodiment of shoe  10 , the height of each tab  35  is the same as the height of ridge  23  at the location where that tab  35  is joined to ridge  23 . 
     Two flex grooves are also formed in bottom side  24  of web  21 . A forefoot flex groove  55  extends rearward along a longitudinal line approximately located under the second phalanges and second metatarsal. Groove  55  then rearwardly angles outward to the medial side in the midfoot region. Groove  56  extends forward along a longitudinal line approximately located under the lateral side of the center of the calcaneus. Groove  56  then forwardly angles outward to the lateral side in the midfoot region. Grooves  55  and  56  also increase flexibility of web  21 . 
     A shoe with a sole structure configuration such as that of shoe  10  offers various advantages. When walking on the golf course, traction elements  30  and tabs  35  assist the wearer of shoe  10  by providing traction in sand, grass, wet ground, uneven terrain, etc. When traversing these and other types of surfaces, the wearer&#39;s foot will typically depress the surface somewhat, thereby pushing the fraction elements into the ground surface. 
     When a wearer of shoe  10  swings a golf club, the shifting weight of the wearer over the course of the swing results in an increase in the downward force applied to certain areas of web  21 . In other words, as a wearer swings a golf club, the wearer shifts more of his or her weight to a particular foot and to particular parts of that foot. Those foot parts push down on the regions of web  21  with increased force during the swing and cause those regions of web  21  to protrude downward. Traction elements located on those downwardly protruding portions of the web can then engage the ground. By engaging the ground at zones of localized foot pressure, shoe  10  can increase golfer stability during the swing. 
     The sizes, heights and/or placements of these differently-configured tractions elements are, in at least some embodiments, chosen based on pressure mapping of forces applied by a golfer&#39;s foot during a golf swing. As indicated above, first cluster  51  is located in the forefoot region and is slightly weighted toward the medial side. During the downswing phase of a golf swing, a golfer typically pushes off on the medial toe side of his or her back foot. Accordingly, traction elements within cluster  51 , especially fraction elements in the medial side of cluster  51 , would be pushed downward and provide ground engagement for the golfer during the downswing. 
     The preceding example assumes that shoe  10 , a left shoe, is worn by a right handed golfer. However, a similar result would occur if a right shoe counterpart of shoe  10  were worn by a left handed golfer during that left handed golfer&#39;s downswing. 
     When a wearer of shoe  10  is not on the golf course, shoe  10  does not interfere with other activities. For example, when the wearer is standing on a hard surface, web  21  will be minimally deformed, and much of the wearer weight will be transferred to the ground by ridge  23  and tabs  35 . This allows the wearer to comfortably stand on that hard surface. When the wearer of shoe  10  walks on that hard surface, web  21  will be slightly more deformed, and more of the weight of the wearer will be supported by traction elements that contact the ground as the wearer walks. However, that deformation will be more evenly distributed across web  21  than would be the case during a golf swing, and a large portion of the wearer weight will still be transferred to the ground through ridge  23  and tabs  35 . As a result, structures on shoe  10  that provide stability and traction on the golf course do not cause discomfort or inconvenience when in an off-course setting. 
     The foregoing merely describes certain embodiments. Additional embodiments include numerous variations. Numerous materials other than those identified above could be used. The specific traction element shapes described above, as well as the pattern and arrangement of traction elements described herein, merely represent one embodiment. Other embodiments include sole structures in which the traction elements have different shapes, as well as embodiments in which the fraction elements may be arranged in other patterns. In some embodiments, a left shoe and a right shoe of a pair may not have the same pattern of traction elements. In some embodiments, one or more features described above may not be present. As but one example thereof, a sidewall, a ridge or other sole structure element may only substantially surround a sole structure. In some such embodiments, there may be one or more gaps in a ridge and/or sidewall. Similarly, a flexible web may be attached substantially all around the perimeter of a shoe to a ridge, sidewall, and/or other support structure, but there may be one or more gaps where the web is not attached. 
     The foregoing description of embodiments has been presented for purposes of illustration and description. The foregoing description is not intended to be exhaustive or to limit embodiments to the precise form explicitly described or mentioned herein. Modifications and variations are possible in light of the above teachings or may be acquired from practice of various embodiments. The embodiments discussed herein were chosen and described in order to explain the principles and the nature of various embodiments and their practical application to enable one skilled in the art to make and use these and other embodiments with various modifications as are suited to the particular use contemplated. Any and all permutations of features from above-described embodiments are the within the scope of the invention. References in the claims to characteristics of a physical element relative to a wearer of claimed article, or relative to an activity performable while the claimed article is worn, do not require actual wearing of the article or performance of the referenced activity in order to satisfy the claim.