Patent Description:
The present disclosure relates generally to articles of footwear and more particularly to a sole structure for an article of footwear.

<CIT> describes for example a method of making a custom article of footwear. Further, the article of footwear can include a knitted upper and means for cushioning. In addition, the components of the article of footwear can be selected from a wide range of options, and can be easily removed and replaced, as desired. Further, <CIT> describes support plates, and footwear soles and articles of footwear containing the same. The support plate generally may provide one or more of heel cushioning, arch support in a midfoot region of the support plate, and integral medial and lateral legs extending from the midfoot region of the support plate towards an anterior end of the support plate. An article of footwear may include a support plate at least partially embedded within a sole assembly, such as a midsole thereof. The support plate may be configured to provide energy return and arch support to a wearer of the article of footwear. The support plate may include a domed structure with radially extending arms extending from a central heel portion, where the domed structure provides heel cushioning to the wearer when a force is transmitted through the midsole to the domed structure.

Sole structures generally include a layered arrangement extending between a ground surface and the upper. One layer of the sole structure includes an outsole that provides abrasion-resistance and traction with the ground surface. The outsole may be formed from rubber or other materials that impart durability and wear-resistance, as well as enhancing traction with the ground surface. Another layer of the sole structure includes a midsole disposed between the outsole and the upper. The midsole provides cushioning for the foot and is generally at least partially formed from a polymer foam material that compresses resiliently under an applied load to cushion the foot by attenuating ground-reaction forces. The midsole may define a bottom surface on one side that opposes the outsole and a footbed on the opposite side that may be contoured to conform to a profile of the bottom surface of the foot. Sole structures may also include a comfort-enhancing insole and/or a sockliner located within a void proximate to the bottom portion of the upper.

Midsoles using polymer foam materials are generally configured as a single slab that compresses resiliently under applied loads, such as during walking or running movements. Generally, single-slab polymer foams are designed with an emphasis on balancing cushioning characteristics that relate to softness and responsiveness as the slab compresses under gradient loads. Polymer foams providing cushioning that is too soft will decrease the compressibility and the ability of the midsole to attenuate ground-reaction forces after repeated compressions. Conversely, polymer foams that are too hard and, thus, very responsive, sacrifice softness, thereby resulting in a loss in comfort. While different regions of a slab of polymer foam may vary in density, hardness, energy return, and material selection to balance the softness and responsiveness of the slab as a whole, creating a single slab of polymer foam that loads in a gradient manner from soft to responsive is difficult to achieve.

A sole structure according to the claimed invention is defined by the independent claim. Additional embodiments are defined in the dependent claims. Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope of those who are skilled in the art. In some example embodiments, well-known processes, well-known device structures, and well known technologies are not described in detail.

The terms "comprises," "comprising," "including," and "having," are inclusive and therefore specify the presence of features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

With reference to the figures, a sole structure for an article of footwear having an upper is provided. The sole structure includes a first plate having a first surface facing away from the upper. The first plate includes a forefoot region at an anterior end of the first plate, a heel region at a posterior end of the first plate, and a mid-foot region intermediate the forefoot region and the heel region. The sole structure further includes a second plate having a second surface opposing the first surface of the first plate. The second plate has a first end attached at the forefoot region of the first plate, and extends to a second end that is spaced apart from the first surface of the first plate. A cushion is disposed between the first plate and the second plate in the forefoot region and has a first side attached to the first surface of the first plate and a second side attached to the second surface of second plate. The cushion extends from a medial side of the sole structure to a lateral side of the sole structure. The cushion is a fluid-filled bladder and includes a tensile member disposed therein.

Implementations of the disclosure may include one of more of the following optional features.

In some examples, the fluid-filled bladder is pressurized. Optionally, the fluid-filled bladder is at a pressure between <NUM>,<NUM> bar (<NUM> psi) and <NUM>,<NUM> bar (<NUM> psi). Alternatively, the fluid-filled bladder is at a pressure between <NUM>,<NUM> bar (<NUM> psi) and <NUM>,<NUM> bar (<NUM> psi). In other examples, the fluid-filled bladder is at a pressure of <NUM>,<NUM> bar (<NUM> psi). In some examples, the fluid-filled bladder is at a pressure of <NUM>,<NUM> bar (<NUM> psi).

In some implementations, the cushion extends continuously from a medial side of the sole structure to a lateral side of the sole structure.

The sole structure may further include a toe pad disposed between the first plate and the second plate and disposed at the anterior end of the first plate. In some implementations, the first end of the second plate is attached to the toe pad. In some examples, the toe pad is formed of a foamed polymeric material. In some implementations, wherein a first surface of the toe pad is attached to the first surface of the first plate and a second surface of the toe pad is attached to the second surface of the second plate. The first surface of the toe pad and the second surface of the toe pad may diverge from each other along a direction from the anterior end of the first plate to the posterior end of the first plate. The toe pad may include a groove extending from a medial side of the sole structure to a lateral side of the sole structure. Optionally, the cushion may be spaced apart from the toe pad by a gap, the gap extending continuously from the medial side to the lateral side.

In some implementations, the first plate is formed of a composite material and the second plate is formed of a polymeric material. Here, the composite material may comprise a carbon fiber material and a binder.

In some examples, the first plate includes fiber bundles arranged on a substrate. Optionally, the first plate includes unidirectional tape.

In some implementations, the first plate is formed by an injection molding process.

In some examples, the second plate includes a third surface formed on an opposite side of the second plate than the second surface and including a plurality of traction elements protruding therefrom. Optionally, at least one of the traction elements includes a flange attached to the second plate. The flange may be attached between the second surface and the third surface of the second plate. In some examples, the flange is encapsulated in the second plate. A spike may extend from the flange and from the third surface. The spike may be removably attached to the flange. Alternatively, the spike is integrally formed with the flange.

In some examples, the second plate includes a receptacle attached to the second plate. The receptacle may be attached between the second surface and the third surface of the second plate.

Here, the receptacle may include a retention feature exposed through the third surface of the second plate. In some examples, a traction element is removably received by the retention feature. The retention feature may be a helical thread.

In some implementations, the plurality of traction elements include primary traction elements and secondary traction elements. Here, the secondary traction elements are integrally formed with the third surface of the second plate.

In some examples, the second plate includes a third surface formed on an opposite side of the second plate than the second surface and including a network of ribs protruding from the third surface. The third surface of the second plate may include a protrusion disposed within the network of ribs, the protrusion configured to receive a traction element. The protrusion and the network of ribs may cooperate to define a ground-engaging surface.

In some implementations, the second end of the second plate is cantilevered off of a posterior end of the cushion.

In some examples, the second plate is cantilevered from the anterior end of the first plate.

In some implementations, the first end of the second plate extends upwardly at the anterior end of the first plate and forms a toe cap.

In some examples, a majority of a length of the second plate is supported by the cushion, the length extending from the first end of the second plate to the second end of the second plate.

In some implementations the sole structure includes a midsole including a toe pad disposed in a toe portion of the mid-foot region and a cushion disposed in the heel region.

The sole structure may further include a shank attached to the first surface of the first plate, the shank extending from an anterior end disposed between the first plate and the cushion to a posterior end of the shank adjacent the heel region. Here, the shank includes a protuberance having an outer periphery offset inwardly from an outer periphery of the shank, an anterior end of the protuberance spaced apart from and complementary to an outer periphery of the cushion.

The sole structure includes a heel pad attached to the second surface of the first plate at the posterior end. The heel pad may include a plurality of traction elements. The traction elements of the heel pad may be arranged in alternating rows and columns.

In another aspect of the disclosure, a sole structure for an article of footwear having an upper is provided. The sole structure includes a first plate having a first surface. The first plate includes a forefoot region at an anterior end of the first plate, a heel region at a posterior end of the first plate, and a mid-foot region intermediate the forefoot region and the heel region. The sole structure further includes a second plate having a second surface opposing the first surface of the first plate. The second plate includes a first end attached to the forefoot region of the first plate and extending to a second end that is spaced apart from the first surface of the first plate. A cushion has a first side attached to the first surface of the first plate and a second side attached to the second surface of second plate. The cushion extends from a first peripheral side surface of the second plate to an opposing second peripheral side surface of the second plate.

Implementations of the disclosure may include one of more of the following optional features. According to the claimed invention, the cushion is a fluid-filled bladder and includes a tensile member disposed therein.

In some implementations, the cushion extends continuously from the medial side of the sole structure to the lateral side of the sole structure.

The sole structure may further include a toe pad disposed between the first plate and the second plate and disposed at the anterior end of the first plate. In some implementations, the first end of the second plate is attached to the toe pad. In some examples, the toe pad is formed of a foamed polymeric material. In some implementations, wherein a first surface of the toe pad is attached to the first surface of the first plate and a second surface of the toe pad is attached to the second surface of the second plate. The first surface of the toe pad and the second surface of the toe pad may diverge from each other along a direction from the anterior end of the first plate to the posterior end of the first plate. The toe pad may include a groove extending from the medial side of the sole structure to the lateral side of the sole structure. Optionally, the cushion may be spaced apart from the toe pad by a gap, the gap extending continuously from the medial side to the lateral side.

The sole structure may further include a shank attached to the first surface of the first plate, the shank extending from an anterior end disposed between the first plate and the cushion to a posterior end of the shank adj acent the heel region. Here, the shank includes a protuberance having an outer periphery offset inwardly from an outer periphery of the shank, an anterior end of the protuberance spaced apart from and complementary to an outer periphery of the cushion.

The sole structure according to the claimed invention includes a heel pad attached to the second surface of the first plate at the posterior end. The heel pad may include a plurality of traction elements. The traction elements of the heel pad may be arranged in alternating rows and columns.

Referring to <FIG>, an article of footwear <NUM> includes an upper <NUM> and sole structure <NUM>. The article of footwear <NUM> may be divided into one or more regions. The regions may include a forefoot region <NUM>, a mid-foot region <NUM>, and a heel region <NUM>. The forefoot region <NUM> may be subdivided into a toe portion <NUM>T corresponding with phalanges, and a ball portion <NUM>B associated with metatarsal bones of a foot. The mid-foot region <NUM> may correspond with an arch area of the foot, and the heel region <NUM> may correspond with rear portions of the foot, including a calcaneus bone. The footwear <NUM> may further include an anterior end <NUM> associated with a forward-most point of the forefoot region <NUM>, and a posterior end <NUM> corresponding to a rearward-most point of the heel region <NUM>. As shown in <FIG>, a longitudinal axis AF of the footwear <NUM> extends along a length of the footwear <NUM> from the anterior end <NUM> to the posterior end <NUM>, and generally divides the footwear <NUM> into a medial side <NUM> and a lateral side <NUM>. Accordingly, the medial side <NUM> and the lateral side <NUM> respectively correspond with opposite sides of the footwear <NUM> and extend through the regions <NUM>, <NUM>, <NUM>.

The upper <NUM> includes interior surfaces that define an interior void <NUM> configured to receive and secure a foot for support on sole structure <NUM>. The upper <NUM> may be formed from one or more materials that are stitched or adhesively bonded together to form the interior void <NUM>. Suitable materials of the upper may include, but are not limited to, mesh, textiles, foam, leather, and synthetic leather. The materials may be selected and located to impart properties of durability, air-permeability, wear-resistance, flexibility, and comfort.

In some examples, one or more fasteners <NUM> extend along the upper <NUM> to adjust a fit of the interior void <NUM> around the foot and to accommodate entry and removal of the foot therefrom. The upper <NUM> may include apertures <NUM> such as eyelets and/or other engagement features such as fabric or mesh loops that receive the fasteners <NUM>. The fasteners <NUM> may include laces, straps, cords, hook-and-loop, or any other suitable type of fastener. The upper <NUM> may include a tongue portion <NUM> that extends between the interior void <NUM> and the fasteners.

With reference to <FIG> and <FIG>, in some examples the upper <NUM> includes a strobel <NUM> having a bottom surface opposing the sole structure <NUM> and an opposing top surface defining a footbed <NUM> of the interior void <NUM>. Stitching or adhesives may secure the strobel to the upper <NUM>. The footbed <NUM> may be contoured to conform to a profile of the bottom surface (e.g., plantar) of the foot. Optionally, the upper <NUM> may also incorporate additional layers such as an insole <NUM> or sockliner that may be disposed upon the strobel <NUM> and reside within the interior void <NUM> of the upper <NUM> to receive a plantar surface of the foot to enhance the comfort of the article of footwear <NUM>. An ankle opening <NUM> in the heel region <NUM> may provide access to the interior void <NUM>. For example, the ankle opening <NUM> may receive a foot to secure the foot within the void <NUM> and to facilitate entry and removal of the foot from and to the interior void <NUM>.

With reference to <FIG>, the sole structure <NUM> includes a chassis <NUM> having a chassis plate <NUM> extending between the medial side <NUM> and the lateral side <NUM> from the anterior end <NUM> to the posterior end <NUM>. A shank <NUM> is attached to the plate <NUM> and extends from the mid-foot region <NUM> to the heel region <NUM>. The sole structure <NUM> further includes a midsole <NUM> attached to the chassis <NUM> and including an toe pad <NUM> disposed adjacent the anterior end <NUM> of the chassis <NUM>, a heel pad <NUM> disposed adjacent the posterior end <NUM> of the chassis <NUM>, and a cushion <NUM> disposed in the forefoot region <NUM> of the chassis <NUM>. The sole structure <NUM> further includes an outsole <NUM> having a forefoot plate <NUM> attached to each of the toe pad <NUM> and the cushion <NUM>, and a heel plate <NUM> attached to the heel pad <NUM>. The forefoot plate <NUM> and the heel plate <NUM> cooperate to define a ground-engaging surface <NUM> of the sole structure <NUM>. A plurality of traction elements <NUM>, 224a, 224b may extend from the outsole <NUM>, and form part of the ground-engaging surface <NUM>.

With reference to <FIG> and <FIG>, the chassis plate <NUM> extends from a first end <NUM> at the anterior end <NUM> of the sole structure <NUM> to a second end <NUM> at the posterior end <NUM>, and spans a width of the sole structure <NUM> from the medial side <NUM> to the lateral side <NUM>. Accordingly, an upper surface <NUM> of the chassis <NUM> defines a profile of the footbed <NUM> of the upper <NUM>. The chassis plate <NUM> further includes a lower surface <NUM> formed opposite the upper surface <NUM>. A distance between the upper surface <NUM> and the lower surface <NUM> defines a thickness TC of the chassis plate <NUM>.

The chassis plate <NUM> may be manufactured using fiber sheets or textiles, including preimpregnated (i.e., "prepreg") fiber sheets or textiles. Alternatively or additionally, the chassis plate <NUM> may be manufactured by strands formed from multiple filaments of one or more types of fiber (e.g., fiber tows) by affixing the fiber tows to a substrate or to each other to produce a plate having the strands of fibers arranged predominately at predetermined angles or in predetermined positions. When using strands of fibers, the types of fibers included in the strand can include synthetic polymer fibers which can be melted and re-solidified to consolidate the other fibers present in the strand and, optionally, other components such as stitching thread or a substrate or both. Alternatively or additionally, the fibers of the strand and, optionally the other components such as stitching thread or a substrate or both, can be consolidated by applying a resin after affixing the strands of fibers to the substrate and/or to each other. The above processes are described below.

In some configurations, chassis plate <NUM> may be formed from one or more layers of tows of fibers and/or layers of fibers including at least one of carbon fibers, boron fibers, glass fibers, and polymeric fibers. In a particular configuration, the fibers include carbon fibers, or glass fibers, or a combination of both carbon fibers and glass fibers. The tows of fibers may be affixed to a substrate. The tows of fibers may be affixed by stitching or using an adhesive. Additionally or alternatively, the tows of fibers and/or layers of fibers may be consolidated with a thermoset polymer and/or a thermoplastic polymer. Accordingly, the chassis plate <NUM> may have a tensile strength or flexural strength in a transverse direction substantially perpendicular to the longitudinal axis AL. The stiffness of the chassis plate <NUM> may be selected for a particular wearer based on the wearer's tendon flexibility, calf muscle strength, and/or metatarsophalangeal (MTP) joint flexibility. Moreover, the stiffness of the chassis plate <NUM> may also be tailored based upon a running motion of the athlete. In other configurations, the chassis plate <NUM> is formed from one or more layers/plies of unidirectional tape. In some examples, each layer in the stack includes a different orientation than the layer disposed underneath. The plate may be formed from unidirectional tape including at least one of carbon fibers, boron fibers, glass fibers, and polymeric fibers. In some examples, the one or more materials forming the chassis plate <NUM> include a Young's modulus of at least <NUM> gigapascals (GPa).

In some implementations, the chassis plate <NUM> includes a substantially uniform thickness TC. In some examples, the thickness of the chassis plate <NUM> ranges from about <NUM> millimeter (mm) to about <NUM>. In one example, the thickness of the chassis plate <NUM> is substantially equal to one <NUM>. In other implementations, the thickness TC of the chassis plate <NUM> is nonuniform such that the chassis plate <NUM> may have a greater thickness TC in the mid-foot region <NUM> of the sole structure <NUM> than the thicknesses TC in the forefoot region <NUM> and the heel region <NUM>.

With continued reference to <FIG>, the shank <NUM> of the chassis <NUM> is attached to the lower surface <NUM> of the chassis plate <NUM> and extends from a first end <NUM> in the mid-foot region <NUM> to a second end <NUM> in the heel region <NUM>. An upper surface <NUM> of the shank <NUM> is attached to the lower surface <NUM> of the chassis plate <NUM>. The shank <NUM> includes a peripheral side surface <NUM> extending between the upper surface <NUM> and the lower surface <NUM>.

With reference to <FIG>, the peripheral side surface <NUM> of the shank <NUM> includes a plurality of side surfaces 242a-242c defining an outer periphery of the shank <NUM>. For example, the side surfaces <NUM> include an anterior-facing, front surface 242a, a medial side surface 242b, and a lateral side surface 242c. The front surface 242a extends along the first end <NUM> of the shank <NUM> between the medial side <NUM> and the lateral side <NUM>. The front surface 242a may be arcuate and define a concave recess <NUM> formed through the first end <NUM> of the shank <NUM>. As discussed below, the recess <NUM> complements to a peripheral profile of the cushion <NUM>, and is configured to receive a portion of the cushion <NUM> therethrough to allow the cushion <NUM> to be attached directly to the chassis plate <NUM>.

The medial and lateral side surfaces 242b, 242c extend, generally, from opposing ends of the front surface 242a and converge with each other at the second end <NUM> of the shank <NUM>. Accordingly, a width of the shank <NUM> may taper from the first end <NUM> to the second end <NUM>, such that the width of the shank is greater at the first end <NUM> than at the second end <NUM>. Respective intersections between each of the side surfaces 242a-242c may be convex, and form convex tips <NUM>, 244a-244c of the shank <NUM>.

The shank <NUM> may further include a boss <NUM> protruding from the lower surface <NUM>. The boss <NUM> provides a stepped increase in a thickness of a central portion of the shank <NUM>. The boss <NUM> has an outer periphery that is offset inwardly from the outer periphery of the shank <NUM>. A thickness of the boss <NUM>, and consequentially - the shank <NUM> - may taper from a first thickness at a central vertex <NUM> to lesser thicknesses at the outer periphery of the shank <NUM>. As shown, the vertex <NUM> is formed by the convergence of three boss surfaces <NUM>, <NUM>-250c, each extending inwardly from the respective side surfaces <NUM>, 242a-242c.

The shank <NUM> is formed of a rigid polymeric material and may be attached to the lower surface <NUM> of the chassis plate <NUM> using an adhesive. Alternatively, the shank <NUM> may be integrally molded with the chassis plate <NUM>, such that at least a portion of the shank <NUM> is encapsulated within the resin of the chassis plate <NUM>. Additionally or alternatively, the shank <NUM> may be attached to the chassis plate <NUM> by melding a material of the shank <NUM> to a material of the chassis plate <NUM>.

With reference to <FIG>, the midsole <NUM> is disposed between the chassis <NUM> and the outsole <NUM>, and is configured to attenuate forces associated with impact of the sole structure <NUM> with a ground surface. As shown in <FIG>, the midsole <NUM> includes the toe pad <NUM>, the heel pad <NUM>, and the cushion <NUM>.

With reference to <FIG>, <FIG>, and <FIG>, the toe pad <NUM> extends from a first end <NUM> at the anterior end <NUM> of the sole structure <NUM> to a second end <NUM> within the forefoot region <NUM>. In the illustrated embodiment, the toe pad <NUM> is disposed within the toe portion <NUM>T of the forefoot region <NUM>. An upper surface <NUM> of the toe pad <NUM> is attached to the lower surface <NUM> of the chassis plate <NUM>. The toe pad <NUM> further includes a lower surface <NUM> formed opposite the upper surface <NUM>, and a peripheral side surface <NUM> extending between the lower surface <NUM> and the upper surface <NUM>. A distance between the upper surface <NUM> and the distal side surface defines a thickness TTP of the toe pad <NUM>. As shown in <FIG>, the upper surface <NUM> and the lower surface <NUM> diverge from each other in a direction from the first end <NUM> to the second end <NUM>. Accordingly, the thickness TTP of the toe pad <NUM> increases continuously from the first end <NUM> to the second end <NUM>, such that the toe pad forms a wedge between the chassis plate <NUM> and the forefoot plate <NUM> of the outsole <NUM> in the toe portion <NUM>T. As illustrated in <FIG> and <FIG>, the second end <NUM> of the toe pad <NUM> may be contoured, and extend along an arcuate or concave path between the medial side <NUM> and the lateral side <NUM>.

Additionally, as shown in <FIG> and <FIG>, the peripheral side surface <NUM> may define a groove <NUM> extending from the medial side <NUM> to the lateral side <NUM> along the second end <NUM> of the toe pad <NUM>. For example, as indicated in <FIG>, the peripheral side surface <NUM> may include an upper peripheral side surface 260a extending inwardly from an outer periphery of the upper surface <NUM> at a first angle, and a lower peripheral side surface 260b extending inwardly from an outer periphery of the lower surface <NUM> at a second angle. Accordingly, the upper peripheral side surface 260a and the lower peripheral side surface 260b converge with each other to define a V-shaped groove <NUM> between the upper surface <NUM> and the lower surface <NUM>. As shown, a height of the groove may taper along each of the medial side <NUM> and the lateral side <NUM>.

With reference to <FIG> and <FIG>, the groove <NUM> may include a channel <NUM> formed along a length thereof, where the upper peripheral side surface 260a and the lower peripheral side surface 260b converge. As shown in <FIG>, the channel <NUM> is inwardly offset from the respective peripheral side surfaces 260a, 260b. As described in greater detail below, the toe pad <NUM> may function as a fulcrum for the forefoot plate <NUM>, such that the forefoot plate <NUM> is cantilevered along the forefoot region <NUM>. Accordingly, the groove <NUM> and the channel <NUM> of the peripheral side surface <NUM> cooperate to allow the respective outer peripheries of the upper surface <NUM> and the lower surface <NUM> to bend relative to each other.

Referring to <FIG>, the heel pad <NUM> is attached to the lower surface <NUM> of the chassis plate <NUM> and extends from a first end <NUM> adjacent the mid-foot region <NUM> to a second end <NUM> at the anterior end <NUM> of the sole structure <NUM>. The first end <NUM> of the heel pad <NUM> may include a V-shaped notch <NUM> configured to receive the second end <NUM> of the shank <NUM>, as shown in <FIG>. Accordingly, a profile of the notch <NUM> may be offset from a profile of the medial and lateral side surfaces 242b, 242c of the shank <NUM>.

The heel pad <NUM> includes an upper surface <NUM> attached to the lower surface <NUM> of the chassis plate <NUM>, and a lower surface <NUM> formed opposite the upper surface <NUM>. The lower surface <NUM> may include a surface feature <NUM> configured to engage the heel plate <NUM>. For example, the illustrated heel pad <NUM> includes a triangular boss <NUM> extending from the lower surface <NUM>. In other examples, the surface feature may be a plurality of bosses or recesses, and may have any shape for cooperating with the heel plate <NUM>.

The heel pad <NUM> further includes a peripheral side surface <NUM> extending between the upper surface <NUM> and the lower surface <NUM>. The peripheral side surface <NUM> may include a medial side surface 278a and a lateral side surface 278b that converge with each other at the second end <NUM>, such that the posterior end <NUM> of the sole structure <NUM> is streamlined. In some examples, the upper surface <NUM> may be convex and curve upwardly towards the peripheral side surface <NUM> to define a heel cup around the anterior end <NUM> of the upper <NUM>, as shown in <FIG> and <FIG>.

Each of the toe pad <NUM> and the heel pad <NUM> may be formed from an energy absorbing material such as, for example, polymer foam. Forming the pads <NUM>, <NUM> from an energy-absorbing material such as polymer foam allows the sole structure <NUM> to attenuate ground-reaction forces caused by movement of the article of footwear <NUM> over ground during use.

With reference to <FIG>, and <FIG>, the cushion <NUM> is disposed between the chassis plate <NUM> and the forefoot plate <NUM> of the outsole <NUM>. The cushion <NUM> is attached to the chassis plate <NUM> between the toe pad <NUM> and the heel pad <NUM>, and extends from a first end <NUM> in the forefoot region <NUM> to a second end <NUM> in mid-foot region <NUM>. The first end <NUM> of the cushion <NUM> opposes the second end <NUM> of the toe pad <NUM>, and is spaced apart from the second end <NUM> by a gap <NUM>, as shown in <FIG>, and <FIG>. As discussed above and shown in <FIG>, the second end <NUM> of the toe pad <NUM> may have an arcuate profile, such that a width WG of the gap <NUM> is variable along the direction from the medial side <NUM> to the lateral side <NUM>.

As described above, the cushion <NUM> is received between the chassis plate <NUM> and the forefoot plate <NUM>. In one configuration, the cushion <NUM> extends continuously from the medial side <NUM> to the lateral side <NUM> of the sole structure. For example, as shown in <FIG>, the cushion <NUM> extends from a first peripheral edge <NUM> of the forefoot plate <NUM> at the medial side <NUM> to a second peripheral edge <NUM> of the forefoot plate <NUM> at the lateral side <NUM>. Accordingly, the chamber <NUM> of the cushion <NUM> is continuous and uninterrupted between the medial side <NUM> and the lateral side <NUM>.

With reference to <FIG>, the first end <NUM> of the shank <NUM> may be disposed between the second end <NUM> of the cushion <NUM> and the chassis plate <NUM>, such that the second end <NUM> of the cushion <NUM> may be attached to the first end <NUM> of the shank <NUM>. As discussed above, the first end <NUM> of the shank <NUM> may be concave and include the recess <NUM> for allowing a portion of the cushion to be attached directly to the lower surface <NUM> of the chassis plate <NUM>. While the first end <NUM> of the shank <NUM> extends between the cushion <NUM> and the chassis plate <NUM>, a first end of the boss <NUM> is offset outwardly from an outer periphery of the cushion <NUM>. Accordingly, the first end of the boss <NUM> is spaced apart from and has a profile that is complementary to a peripheral profile of the second end <NUM> of the cushion <NUM>, as shown in <FIG>.

With particular reference to <FIG>, the cushion <NUM> of the illustrated example is a fluid-filled bladder <NUM> defining a chamber <NUM> for including a pressurized fluid. The cushion <NUM> may include a first barrier element <NUM> and a second barrier element <NUM>. The first barrier element <NUM> and the second barrier element <NUM> may be formed from a sheet of thermoplastic polyurethane (TPU). Specifically, the first barrier element <NUM> may be formed from a sheet of TPU material and may include a substantially planar shape. The second barrier element <NUM> may likewise be formed from a sheet of TPU material and may be formed into the configuration shown in <FIG> and <FIG> to define the chamber <NUM>. The first barrier element <NUM> may be attached to the second barrier element <NUM> by applying heat and pressure at a perimeter of the first barrier element <NUM> and the second barrier element <NUM> to define a peripheral seam <NUM>. The peripheral seam <NUM> seals the chamber <NUM> and defines the peripheral profile of the cushion <NUM>.

The chamber <NUM> of the cushion <NUM> may receive a tensile element <NUM> therein. Each tensile element <NUM> may include a series of tensile strands <NUM> extending between an upper tensile sheet <NUM> and a lower tensile sheet <NUM>. The upper tensile sheet <NUM> may be attached to the first barrier element <NUM> while the lower tensile sheet <NUM> may be attached to the second barrier element <NUM>. In this manner, when the chamber <NUM> receives the pressurized fluid, the tensile strands <NUM> of the tensile element <NUM> are placed in tension. Because the upper tensile sheet <NUM> is attached to the first barrier element <NUM> and the lower tensile sheet <NUM> is attached to the second barrier element <NUM>, the tensile strands <NUM> retain a desired shape of the cushion <NUM> when the pressurized fluid is injected into the chamber <NUM>.

In some examples, the chamber <NUM> is at a pressure ranging from <NUM> psi (pounds per square inch) to <NUM> psi, wherein <NUM> psi is <NUM>,<NUM> bar. In other examples, the chamber <NUM> may have a pressure ranging from <NUM> psi to 25psi. In some examples, the chamber <NUM> has a pressure of <NUM> psi. In other examples, the chamber has a pressure of <NUM> psi.

While the cushion <NUM> is described and shown as including a continuous fluid-filled chamber <NUM>, the cushion <NUM> could alternatively include other cushioning elements. For example, the cushion may include a foam block that replaces or supplements the pressurized fluid. The foam block(s) may be received within the chamber <NUM> defined by the first barrier element <NUM> and the second barrier element <NUM>. Positioning the foam block(s) within the chamber <NUM> defined by the first barrier element <NUM> and the second barrier element <NUM> allows the barrier elements <NUM>, <NUM> to restrict expansion of the foam blocks beyond a predetermined amount when subjected to a predetermined load. Accordingly, the overall shape and, thus, the performance of the foam blocks may be controlled by allowing the foam blocks to interact with the barrier elements <NUM>, <NUM> during loading. While the foam blocks are described as being received within the chamber <NUM> of the barrier elements <NUM>, <NUM>, the foam blocks could alternatively be positioned between the chassis plate <NUM> and the forefoot plate <NUM> absent the barrier elements <NUM>, <NUM>. In such a configuration, the foam blocks would be directly attached to the lower surface <NUM> of the chassis plate <NUM> and to forefoot plate <NUM>, respectively.

As provided above, the outsole <NUM> includes the forefoot plate <NUM> and the heel plate <NUM>, which cooperate to define the ground-engaging surface <NUM> of the sole structure <NUM>. One or both of the forefoot plate <NUM> and the heel plate <NUM> may include traction elements <NUM> forming at least a portion of the ground-engaging surface <NUM>.

With reference to <FIG>, the forefoot plate <NUM> includes a first end <NUM> attached to the lower surface <NUM> of the toe pad <NUM>. In some examples, the first end <NUM> of the forefoot plate <NUM> extends upwardly along the anterior end <NUM> of the footwear <NUM>, and forms a toe cap <NUM>. The toe cap <NUM> may extend over the anterior end <NUM> of the upper <NUM>. The forefoot plate <NUM> extends from the first end <NUM> to distal second end <NUM> within the mid-foot region <NUM> of the sole structure <NUM>. The forefoot plate <NUM> further includes an upper surface <NUM>, an opposing lower surface <NUM>, and the peripheral side surface <NUM> extending between the upper surface <NUM> and the lower surface <NUM>.

With reference to <FIG>, and <FIG>, the upper surface <NUM> is spaced apart from the lower surface <NUM> of the chassis plate <NUM>, and defines a cavity <NUM> between the chassis plate <NUM> and the forefoot plate <NUM> for receiving the cushion <NUM>. As provided above, the first end <NUM> of the forefoot plate <NUM> is attached to the toe pad <NUM>, while the remainder of the forefoot plate <NUM> is separated from the chassis plate <NUM> by the cavity <NUM>. Accordingly, the forefoot plate <NUM> is cantilevered with respect to the chassis plate <NUM>, such that the second end <NUM> is able to bend relative to the first end <NUM>.

As discussed above, the cushion <NUM> is disposed within the cavity <NUM>, and is attached to the lower surface <NUM> of the chassis plate <NUM> on a first side, and to the upper surface <NUM> of the forefoot plate on a second side. Accordingly, flex of the forefoot plate <NUM> may be attenuated by the cushion <NUM>. Referring to <FIG>, the first end <NUM> of the cushion <NUM> is spaced apart from the toe pad <NUM> by the gap <NUM>, while the second end <NUM> of the cushion <NUM> is offset inwardly from the second end <NUM> of the forefoot plate <NUM>. Accordingly, the second end of the forefoot plate <NUM> extends beyond the second end <NUM> of the cushion <NUM>, and is configured to cantilever with respect to the second end <NUM> of the cushion <NUM>. As shown, the cushion <NUM> supports a substantial majority of a length of the forefoot plate <NUM> between the toe pad <NUM> and the second end <NUM> of the forefoot plate <NUM>.

The second end <NUM> of the cushion <NUM> may be engaged by a retention feature <NUM> formed on the upper surface <NUM> of the forefoot plate <NUM>. For example, the upper surface <NUM> may include a protuberance <NUM> or recess configured to cooperate with the second barrier element <NUM> to maintain a position of the cushion <NUM>. With continued reference to <FIG>, the cushion <NUM> extends continuously from the peripheral side surface <NUM> of the forefoot plate <NUM> on the medial side <NUM> to the peripheral side surface <NUM> of the forefoot plate <NUM> on the lateral side <NUM>.

With reference to <FIG> and <FIG>, the lower surface <NUM> of the forefoot plate <NUM> includes a plurality of the traction elements <NUM> extending therefrom. The traction elements <NUM> include integral traction elements 224a and attached traction elements 224b. The integral traction elements 224a are formed from the same material as the forefoot plate <NUM>, and are formed unitary with the lower surface <NUM> during a molding process. In the illustrated example, the integral traction elements 224a are pyramidal in shape, and are formed as a first group adjacent the first end <NUM>, and second group adjacent the second end <NUM>, and a third group along the lateral side <NUM>. The second group of the integral traction elements 224a may be arranged in a chevron configuration along the second end <NUM> of the forefoot plate <NUM>.

In contrast to the integral traction elements 224a, the attached traction elements 224b are initially formed separately from the forefoot plate <NUM>, and are fixed to the forefoot plate <NUM> during or after the molding process. As shown in <FIG> and <FIG>, the attached traction elements 224b may include a flange <NUM> and a spike <NUM> extending from the flange <NUM>. In some examples, the flange <NUM> may include a plurality of radially arranged tabs configured to engage the material of the forefoot plate <NUM> to prevent rotation of the traction elements 224b. The spike <NUM> may be conical, and protrudes from the lower surface <NUM> of the forefoot plate <NUM>.

In some examples, the flanges <NUM> of the attached traction elements 224b are encapsulated within the forefoot plate <NUM>, intermediate the upper surface <NUM> and the lower surface <NUM>. For example, during the molding process for forming the forefoot plate <NUM>, the attached traction elements 224b may be initially provided to a forefoot plate mold such that the spike <NUM> is received through the mold surface corresponding to the lower surface <NUM> of the forefoot plate <NUM>, while the flange <NUM> is spaced apart from the mold surface corresponding to the lower surface <NUM> of the forefoot plate <NUM>. Molten material is then provided to the forefoot plate mold and encapsulates the flange <NUM> within the forefoot plate <NUM>, while the spike <NUM> extends through the forefoot plate <NUM> and protrudes from the lower surface <NUM>, as shown in <FIG>. The forefoot plate <NUM> may include areas of increased thickness, or bulges, corresponding to the locations of the flanges <NUM>.

Additionally or alternatively, the attached traction elements 224b may be removably attached to the forefoot plate <NUM>, such that the attached traction elements 224b can be replaced. For example, the forefoot plate <NUM> may have threaded bushings including flanges (not shown) that are encapsulated within the forefoot plate <NUM> in a similar fashion as described above with respect to the flange <NUM>. The threaded bushing may be exposed through the lower surface <NUM> of the forefoot plate <NUM>, such that corresponding threads of a traction element <NUM> can engage the threaded bushing to removably secure the traction element <NUM>.

With reference to <FIG>, the attached traction elements 224b are arranged in areas of the forefoot plate <NUM> associated with the midsole <NUM>. For example, a first pair of the attached traction elements 224b is arranged in the toe portion <NUM>T of the sole structure <NUM>, and are aligned with the toe pad <NUM>. A second pair of the attached traction elements 224b is associated with the first end <NUM> of the cushion, and includes a first attached traction element 224b adj acent the medial side <NUM> and another attached traction element 224b adjacent the lateral side <NUM>. Another group of four attached traction elements 224b is spaced along a width of the forefoot plate <NUM> from the medial side <NUM> to the lateral side <NUM>, and is associated with an intermediate region of the cushion <NUM>.

The lower surface <NUM> may be serrated and includes a plurality of corrugations <NUM> defined by alternating ridges and flutes. As shown in <FIG> and <FIG>, forefoot plate <NUM> includes a first plurality of corrugations 320a formed in the toe portion <NUM>T, which extend along a direction from the medial side <NUM> to the lateral side <NUM>, substantially perpendicular to the longitudinal axis AL of the footwear <NUM>. A second plurality of corrugations 320b is formed between the medial side <NUM> and an intermediate portion of the lower surface <NUM> between the medial side <NUM> and the lateral side <NUM>. The second plurality of corrugations 320b extend along a second direction at a first oblique angle with respect to the longitudinal axis AL. A third plurality of the corrugations 320c is formed between the lateral side <NUM> and the intermediate portion of the lower surface <NUM>, and extend along a third direction at a second oblique angle with respect to the longitudinal axis AL. As shown, the first oblique angle of the second plurality of corrugations 320b is greater than the second oblique angle of the third plurality of corrugations 320c.

The first plurality of corrugations 320a may be spaced apart from the second and third pluralities of corrugations 320b, 320c along region of the lower surface <NUM> corresponding to the gap <NUM> between the toe pad <NUM> and the cushion <NUM>. For example, as shown in <FIG>, a band <NUM> of the lower surface <NUM> extends continuously and uninterrupted from the medial side <NUM> to the lateral side <NUM>, and is aligned with the gap <NUM> such that the band <NUM> provides a flexure bearing or living hinge between the fixed first end <NUM> and the second end <NUM>.

In another example of the sole structure 200a, the forefoot plate 218a includes a plurality of ribs <NUM> extending from the lower surface <NUM>, as shown in <FIG> and <FIG>. The ribs <NUM> are interconnected with each other and form a network of the ribs <NUM> extending along an entirety of the lower surface <NUM> of the forefoot plate. In the illustrated example, the ribs <NUM> may be arranged in a honeycombed-shaped network, including a plurality of polygonal (e.g. hexagonal) voids <NUM>. In some examples, the lower surface <NUM> includes a plurality of protrusions <NUM> configured to provide areas of increased thickness along the forefoot plate <NUM>. For example, the protrusions <NUM> may be integrated within the network of the ribs <NUM>, such that a plurality of the ribs <NUM> define an outer periphery of the protrusion and/or emanate from the protrusions <NUM>. The ribs <NUM> and the protrusions <NUM> may cooperate to define the ground-engaging surface <NUM> of the forefoot plate <NUM>. Alternatively, the ribs <NUM> and the protrusions <NUM> may be described as defining a secondary surface spaced apart from the lower surface <NUM> (i.e. bottom of the voids <NUM>) of the forefoot plate <NUM>.

As discussed above, the protrusions <NUM> are configured to receive the detachable traction elements 224b. As shown in <FIG>, the protrusions <NUM> may have bushings <NUM> embedded therein. For example, the bushings may include a helically-threaded receptacle, configured to receive a threaded stud of a traction element <NUM>.

With reference to <FIG>, the heel plate <NUM> may be attached to the surface feature <NUM> of the heel pad <NUM>, and includes a plurality of the traction elements <NUM> formed therein. In some examples, the heel plate <NUM> may be adhesively bonded to the heel pad <NUM>. Additionally or alternatively, the heel plate <NUM> may be at least partially embedded within the heel pad <NUM>, or may be melded to the heel pad <NUM>.

During operation, when the ground-engaging surface <NUM> contacts the ground, a force is transmitted via the outsole <NUM> to the midsole <NUM>. Namely, the force is transmitted from the forefoot plate <NUM> to the cushion <NUM>. The applied force causes the cushion <NUM> to compress, thereby absorbing the forces associated with the outsole <NUM> contacting the ground. The force is transmitted to the cushion <NUM> and the chassis <NUM> but is not experienced by the user as a point or localized load. Namely, and as described above, the chassis <NUM> is described as being formed from one or more rigid materials. Accordingly, even though the cushion <NUM> is located at a discrete area of the sole structure <NUM>, the forces exerted on the chassis <NUM> - particularly on the chassis plate <NUM> - by the cushion <NUM> are dissipated over a length of the sole structure <NUM> such that the applied forces are not localized along the foot of the user. Rather, the forces applied at the location of the cushion <NUM> are dissipated along a length of the chassis plate <NUM> due to the rigidity of the chassis plate <NUM> and, as such, point loads are not experienced by the user's foot when the foot is in contact with an insole <NUM> disposed within the interior void <NUM>.

Claim 1:
A sole structure (<NUM>) for an article of footwear (<NUM>) having an upper (<NUM>), the sole structure (<NUM>) comprising:
a first plate (<NUM>) having a first surface facing away from the upper (<NUM>), the first plate (<NUM>) including a forefoot region (<NUM>) at an anterior end (<NUM>) of the first plate (<NUM>), a heel region (<NUM>) at a posterior end (<NUM>) of the first plate (<NUM>), and a mid-foot region (<NUM>) intermediate the forefoot region (<NUM>) and the heel region (<NUM>);
a second plate (<NUM>) having (i) a second surface opposing the first surface of the first plate (<NUM>) and (ii) a first end attached at the forefoot region (<NUM>) of the first plate (<NUM>), the second plate (<NUM>) extending from the first end to a second end that is spaced apart from the first surface of the first plate (<NUM>);
a cushion (<NUM>) disposed between the first plate (<NUM>) and the second plate (<NUM>) in the forefoot region (<NUM>) and having a first side attached to the first surface of the first plate (<NUM>) and a second side attached to the second surface of the second plate (<NUM>), the cushion (<NUM>) extending from a medial side (<NUM>) of the sole structure (<NUM>) to a lateral side (<NUM>) of the sole structure (<NUM>);
a heel pad (<NUM>) attached to the second surface of the first plate (<NUM>) at the posterior end; and
a heel plate (<NUM>) attached to the heel pad (<NUM>); wherein
the second plate (<NUM>) and the heel plate (<NUM>) cooperate to define a ground-engaging surface (<NUM>) of the sole structure (<NUM>) which is configured to contact a ground during operation, and
the cushion (<NUM>) comprises a fluid-filled bladder and the fluid-filled bladder includes a tensile member disposed therein.