Patent Description:
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.

Different sports and other physical activities cause differing patterns and/or intensities of forces on a foot of a participant. A stiffness profile that is beneficial in a sole structure of a shoe for one sport or activity may be less beneficial (or perhaps even harmful) in a sole structure of a shoe for a different sport or activity. Applicant has determined that footwear sole structures having configurations that permit adaptation to different types of sports or activities would be beneficial.

In at least some embodiments, a sole structure for an article of footwear has a configuration that facilitates design modifications to tune a stiffness profile for a particular sport or activity. A first part of the sole structure comprises a chassis. The chassis includes a frame and a base. The frame includes walls that define cells. At least some of the cells may varied with respect to at least one of size, shape, orientation, and spacing, and/or at least some of the walls may be varied with respect to wall height and wall thickness, so as to define one or more regions and/or directions of increased stiffness. The base has a shape corresponding to at least a portion of a footwear sole. The base may be attached to the bottom of the frame and may provide a surface to which an upper may be attached. Utilizing this general configuration of a frame and base, sole structures for different activities can readily be designed by selecting sizes, shapes, and/or arrangements of cells, and/or height and/or thickness of walls in various regions, to achieve a desired combination of stiffness in some regions and/or flexibility in other regions.

The accompanying drawings show a sole structure designed for footwear worn by a participant in the sport of international style football, which sport is also known as soccer. Unless otherwise indicated, "football" as used herein refers to international style football. Other embodiments include sole structures and footwear intended for use in other sports or activities (e.g., American style football, rugby, or other sports), and which may include different stiffness profiles.

According to the claimed invention, a shoe includes an upper and a chassis. The upper includes a plantar section, side sections, and a dorsal section, and the plantar, side and dorsal sections define a void. The chassis includes a base and a frame. The chassis is located in a bottom of the void, and a bottom side of the base may be fixed relative to a top surface of the plantar section. The frame is disposed at a top side of the base. The frame includes a network of interconnected walls defining a plurality of cells, each of at least a portion of the cells having a bottom at least partially closed by an underlying portion of the base.

According to the claimed invention, a chassis for an article of footwear includes a base and a frame. The base has a peripheral edge, and the peripheral edge has a footwear sole shape. For example, a footwear sole shape may have a heel region, a midfoot region, and a forefoot region, a heel end at a rear-most part of the heel region, a toe end at a forward-most part of the forefoot region, a medial side, and a lateral side. The heel region may be narrower than a central portion of the forefoot region. A path from the heel end to the toe that remains generally equidistant from the medial and lateral sides may have a gentle curve toward the medial side. The forefoot region may have a rounded taper toward the toe end. Optionally the shape may be pinched inward on the medial and/or lateral sides in the midfoot region. The frame is disposed at a top side of the base and includes may a network of interconnected walls defining a plurality of cells. Each of at least a portion of the cells has a bottom at least partially closed by an underlying portion of the base. A first set of the cells is located in at least a heel region. Each of the cells of the first set is oriented with its major axis pointing forward and laterally. A second set of the cells is located in at least a portion of a forefoot region. Each of the cells of the second set is oriented with its major axis pointing forward and medially.

According to the claimed invention, a shoe includes an upper, a support surface, and a sock liner. The upper includes a plantar section, side sections, and a dorsal section, and the plantar, side and dorsal sections define a void. The support surface is located in a bottom of the void and has a top side. The support surface top side has a plurality of upwardly open cavities formed therein. The sock liner is located within the void and rests on the top side of the support surface. The sock liner is indexed to the support surface. A bottom of the sock liner includes downwardly extending tabs. Each of the tabs extends into a corresponding one of the cavities.

In at least some examples not according to the claimed invention, a method for fabricating a shoe may include a step of bonding a plantar portion of an upper to a bottom side of a chassis having a base and a frame attached to a top side of the base, the base comprising a network of interconnected walls defining a plurality of cells, each of at least a portion of the cells having a bottom at least partially closed by an underlying portion of the base.

Additional embodiments are described herein.

To assist and clarify subsequent description of various embodiments, various terms are defined herein. Unless context indicates otherwise, the following definitions apply throughout this specification. "Shoe" and "article of footwear" are used interchangeably to refer to an article intended for wear on a human foot. A shoe may or may not enclose the entire foot of a wearer. For example, a shoe could be a sandal or other article that exposes large portions of a wearing foot.

Shoe elements can be described based on regions and/or anatomical structures of a human foot wearing that shoe, and by assuming that the interior of the shoe generally conforms to and is otherwise properly sized for the wearing foot. A forefoot region of a foot includes the phalanges, as well as the heads and bodies of the metatarsals. A forefoot element of a shoe is an element having one or more portions located under, over, to the lateral and/or medial side of, and/or in front of a wearer's forefoot (or portion thereof) when the shoe is worn. A midfoot region of a foot includes the cuboid, navicular, and cuneiforms, as well as the bases of the metatarsals. A midfoot element of a shoe is an element having one or more portions located under, over, and/or to the lateral and/or medial side of a wearer's midfoot (or portion thereof) when the shoe is worn. A heel region of a foot includes the talus and the calcaneus. A heel element of a shoe is an element having one or more portions located under, to the lateral and/or medial side of, and/or behind a wearer's heel (or portion thereof) when the shoe is worn. The forefoot region may overlap with the midfoot region, as may the midfoot and heel regions.

For purposes of describing axes and directions for a sole structure, it is assumed that surfaces of a sole structure intended for ground contact are resting on a horizontal reference plane. It is further assumed that studs or other projections from a bottom side of a sole structure do not penetrate that reference plane, and that the sole structure is not deformed. A longitudinal axis refers to a horizontal heel-toe axis that extends from a forward-most toe location on a sole structure component (e.g., "FT" in <FIG>) to a rearmost heel location on that sole structure component (e.g., "RH" in <FIG>). A longitudinal axis may be inclined with regard to the reference plane. A longitudinal direction is parallel to the longitudinal axis. A transverse axis is an axis that intersects and is perpendicular to the longitudinal axis, and that is also parallel or approximately parallel to the reference plane. A transverse direction is a direction along a transverse axis.

"Upper," when used as a noun, refers to a portion of a shoe that provides a covering for some or all of a wearer's foot and that positions that foot relative to a sole structure of that shoe. A "bottom side" of a shoe (or component thereof) refers to a side of a shoe (or component thereof) that faces towards the reference plane. A "top side" of a shoe (or component thereof) refers to a side of a shoe (or component thereof) that faces away from the reference plane.

<FIG> is a medial side view of a shoe <NUM> according to some embodiments. Shoe <NUM> is configured for wear by a participant in the sport of football. <FIG> is a lateral side view of shoe <NUM>. <FIG> is a bottom view of shoe <NUM>. Shoe <NUM> is configured for wear on a right foot and is part of a pair that includes a shoe (not shown) that is a mirror image of shoe <NUM> and configured for wear on a left foot. Shoe <NUM> includes an upper <NUM> that defines a void. Upper <NUM> may be formed from any of various types of material and may have any of a variety of different constructions. The void defined by upper <NUM> includes space into which a wearer foot is received via ankle opening <NUM>, as well as space for portions of a sole structure of shoe <NUM>.

In particular, the sole structure of shoe <NUM> includes external components outside of upper <NUM> and interior components located within the void of upper <NUM>. The exterior components include forward stud island <NUM> and rear stud island <NUM>. Forward stud island <NUM> includes a stud plate <NUM> attached to a bottom surface of upper <NUM> in a forefoot region of shoe <NUM>. A plurality of downwardly-extending studs <NUM> are attached to plate <NUM>. Rear stud island <NUM> includes a stud plate <NUM> attached to a bottom surface of upper <NUM> in a heel region of shoe <NUM>. A plurality of downwardly-extending studs <NUM> are attached to plate <NUM>. In some embodiments, studs <NUM> may be integral to plate <NUM> and island <NUM> may be formed as unitary component by injection molding of thermoplastic polyurethane (TPU) and/or other polymeric materials. Similarly, studs <NUM> may be integral to plate <NUM> and island <NUM> may also be formed as unitary component by injection molding of TPU and/or other polymeric materials.

Stud islands <NUM> and <NUM> are configured to facilitate comfort and desired motion during play of a football match. For example, the separation between islands <NUM> and <NUM> in the midfoot region, the forwardly projecting gap <NUM> in the rear of island <NUM>, and the rearwardly projecting gap <NUM> in the front of island <NUM> facilitate torsional motion about a longitudinal axis of a wearer's foot. Inwardly projecting gaps <NUM> and <NUM> on the medial and lateral sides of island <NUM> facilitate dorsiflexion in the forefoot region.

<FIG> is a medial side exploded view of the sole structure of shoe <NUM>. In addition to stud islands <NUM> and <NUM>, the shoe <NUM> sole structure includes a chassis <NUM> and a sock liner <NUM>. The location of upper <NUM> relative to other components is schematically indicated in <FIG> with a broken line representing a slightly expanded portion of the envelope of the void defined by upper <NUM>. Chassis <NUM> and sock liner <NUM> are contained within that void. A bottom side <NUM> of chassis <NUM> is bonded to a corresponding top side of a plantar section of upper <NUM>.

Sock liner <NUM> rests on top of, and partially nests within, chassis <NUM>. The bottom side of sock liner <NUM> includes a plurality of downwardly-projecting tabs 201a through <NUM>, with only tabs 201a-201c and 201e-<NUM> being visible in the view of <FIG>. Those tabs will be referenced collectively and/or generically using the same reference number <NUM>, but without an appended lower case letter. Tabs <NUM> index sock liner <NUM> to chassis <NUM>. As explained in more detail below, each of tabs <NUM> rests within a cell of chassis <NUM> and helps to secure sock liner <NUM> from transverse and longitudinal movement relative to chassis <NUM>. Surfaces of the sock liner <NUM> bottom side surrounding tabs <NUM> have contours corresponding to contours defined by peaks of walls in the frame of chassis <NUM>, as also explained below. A top side of sock liner <NUM> has a surface contoured to comfortably support a socked human foot.

<FIG> is a top view of forward stud island <NUM> and rear stud island <NUM>. <FIG> is a top front medial perspective view of stud islands <NUM> and <NUM>. In <FIG> and <FIG>, stud islands <NUM> and <NUM> are in the same relative positions as are occupied when stud islands <NUM> and <NUM> are attached to upper <NUM> (see <FIG>). Forward stud plate <NUM> and rear stud plate <NUM> respectively include top surfaces <NUM> and <NUM> that are bonded to exterior portions of a plantar section of upper <NUM>. Studs <NUM> and <NUM> are hollow to reduce weight, though solid studs may be used in some embodiments.

<FIG> and <FIG> are respective top and bottom views of chassis <NUM>. <FIG> is a top front medial perspective view of chassis <NUM>. A peripheral boundary of chassis <NUM> has a shape that generally defines a shape of the shoe <NUM> sole in a plantar plane. The front-most end of chassis <NUM> in the toe region is indicated by "FT" in <FIG>. Similarly, the rearmost end of chassis <NUM> in the heel region is indicated by "RH. " As seen in <FIG>, chassis <NUM> includes a base <NUM> and a frame <NUM>. The distinction between base <NUM> and frame <NUM> is further shown in <FIG> and <FIG>. <FIG> is a medial side top perspective of view of chassis <NUM> that omits frame <NUM> and only shows base <NUM>. <FIG> is a medial side top perspective of view of chassis <NUM> that omits base <NUM> and only shows frame <NUM>.

Although base <NUM> and frame <NUM> are shown as separate elements in <FIG> and <FIG> for purposes of explanation, base <NUM> and frame <NUM> form a unitary structure. In particular, the bottom side of frame <NUM> is joined to the top side of base <NUM>. In the embodiment of chassis <NUM>, all but one of cells <NUM> (i.e., cell <NUM>) are closed at the bottom by base <NUM>, and all cells <NUM> are open at the top. Closing a large portion of cells in a frame offers several advantages. For example, the additional material of base <NUM> in the cell bottoms increases the stiffness of chassis <NUM>. Moreover, and as explained in further detail below, upper <NUM> is bonded to the chassis <NUM> bottom side. Closing of the cell bottoms increases the surface area on the chassis <NUM> bottom side available to create a bond. In other embodiments, however, fewer cells in a chassis may be closed at the bottom, and/or some cells may be closed at the top.

In some embodiments, chassis <NUM> is formed from one or more materials that are flexible, but that are incompressible. As used herein, a material is "incompressible" if, under typical loads experienced during normal wear associated with athletic activities, no volume reduction can be detected (visually or tactilely) by a normal human without the aid of a measuring device. A load is experienced during normal wear associated with an athletic activity if the load results from force of the wearer's own weight (e.g., while standing) and/or from the wearer moving from forces generated by his or her own muscular activity. Examples of incompressible materials include solid (e.g., non-foamed) polymers such as thermoplastic polyurethane, Nylon, and polyether block amide, as well as non-foamed composite materials (e.g., glass-reinforced Nylon, graphite-reinforced epoxy).

In some embodiments, chassis <NUM> is formed by injection molding. In some such embodiments in which base <NUM> is formed from a first polymeric material and frame <NUM> is formed from a different second polymeric material, chassis <NUM> may be formed using a two shot injection molding process. In some embodiments, frame <NUM> is formed of a material (e.g., Nylon, glass-reinforced nylon, graphite reinforced epoxy) that is less soft and/or that has a greater material stiffness than a material (e.g., polyether block amide such as that sold under the trade name PEBAX) used to form base <NUM>. In other embodiments, a different material may be used for base <NUM> and/or for frame <NUM>. In some embodiments, base <NUM> and frame <NUM> may be formed from the same material. As used herein, material stiffness is distinguished from structural stiffness and refers to inherent stiffness of a material relative to other materials. For material stiffness, a material A is stiffer than a material B if a sample of material A is more resistant to bending or other deformation than a sample of material B having the same size and cross-section as the sample of material A, and when the samples are tested in the same manner. Structural stiffness refers stiffness of a component (or combination of components) that results from both the material(s) of the component(s) and the shape of the component(s). If not otherwise indicated "stiffness" used without the modifier "material" or "structural" refers to structural stiffness.

As seen in <FIG> and <FIG>, frame <NUM> includes a network of interconnected walls <NUM> that form a network of cells <NUM>. To avoid obscuring <FIG> and <FIG> with excessive reference numbers, only a few of walls <NUM> and cells <NUM> are labeled in <FIG> and <FIG>. The labels of several of cells <NUM>, i.e., cells 109a-<NUM>, 109y, and 109z, further include an appended lower case letter so as to permit identification of specific cells in connection with features discussed below. When used in this description without an appended lower case letter, number <NUM> references cells collectively and/or generically.

Several characteristics can be used to better describe features of chassis <NUM>. These characteristics are further explained in connection with <FIG>, an enlarged view of the portion of chassis <NUM> indicated in <FIG>. Each of cells <NUM> has a major width Wma. A major width Wma of a cell is the longest width that can be measured between the midpoints of any two opposing cell walls, and with the width measured between the centers of the thicknesses of the opposing walls. For example, major widths Wma(y) and Wma(z) are respectively indicated in <FIG> for two cells 109y and 109z. Each of cells <NUM> also has a minor width Wmi. A minor width Wmi is the largest width of a cell, in a direction perpendicular to the direction of the major width for that cell, that can be measured starting at a midpoint and thickness center of one wall and ending at a thickness center of an opposing wall. At least one of the endpoints of a minor width of a cell is at the midpoint of a wall defining that cell. Minor widths Wmi(y) and Wmi(z) are also indicated in <FIG> for cells 109y and 109z, respectively. An aspect ratio for a cell may be defined as a ratio of major width to minor width (Wma/Wmi).

The major axis of a cell may be an axis connecting the end points of the major width Wma of that cell. Each of cells <NUM> also has an orientation angle a formed between an orthogonal projection in the horizontal reference plane of the cell major axis and an orthogonal projection in the horizontal reference plane of the chassis <NUM> longitudinal axis LA. Cell orientation angle may be measured in a forward quadrant of the intersection between the projections of the cell major axis and longitudinal axis LA. As indicated in <FIG>, cell 109y has an orientation angle α(y) between P(LA), an orthogonal projection in the horizontal reference plane of longitudinal axis LA, and P(Ay), an orthogonal projection in that same horizontal reference plane of cell 109y major axis Ay. Similarly, cell 109z has an orientation angle α(z) between P(LA) and P(Az), an orthogonal projection in that same horizontal reference plane of cell 109z major axis Az.

The major axes of cells 109y and 109z point forwardly and laterally. In particular, orientation angles α(y) and α(z), in forward lateral quadrants of intersections between horizontal plane orthogonal projections of the cell major axes and a horizontal plane orthogonal projection of longitudinal axis LA, are significantly less than <NUM>°. An orientation angle may be considered "significantly less than <NUM>°" if that angle is between <NUM>° and <NUM>°. In the embodiment of chassis <NUM>, orientation angles α(y) and α(y) are roughly equal and are approximately <NUM>°.

<FIG> is a partially schematic area cross-sectional view taken from the location indicated in <FIG> and rotated by <NUM>°. <FIG> is also further enlarged relative to <FIG>. As shown in <FIG>, each wall <NUM> has a height h in any cross-sectional plane passing through the wall. Moreover, base <NUM> has a corresponding thickness t under that height h.

<FIG> is a top view of chassis <NUM> similar to that of <FIG>, but with several sets of cells <NUM> indicated. A first set <NUM> includes cells <NUM> distributed in heel and rear midfoot regions of chassis <NUM>. The cells <NUM> in set <NUM> include cells 109y and 109z discussed above, as well as cells 109a-<NUM> discussed below. Each of the cells <NUM> in set <NUM> has a major axis that points forwardly and laterally. In some embodiments, each of the cells <NUM> in set <NUM> has an orientation angle, in a forward lateral quadrant of an intersection between a horizontal reference plane orthogonal projection of the cell major axis and a horizontal reference plane orthogonal projection of longitudinal axis LA, of between <NUM>° and <NUM>°. In some such embodiments, that range is between <NUM>° and <NUM>°.

A second set <NUM> includes cells <NUM> distributed in a forefoot region of chassis <NUM>. Each of the cells <NUM> in set <NUM> has a major axis that points forwardly and medially. In some embodiments, each of the cells <NUM> in set <NUM> has an orientation angle, in a forward medial quadrant of an intersection between a horizontal reference plane orthogonal projection of the cell major axis and a horizontal reference plane orthogonal projection of longitudinal axis LA, of between <NUM>° and <NUM>°. In some such embodiments, that range is between <NUM>° and <NUM>°. In the embodiment of <FIG>, multiple cells <NUM> in set <NUM> have orientation angles (in the forward medial quadrant) of approximately <NUM>°.

A third set <NUM> includes cells <NUM> distributed in a phalangeal region of chassis <NUM>. Each of the cells <NUM> in set <NUM> has a major axis that points forwardly, forwardly and slightly laterally, or forwardly and slightly medially. In some embodiments, each of the cells <NUM> in set <NUM> has an orientation angle, in either a forward medial or forward lateral quadrant of an intersection between a horizontal reference plane orthogonal projection of the cell major axis and a horizontal reference plane orthogonal projection of longitudinal axis LA, of between <NUM>° and <NUM>°. In some such embodiments, that range is between <NUM>° and <NUM>°.

The cell shapes and orientations shown in <FIG>, in combination with heights of walls <NUM> of those cells, offer advantages for a football shoe. Cells <NUM> in set <NUM> facilitate some twisting of a wearer foot in the heel and rear midfoot region about an axis generally aligned with the major axes of the cells <NUM> in set <NUM>. That axis is indicated in <FIG> as A<NUM>. However, those cells provide increased resistance to bending in the heel and rear midfoot region about horizontal axes perpendicular to axis A<NUM>. Cells <NUM> in set <NUM> provide minimal resistance to bending/twisting of a wearer foot in a rear forefoot region about an axis generally aligned with the major axes of the cells <NUM> in set <NUM>. That axis is indicated in <FIG> as A<NUM>. However, those cells provide somewhat greater resistance to bending and twisting in the rear forefoot region about horizontal axes perpendicular to axis A<NUM>. Cells <NUM> in set <NUM> provide minimal resistance to bending/twisting of a wearer foot in a phalangeal region about an axis generally aligned with the major axes of the cells <NUM> in set <NUM>. That axis is indicated in <FIG> as A<NUM>. However, those cells provide somewhat greater resistance to bending and twisting in the phalangeal region about horizontal axes perpendicular to axis A<NUM>. Axes A<NUM>, A<NUM>, and A<NUM> generally correspond to axes of foot motions during football.

<FIG> is a top view of sock liner <NUM>. The top side of sock liner <NUM> includes a surface <NUM> that is contoured to comfortably conform to and support the plantar region of a socked human foot wearing shoe <NUM>. A peripheral boundary of sock liner <NUM> has a shape corresponding to a shape of a shoe sole in a plantar plane.

<FIG> is a bottom view of sock liner <NUM>. The bottom side of sock liner <NUM> includes downwardly projecting tabs 201a-<NUM>. Tabs 201a-<NUM> correspond to cells 109a-<NUM> (see <FIG>). Each of tabs 201a-<NUM> has a shape that matches the internal volume of the upper portion of the corresponding cell. When shoe <NUM> is assembled, each of tabs 201a-<NUM> nests within its corresponding cell. In this manner, transverse and longitudinal shifting of sock liner <NUM> relative to chassis <NUM> is restricted.

Tabs 201a-201d are located in a midfoot region of sock liner <NUM> and tabs 201e-<NUM> are located in a heel region of sock liner <NUM>. In other embodiments, sock liner <NUM> may also or alternatively include heel, midfoot, and/or forefoot region tabs corresponding to other cells of chassis <NUM>.

The remainder of the sock liner <NUM> bottom side surrounding tabs 201a-<NUM> has a contour that generally correspond to a contour defined by the top edges of walls <NUM> of frame <NUM>. As seen in <FIG>, <FIG>, <FIG>, and <FIG>, this allows sock liner <NUM> to partially nest within, and be supported by, chassis <NUM>.

<FIG> is a top front medial perspective view of sock liner <NUM> showing additional details of the contour of surface <NUM>.

<FIG> is a partially schematic area cross-sectional view of shoe <NUM> taken from the location indicated in <FIG> as sectioning plane <NUM>-<NUM>. Visible in <FIG> are portions of upper <NUM>, sock liner <NUM>, chassis <NUM>, and forward stud island <NUM>. As seen in <FIG>, upper <NUM> includes a plantar section <NUM>, a medial side section <NUM>, a lateral side section <NUM>, and a dorsal section <NUM>. Sections <NUM>-<NUM> surround and define a void <NUM>. Chassis <NUM> and sock liner <NUM> are positioned in the bottom of void <NUM> and extend through heel, midfoot and forefoot regions of the void. The remainder of void <NUM> above top surface <NUM> of sock liner <NUM> is sized and shaped to receive and conform to a foot of a shoe <NUM> wearer.

Bottom side <NUM> of chassis <NUM> is bonded to the top surface <NUM> of plantar section <NUM>. As used herein, "bonding" includes joining through use of glue or other adhesive agents, as well as fusing by thermally melting (or chemically dissolving) one or more elements and allowing those elements to solidify as part of an interconnected configuration. The bottom side of sock liner <NUM> rests against peaks of walls <NUM> of chassis <NUM>. Top surface <NUM> of stud island <NUM> forward plate <NUM> is bonded to an exterior surface of plantar section <NUM>.

As also shown in <FIG>, sock liner <NUM> may include multiple layers, with each layer comprising a different material. In the embodiment of shoe <NUM>, sock liner <NUM> includes a top layer <NUM> and a bottom layer <NUM>. Top layer <NUM> may be less dense and/or more compressible than bottom layer <NUM> and/or may be configured to facilitate air movement and/or moisture wicking. Bottom layer <NUM> may be denser and/or less compressible than top layer <NUM> so as to provide support for and define the shape of top surface <NUM>, and so as to provide additional structural reinforcement for tabs 201a-<NUM>. Examples of materials that can be used for top layer <NUM> include, without limitation, foamed ethylene vinyl acetate (EVA), foamed polyurethane (PU), or blown rubber. Examples of materials that can be used for bottom layer <NUM> include, without limitation, foamed EVA, foamed PU, or blown rubber. Layers <NUM> and <NUM> may be bonded across their entire interface. In some embodiments, sock liner <NUM> may be formed by injection molding.

In some embodiments, the bottom side of sock liner <NUM> may be treated so as to create tackiness to help secure sock liner <NUM> in position, but to also allow non destructive removal of sock liner <NUM> from shoe <NUM>.

Additional details of the shoe <NUM> sole structure, relative to the cross-sectional plane on which <FIG> is based, can be seen in <FIG>. <FIG> is a partially schematic cross-sectional view, taken from sectioning plane <NUM>-<NUM> (<FIG>), showing only stud islands <NUM> and <NUM>. <FIG> is a partially schematic cross-sectional view, taken from sectioning plane <NUM>-<NUM>, showing only chassis <NUM>. <FIG> is also a partially schematic cross-sectional view taken from the location indicated in <FIG> as sectioning plane 6C-6C and rotated by <NUM>°. <FIG> is a partially schematic cross-sectional view, taken from sectioning plane <NUM>-<NUM>, showing only sock liner <NUM>.

<FIG> is a partially schematic area cross-sectional view taken from sectioning plane <NUM>-<NUM> (<FIG>) and limited to chassis <NUM>. <FIG> is also a partially schematic area cross-sectional view taken from sectioning plane 6C-6C (<FIG>) and rotated by <NUM>°. As seen in <FIG>, walls <NUM> have relatively short heights h in the forefoot region. In some embodiments, frame walls <NUM> in a forefoot region corresponding to <FIG> have heights that less than or equal to the corresponding thicknesses of base <NUM>.

<FIG> is a partially schematic area cross-sectional view of shoe <NUM> taken from the location indicated in <FIG> as sectioning plane <NUM>-<NUM>. In <FIG>, portions of upper <NUM> have been omitted for convenience. As in <FIG>, chassis <NUM> and sock liner <NUM> are positioned in the bottom of void <NUM>, with bottom side <NUM> of chassis <NUM> bonded to the top surface <NUM> of plantar section <NUM>, and with the bottom side of sock liner <NUM> resting against peaks of walls <NUM> of chassis <NUM>. Top surface <NUM> of stud island <NUM> forward plate <NUM> is bonded to an exterior surface of plantar section <NUM>.

Additional details of the shoe <NUM> sole structure, relative to the cross-sectional plane on which <FIG> is based, can be seen in <FIG>. <FIG> is a partially schematic cross-sectional view, taken from sectioning plane <NUM>-<NUM> (<FIG>), showing only stud islands <NUM> and <NUM>. <FIG> is a partially schematic cross-sectional view, taken from sectioning plane <NUM>-<NUM>, showing only chassis <NUM>. <FIG> is also a partially schematic cross-sectional view taken from the location indicated in <FIG> as sectioning plane 7C-7C and rotated by <NUM>°. <FIG> is a partially schematic cross-sectional view, taken from sectioning plane <NUM>-<NUM>, showing only sock liner <NUM>.

<FIG> is a partially schematic area cross-sectional view taken from sectioning plane <NUM>-<NUM> (<FIG>) and limited to chassis <NUM>. <FIG> is also a partially schematic area cross-sectional view taken from sectioning plane 7C-7C (<FIG>) and rotated by <NUM>°. As seen in <FIG>, walls <NUM> have larger heights h in the rear forefoot and forward midfoot regions. In some embodiments, at least some frame walls <NUM> in a forward forefoot region corresponding to <FIG> have heights that are at least twice the corresponding thicknesses of base <NUM>.

<FIG> is a partially schematic area cross-sectional view of shoe <NUM> taken from the location indicated in <FIG> as sectioning plane <NUM>-<NUM>. In <FIG>, portions of upper <NUM> have again been omitted for convenience. As in <FIG> and <FIG>, chassis <NUM> and sock liner <NUM> are positioned in the bottom of void <NUM>, with bottom side <NUM> of chassis <NUM> bonded to the top surface <NUM> of plantar section <NUM>, and with the bottom side of sock liner <NUM> resting against peaks of walls <NUM> of chassis <NUM>.

<FIG> also illustrates the cooperation of tabs 201b and 201c with corresponding cells <NUM> to restrain sock liner <NUM> from shifting relative to chassis <NUM>. Tab 201b has a shape that corresponds to, and that nests snugly within, the top portion of cell 109b. Similarly, tab 201c has a shape that corresponds to, and that nests snugly within, the top portion of cell 109c. Tabs 201a and 201d similarly have shapes that correspond to, and that nest snugly within, the tops of cells 109a and 109d, respectively. Because the sides of tabs 201a-201d contact sides of their corresponding cells <NUM>, transverse shifting of sock liner <NUM> relative to chassis <NUM> is prevented. Similarly, the fronts and rears of tabs 201a-201d contact the fronts and rears of their corresponding cells, thereby preventing longitudinal shifting of sock liner <NUM> relative to chassis <NUM>.

Additional details of the shoe <NUM> sole structure, relative to the cross-sectional plane on which <FIG> is based, can be seen in <FIG>. <FIG> is a cross-sectional view, taken from sectioning plane <NUM>-<NUM> (<FIG>), showing only stud island <NUM>. <FIG> is a partially schematic cross-sectional view, taken from sectioning plane <NUM>-<NUM>, showing only chassis <NUM>. <FIG> is also a partially schematic cross-sectional view taken from the location indicated in <FIG> as sectioning plane 8C-8C and rotated by <NUM>°. <FIG> is a partially schematic cross-sectional view, taken from sectioning plane <NUM>-<NUM>, showing only sock liner <NUM>. <FIG> is also a partially schematic cross-sectional view taken from the location indicated in <FIG> as sectioning plane 8D-8D.

<FIG> is a partially schematic area cross-sectional view taken from sectioning plane <NUM>-<NUM> (<FIG>) and limited to chassis <NUM>. <FIG> is also a partially schematic area cross-sectional view taken from sectioning plane 8C-8C (<FIG>) and rotated by <NUM>°. As seen in <FIG>, walls <NUM> have even larger heights h in the arch midfoot region. In some embodiments, at least some walls <NUM> in an arch midfoot region corresponding to <FIG> have heights that are at least three times the corresponding thicknesses of base <NUM>.

<FIG> is a partially schematic area cross-sectional view of shoe <NUM> taken from the location indicated in <FIG> as sectioning plane <NUM>-<NUM>. In <FIG>, portions of upper <NUM> have again been omitted for convenience. As in <FIG>, <FIG>, and <FIG>, chassis <NUM> and sock liner <NUM> are positioned in the bottom of void <NUM>, with bottom side <NUM> of chassis <NUM> bonded to the top surface <NUM> of plantar section <NUM>, and with the bottom side of sock liner <NUM> resting against peaks of walls <NUM> of chassis <NUM>. Top surface <NUM> of stud island <NUM> rear plate <NUM> is bonded to an exterior surface of plantar section <NUM>.

<FIG> further shows the cooperation of tabs 201f and <NUM> with corresponding cells <NUM>, in a manner similar to that described above for tabs 201a-201d, to restrain sock liner <NUM> from shifting relative to chassis <NUM>. Tab 201f has a shape that corresponds to, and that nests snugly within, the top portion of cell 109f. Tab <NUM> has a shape that corresponds to, and that nests snugly within, the top portion of cell <NUM>. Tabs 201e and <NUM> similarly have shapes that correspond to, and that nest snugly within, the tops of cells 109e and <NUM>, respectively. As with tabs 201a-201d, tabs 201e-<NUM> contact walls of cells 109e-<NUM>, respectively, to prevent longitudinal and transverse shifting of sock liner <NUM> relative to chassis <NUM>.

Additional details of the shoe <NUM> sole structure, relative to the cross-sectional plane on which <FIG> is based, can be seen in <FIG>. <FIG> is a partially schematic cross-sectional view, taken from sectioning plane <NUM>-<NUM> (<FIG>), showing only stud island <NUM>. <FIG> is a partially schematic cross-sectional view, taken from sectioning plane <NUM>-<NUM>, showing only chassis <NUM>. <FIG> is also a partially schematic cross-sectional view taken from the location indicated in <FIG> as sectioning plane 9C-9C and rotated by <NUM>°. <FIG> is a partially schematic cross-sectional view, taken from sectioning plane <NUM>-<NUM>, showing only sock liner <NUM>. <FIG> is also a partially schematic cross-sectional view taken from the location indicated in <FIG> as sectioning plane 9D-9D.

<FIG> is a partially schematic area cross-sectional view taken from sectioning plane <NUM>-<NUM> (<FIG>) and limited to chassis <NUM>. <FIG> is also a partially schematic area cross-sectional view taken from sectioning plane 9C-9C (<FIG>) and rotated by <NUM>°. As seen in <FIG>, walls <NUM> also have significant heights h in the heel region. In some embodiments, at least some walls <NUM> in a heel region corresponding to <FIG> have heights that are at least three times the corresponding thicknesses of base <NUM>.

<FIG> is a partially schematic area cross-sectional view of chassis <NUM> taken from the location indicated in <FIG> as sectioning plane <NUM>-<NUM>.

<FIG> is a top view of upper <NUM>, according to some embodiments, in flattened form prior to assembly of shoe <NUM>. The locations of plantar section <NUM>, medial side section <NUM>, lateral side section <NUM>, and dorsal section <NUM> in flattened upper <NUM> are also indicated. When shoe <NUM> is assembled, edges <NUM> and <NUM> are joined to form the bottom of upper <NUM>. Edges <NUM> and <NUM> are joined to corresponding portions of edge <NUM> to enclose the toe of upper <NUM>. Edges <NUM> and <NUM> are joined, as are edges <NUM> and <NUM>. Edges <NUM> and <NUM> are joined to enclose the rear of upper <NUM>.

<FIG> is a flow chart showing a method for assembly of shoe <NUM> according to some examples not according to the claimed invention. In step <NUM>, sock liner <NUM> and chassis <NUM> are assembled. As part of step <NUM>, sock liner <NUM> is placed into chassis <NUM> so that tabs 201a-<NUM> are located in cells 109a-<NUM>, respectively, and so that the tops of walls <NUM> of chassis <NUM> are contacting the bottom side of sock liner <NUM>. In step <NUM>, assembled sock liner <NUM> and chassis <NUM> are placed onto a last so that top surface <NUM> of sock liner <NUM> is in contact with the bottom of the last, and so that bottom side <NUM> of chassis <NUM> is exposed. In step <NUM>, upper <NUM> is then placed over the last and assembled sock liner <NUM> and chassis <NUM>. Prior to or as part of step <NUM>, the various edges of upper <NUM> are secured together as discussed above. Edges of upper <NUM> may be secured by, e.g., stitching. When upper <NUM> is placed over the last and assembled sock liner <NUM> and chassis <NUM>, the seam between edges <NUM> and <NUM> may extend from toe to heel in roughly the center of chassis <NUM>, and plantar section <NUM> is bonded to bottom side <NUM> of chassis <NUM>. In step <NUM>, stud islands <NUM> and <NUM> are bonded to the bottom of plantar section <NUM> of upper <NUM>. Shoe <NUM> is then removed from the last.

<FIG> is a top front medial perspective view of a sole structure according to some additional embodiments. The sole structure of <FIG> includes stud islands <NUM> and <NUM> that are identical to stud islands <NUM> and <NUM> discussed above, a chassis <NUM>, and a sock liner <NUM>. The sole structure of <FIG> may be incorporated into a shoe in a manner similar to that described above for shoe <NUM>. In particular, chassis <NUM> and sock liner <NUM> of shoe <NUM> could be replaced with chassis <NUM> and sock liner <NUM>, respectively.

<FIG> is a top front medial perspective view of chassis <NUM>. Similar to chassis <NUM>, chassis <NUM> includes a frame <NUM> joined to a base <NUM>. Frame <NUM> includes an interconnected network of walls <NUM> that define multiple cells <NUM>.

<FIG>, <FIG>, and <FIG> are respective top, bottom, and medial side views of chassis <NUM>. As seen in <FIG>, the shapes, sizes, and orientations of cells <NUM> vary throughout chassis <NUM>. In the heel and rear midfoot regions, cells <NUM> are elongated and have orientations in which major axes of those cells point forwardly and laterally. In a forward midfoot region, cells <NUM> become less elongated. Cells <NUM> in rear and central forefoot regions have orientations in which major axes of those cells point forwardly and medially. Cells <NUM> in a phalangeal region become less elongated and larger, and have orientations in which major axes of those cells point forwardly and laterally. Similar to chassis <NUM>, heights of walls <NUM> may be relatively small in forefoot regions, and may increase in midfoot and heel regions.

<FIG> is a bottom view of sock liner <NUM>. The bottom side of sock liner <NUM> includes downwardly-extending tabs 601a-601q that correspond to cells 509a-509q, respectively, of chassis <NUM> (see <FIG>). Tabs 601a-601q cooperate with cells 509a-509q in a manner similar to that described above in connection with tabs 201a-<NUM> and cells 109a-<NUM>. Specifically, each of tabs 601a-601q has a shape that matches the internal volume of the upper portion of its corresponding cell. When a shoe that includes chassis <NUM> and sock liner <NUM> is assembled, each of tabs 601a-601q nests within its corresponding cell. In this manner, transverse and longitudinal shifting of sock liner <NUM> relative to chassis <NUM> is restricted.

Base <NUM> and frame <NUM> of chassis <NUM> may be formed from the same materials that may be used to form base <NUM> and frame <NUM>, respectively, of chassis <NUM>. Sock liner <NUM> may have a multilayer structure similar to that of sock liner <NUM> and be formed from similar materials. Chassis <NUM> and sock liner <NUM> each may be formed by injection molding. A shoe incorporating chassis <NUM> and frame <NUM> may have an upper similar to upper <NUM> and be assembled using a process similar to that described in connection with <FIG>.

In some examples not according to the claimed invention, a sock liner may have downwardly-extending tabs that cooperate with a support structure other than a chassis such as chassis <NUM> or chassis <NUM>, and that restrain the sock liner from shifting relative to that other type of support structure. As but one example, a shoe could include an internal foam midsole instead of a chassis. Tabs on a sock liner may cooperate with depressions in the midsole.

<FIG> shows the top side of a midsole <NUM> according to some such examples. Midsole <NUM> includes depressions 709a-709j formed in its top surface. Midsole <NUM> could be formed from, e.g., a closed cell polymer foam such as ethylene vinyl acetate (EVA).

<FIG> shows the bottom side of a sock liner <NUM> according to some examples. Downwardly extending tabs 801a-801j correspond to depressions 709a-709j, respectively, and cooperate with those depressions in a manner similar to that described above in connection with tabs 201a-<NUM> and cells 109a-<NUM>. Specifically, each of tabs 801a-801j has a shape that matches the internal volume of the upper portion of its corresponding depression. When a shoe that includes midsole <NUM> and sock liner <NUM> is assembled, each of tabs 801a-801j nests within its corresponding depression to prevent transverse and longitudinal shifting of sock liner <NUM> relative to midsole <NUM>.

<FIG> is a partially schematic area cross-sectional view of a shoe incorporating midsole <NUM> and sock liner <NUM>. The view of <FIG> is taken through a transverse cross-sectional plane passing through tabs 801a and 810b and depressions 709a and 709b. The portion of <FIG> showing midsole <NUM> is an area cross-sectional view from the location indicated in <FIG> as sectioning plane <NUM>-<NUM> and rotated by <NUM>°. The portion of <FIG> showing sock liner <NUM> is an area cross-sectional view from the location indicated in <FIG> as sectioning plane <NUM>-<NUM>. Also shown in <FIG> are a portion of an upper <NUM> and a portion of an outsole <NUM>. The bottom and sides of midsole <NUM> are bonded to corresponding inner surfaces of upper <NUM>. Outsole <NUM> is bonded to an exterior portion of upper <NUM>. Sock liner <NUM> has a two-layer construction, similar to that of sock liner <NUM>, that includes an upper layer <NUM> and a lower layer <NUM>. Layers <NUM> and <NUM>, which may be bonded across the entirety of their interface, may be formed from material such as those described in connection with layers <NUM> and <NUM>, respectively.

<FIG> also shows the cooperation of tabs 801a and 801b with corresponding depressions 709a and 709b to restrain sock liner <NUM> from shifting relative to midsole <NUM>. Tab 801a has a shape that corresponds to, and that nests snugly within, the top portion of cell depression 709a. Tab 801b has a shape that corresponds to, and that nests snugly within, the top portion of depression 709b. Tabs 801c through 801j similarly have shapes that correspond to, and that nest snugly within, the tops of depressions 709c through 709j, respectively. Because the sides of tabs 801a-801j contact sides of their corresponding depressions <NUM>, longitudinal and transverse shifting of sock liner <NUM> relative to midsole <NUM> is prevented.

Although tabs 201a-<NUM> and tabs 801a-801j have shapes that match the shapes of their corresponding cells or depressions, this need not be the case. In some embodiments, a tab may have a shape that is not the same as the shape of its corresponding cell or depression, but that nonetheless contacts walls of the depression at a minimum of two points that are displaced from one another along a longitudinal axis passing through the cell, depression, or other cavity, and at a minimum of two points that are displaced from one another along a transverse axis passing through the cell, depression, or other cavity. <FIG> is a partially schematic area cross sectional view showing one example. The view of <FIG> is in a horizontal plane passing through a support structure depression <NUM> and a sock liner tab <NUM>. A similar cross-section of the example of <FIG> would be taken from a plane extending out of the page of <FIG> and passing through tabs 801a and 801b. Also shown in <FIG> are longitudinal and transverse axes AL and AT, respectively. <FIG> is a partially schematic area cross sectional view showing another example. The view of <FIG> is in a horizontal plane passing through a support structure depression <NUM> and a sock liner tab <NUM>.

Other embodiments include numerous additional variations on the components and combinations described above. Without limitation, such variations may include one or more of the following.

In some embodiments, studs or other traction elements may be attached in a different manner. In some embodiments, for example, studs may not be joined to an island and may be individual attached. As another example, studs may also or alternatively be attached using mechanical fasteners. For example, a socket could be formed in or attached to chassis <NUM>, and the portion of upper <NUM> over the opening to that socket could be removed (or omitted). A stud could include a post that is received into the socket. As yet another example, studs, a stud island, and/or other components could be directly molded onto an exterior surface of plantar section <NUM> after upper <NUM> has been bonded to chassis <NUM>.

Claim 1:
An article of footwear (<NUM>), comprising:
an upper (<NUM>), the upper (<NUM>) comprising a plantar section (<NUM>), side sections (<NUM>, <NUM>), and a dorsal section (<NUM>), the plantar (<NUM>), side (<NUM>, <NUM>) and dorsal sections (<NUM>) defining a void (<NUM>);
a support surface located in a bottom of the void (<NUM>) and having a top side, the support surface top side having a plurality of upwardly open cavities formed therein; and
a sock liner (<NUM>) within the void (<NUM>) and resting on the top side of the support surface, wherein a bottom of the sock liner (<NUM>) includes downwardly extending tabs (<NUM>), each of the tabs (<NUM>) extending into a corresponding one of the cavities;
characterized in that:
the support surface is a chassis (<NUM>), the chassis (<NUM>) comprising:
a base (<NUM>) having a peripheral edge, the peripheral edge having a footwear sole shape; and
a frame (<NUM>) disposed at a top side of the base (<NUM>) and comprising a network of interconnected walls (<NUM>) defining a plurality of cells (<NUM>), each of at least a portion of the cells (<NUM>) having a bottom at least partially closed by an underlying portion of the base (<NUM>), wherein
a first set of the cells is located in at least a heel region, each of the cells of the first set being oriented with its major axis pointing forward and laterally,
and
a second set of the cells is located in at least a portion of a forefoot region, each of the cells of the second set being oriented with its major axis pointing forward and medially, wherein
the plurality of cells (<NUM>) corresponds to the plurality of cavities.