Patent Description:
Footwear typically includes a sole structure configured to be located under a wearer's foot to space the foot away from the ground. Sole structures in athletic footwear are configured to provide one or more of desired cushioning, motion control, and resiliency.

<CIT> describes an air circulating, shock absorbing shoes which reduce the impact exerted to the feet of the wearer by providing ventilation in the shoes, resulting in pleasant and comfortable wearing of shoes.

The claimed invention is defined by the independent claim. Particular embodiments are described in the dependent claims.

Referring to the drawings, wherein like reference numbers refer to like components throughout the views, <FIG> is a bottom view of a portion of a sole structure <NUM> for an article of footwear <NUM> shown in <FIG> and <FIG>. <FIG> shows a midsole <NUM> of the sole structure <NUM>. The midsole <NUM> includes a midsole body <NUM> with a plurality of holes <NUM> that open at the proximal surface <NUM>. The midsole body <NUM> may be a polymeric foam material that provides cushioning and support. In the embodiment shown, the holes <NUM> are through-holes that extend from the proximal surface <NUM> of the midsole body <NUM> to a distal surface <NUM> of the midsole body <NUM>. The distal surface <NUM> is shown in the bottom view of <FIG> and is indicated in <FIG>.

The midsole <NUM> also includes a plurality of proprioceptive elements <NUM> disposed in some of the holes <NUM> such that they are translatable in the holes <NUM> as described herein. The proprioceptive elements <NUM> are indicated with dot shading for clarity. Distal ends <NUM> of the proprioceptive elements <NUM> are shown. <FIG> shows the midsole <NUM> prior to installation of the proprioceptive elements <NUM> in the holes <NUM>. A flexible outsole <NUM> (shown in phantom in <FIG> and in cross-sectional view in <FIG>) and an upper <NUM> (shown in <FIG>) are not shown in <FIG>.

The sole structure <NUM> is one of many embodiments of sole structures disclosed herein that include proprioceptive elements that enhance a wearer's awareness of an object in contact with the article of footwear, and of the location of contact of the object on the article of footwear. For example, a midsole with proprioceptive elements as discussed herein improves proprioceptive feedback (i.e., tactile feedback), which may enhance ball control in ball sports, such as soccer. The sole structures disclosed herein may also have enhanced ability to grip a ball, such as due to protrusions of distal ends of the proprioceptive elements at a distal surface of the outsole, and/or due to the ability of the outsole and midsole to flex together both during dorsiflexion and plantarflexion. Other features and advantages of the various embodiments of sole structures with proprioceptive elements are set forth in the discussion herein.

With reference to <FIG>, the article of footwear <NUM> includes an upper <NUM> secured to the sole structure <NUM>. In the embodiment shown, the upper <NUM> is a sock construction, such as a bootie, and may be a unitary, <NUM>-degree knit material that has a distal surface <NUM> secured to a proximal surface <NUM> of the sole structure <NUM> (best shown in <FIG>). The upper <NUM> thus wraps under a foot <NUM> received in a foot-receiving cavity <NUM> of the upper <NUM>, and includes an underfoot portion <NUM> (see <FIG> and <FIG>) in lieu of a strobel. Alternatively, the upper <NUM> may terminate at a lower periphery that is secured to a strobel, with the strobel secured to the sole structure <NUM> similar to upper <NUM> in <FIG>. In some embodiments, both a strobel having holes aligned with the holes <NUM> in the midsole body <NUM>, and a sockliner having holes aligned with the holes in the strobel may overlay the midsole <NUM>. An upper layer of the sockliner may directly overlay the proprioceptive elements <NUM> between the foot <NUM> and the proprioceptive elements <NUM>. <FIG> shows such an upper layer <NUM>, which is a relatively thin, flexible, elastically-stretchable material, such as a four-way stretch fabric. However, in the sole structure <NUM> of <FIG>, the midsole body <NUM> has a thickness sufficient such that a sockliner is not used. In another alternative embodiment, the midsole body <NUM> could be placed between an inner sock and an outer sock, as described with respect to the midsole body <NUM> of <FIG>.

In some embodiments, the proprioceptive elements may be integrally secured to or formed as a unitary, one-piece component with a sockliner, with the proprioceptive elements extending downward therefrom into the holes of the midsole body. In still other embodiments, the proprioceptive elements could be integrally secured to or formed integrally with a connecting web (i.e., a flat, flexible layer interconnected with the proprioceptive elements) and extend therefrom into the holes of the midsole body from the proximal side of the midsole body so that all of the proprioceptive elements can be handled together in unison via the connecting web. The connecting web can be secured at select locations to the proximal surface of the midsole (or, in some embodiments, to the distal surface of the midsole body) such that translation of the proprioceptive elements as described herein is not unduly limited. For example, the web may be left disconnected from the midsole surface at regions around each of the proprioceptive elements.

In still other embodiments, the proprioceptive elements could be integrally secured to or formed integrally with the outsole such that the proprioceptive elements extend into the holes of the midsole body from a proximal surface of the outsole. In still other embodiments, the proprioceptive elements could be separate from one another, each having a flange at its distal end or proximal end. The midsole body could have corresponding recesses that receive the flange such that the proprioceptive elements extend into the holes. These recesses could be either in the proximal surface or the distal surface of the midsole body. If on the proximal side, the recesses could be configured with a depth corresponding to a thickness of the flange such that the proximal surface of the flange is flush with the proximal surface of the midsole body when received in the recess.

As best shown in <FIG>, the proprioceptive elements <NUM> are disposed in the holes <NUM> such that they are not secured to and are translatable relative to the interior walls <NUM> of the midsole body <NUM> within the holes <NUM>. The midsole body <NUM> thus serves as a frame that carries the proprioceptive elements <NUM>. Each proprioceptive element <NUM> is disposed in a different one of the holes <NUM>. All of the holes <NUM> may contain a proprioceptive element <NUM>, or some of the holes <NUM> may be left empty, such that they do not have a proprioceptive element <NUM> in them. <FIG> is an embodiment in which only some of the holes <NUM> contain a proprioceptive element <NUM>. <FIG> is an alternative embodiment of a sole structure 10B with a midsole 14B including midsole body <NUM> and in which each hole <NUM> contains a proprioceptive element <NUM>.

In the embodiment shown, the proprioceptive elements <NUM> are integrally formed with a connecting web <NUM> as a unitary, one-piece component, as best shown in <FIG>, <FIG>. Proximal ends <NUM> of the proprioceptive elements <NUM> are integral with the web <NUM>, while distal ends <NUM> extend into the holes <NUM> and rest at or above the proximal surface of the outsole <NUM>, which is exposed at the bottom of each hole <NUM>. The distal surface of the upper <NUM> is secured to the proximal surface <NUM> of the web <NUM>. Alternatively, the proprioceptive elements <NUM> could be integrally formed in the same way with a sockliner, in embodiments in which a sockliner is used. In that case, no web would be included, as the sockliner would be positioned in place of the web, and would connect all of the proprioceptive elements <NUM>. In yet another embodiment, the connecting web <NUM> could be removed in <FIG>, and the distal ends <NUM> could be integrally formed with the outsole <NUM>. The proximal ends <NUM> could then extend upward toward the upper <NUM> in the holes <NUM>, without connection to any other component.

The proprioceptive elements <NUM> are narrower than the holes <NUM>. Stated differently, the diameters of the proprioceptive elements <NUM> are less than the diameters of the holes <NUM>. Accordingly, the proprioceptive elements <NUM> are spaced apart from the interior walls <NUM> of the holes <NUM>, or at least are not secured thereto such that they are movable relative to the walls <NUM>. As best shown in <FIG>, each proprioceptive element <NUM> is movable relative to the midsole body <NUM> along a central axis CA of the proprioceptive element <NUM> in a direction toward the proximal surface <NUM> of the midsole body <NUM> when under a force F along the central axis at a distal end <NUM> of the proprioceptive element <NUM>. In <FIG>, the forces F on the proprioceptive elements <NUM> are due to a ball <NUM> under the sole structure <NUM> being controlled by the wearer. The ball <NUM> is on the ground, and trapped between the ground and the wearer's foot <NUM> by the article of footwear <NUM>. The translation of the proprioceptive elements <NUM> under the forces F causes the proximal ends <NUM> of some of the proprioceptive elements <NUM> to be pressed toward the foot <NUM> relative to the midsole body <NUM> at the proximal surface <NUM>. More specifically, those ones of the proprioceptive elements <NUM> that are subjected to forces by the ball <NUM> will translate relative to the midsole body <NUM> in this manner, and may be considered active for the particular ball position. The flexible connecting web <NUM> at the active proprioceptive elements <NUM> will also translate toward the foot <NUM> under the force of the translating proprioceptive elements <NUM>. The flexible connecting web <NUM> is secured to the proximal surface <NUM> of the midsole body <NUM>, but not in a small region directly surrounding each of the proprioceptive element <NUM>. This enables the connecting web <NUM> to lift away from the midsole body <NUM>, if necessary, with the translating, active proprioceptive elements <NUM>. For example, a circular region of the distal surface <NUM> of the connecting web <NUM> may be freely movable relative to (i.e., not bonded to) the proximal surface <NUM> of the midsole body <NUM>. The connecting web <NUM> may be bonded to the midsole body <NUM> at other locations not within those regions (i.e., further from each proprioceptive element <NUM>). Other proprioceptive elements <NUM> not in contact with the ball <NUM> do not experience the same degree of translation, and may be considered inactive for the particular ball position. The inactive proprioceptive elements <NUM> will not be pressed toward the foot <NUM>, or at least not to as great an extent as the active proprioceptive elements <NUM>. This dichotomy between active and inactive proprioceptive elements will be sensed by the wearer. The proprioceptive elements <NUM> are thus tactile components that act as sensory indicators to the wearer of the position of the ball <NUM> relative to the foot <NUM>, enhancing ball control.

At least some of the proprioceptive elements <NUM> may have a different density than the midsole body <NUM> so that they are compressible relative to the midsole body <NUM> along their central axes. The midsole body <NUM> may have a first density, and the proprioceptive elements <NUM> may have a second density less than the first density. Alternatively, the second density may be greater than the first density. Some or all of the proprioceptive elements <NUM> may be more dense than the midsole body <NUM>, or some or all may be less dense than the midsole body <NUM>. Some or all could also have the same density as the midsole body <NUM>.

In embodiments discussed herein, the proprioceptive elements may be generally compressed under the weight of the wearer when the outsole of the sole structure is on the ground. When the foot is lifted, however, and the sole structure is used to control a ball, the magnitude of loading on the sole structure is generally lower than when supporting the full weight of the wearer, such that the proprioceptive elements have a greater ability to translate relative to the midsole body <NUM> than when fully loaded, enhancing the proprioceptive feedback to the wearer at each proprioceptive element during ball handling.

As best shown in <FIG>, the proprioceptive elements <NUM> may be referred to as plugs, and are disposed in the holes <NUM> but spaced apart from the interior walls <NUM> of the midsole body <NUM> that define the holes. Accordingly, the proprioceptive elements <NUM> do not in fact plug the holes. The holes <NUM> are cylindrical in shape, and the proprioceptive elements <NUM> may also be cylindrical. As shown, the proprioceptive elements <NUM> are elongated, with a length greater than their width. Depending on the thickness of the midsole body <NUM>, some of the holes <NUM> could have a width greater than their length, in which case the proprioceptive element <NUM> disposed in that hole <NUM> may be a cylinder that is discoid (i.e., has a width greater than its length). In some embodiments, the proximal ends <NUM> and/or the distal ends <NUM> of the proprioceptive elements <NUM> may have a rounded shape or a conical shape, in which case only the midsection of the proprioceptive element is cylindrical. In an embodiment in which the proximal ends <NUM> and the distal ends <NUM> are flat, the entire proprioceptive element <NUM> is cylindrical.

With reference to <FIG>, the midsole body <NUM> is shown as having holes <NUM> in each of a forefoot region <NUM>, a midfoot region <NUM>, and a heel region <NUM> of the midsole body <NUM>. In other embodiments, the holes <NUM> may be disposed in only one of or any two of the forefoot region <NUM>, the midfoot region <NUM>, and the heel region <NUM>. Each hole <NUM> has a distal opening <NUM>, also referred to as a distal end <NUM>, at the distal surface <NUM> of the midsole body <NUM>. The distal ends <NUM> of the holes <NUM> are the ends shown in the bottom view of <FIG>, for example. Each hole <NUM> also has a proximal opening <NUM>, also referred to as a proximal end <NUM>, at the proximal surface <NUM> of the midsole body <NUM> such that each hole <NUM> is a through-hole. <FIG> indicates the proximal ends <NUM> of the holes <NUM>. The holes <NUM> are disposed in both of a bottom portion <NUM> (<FIG>), a medial sidewall portion <NUM> (<FIG>), and a lateral sidewall portion <NUM> (<FIG>) of the midsole body <NUM>. In other embodiments, holes <NUM> may be provided only in the bottom portion <NUM>, or only in one or both of the sidewall portions <NUM>, <NUM>.

The size, location, and angle of the center axis CA of a hole <NUM> relative to vertical V (see <FIG>), as well as whether or not a proprioceptive element <NUM> is disposed in the hole <NUM> all contribute to the cushioning and proprioceptive sensory feedback of the midsole <NUM>. As shown, the holes <NUM> have a variety of different diameters. In general, the midsole body <NUM> can provide greater cushioning at a hole <NUM> with a larger diameter than a hole <NUM> with a smaller diameter, due to the ability of the surrounding foam to collapse into the hole <NUM> under loading, assuming no proprioceptive element <NUM> is disposed in the hole <NUM>. The collapse of the midsole body <NUM> into an empty hole <NUM> when under forces not aligned with the central axis CA of the hole <NUM> is indicated in <FIG>.

The proprioceptive elements <NUM> may be disposed in regions at which ball handling is expected to occur. For example, in some sports, the forefoot region <NUM> and the heel region <NUM> may be used for ball handling more than the midfoot region <NUM>. The forefoot region <NUM> and the heel region <NUM> may be used for rolling the ball underfoot, while the midfoot region <NUM> may be used more often for trapping the ball. Accordingly, proprioceptive elements <NUM> provided in the forefoot region <NUM> and the heel region <NUM> may be most useful for proprioception. In the embodiment of <FIG>, forefoot proprioceptive elements <NUM> are shown in some of the holes <NUM> of the forefoot region <NUM>, and heel proprioceptive elements <NUM> are shown in some of the holes <NUM> of the heel region <NUM>. Holes <NUM> in the midfoot region <NUM> are empty (i.e., they contain no proprioceptive elements <NUM>). The holes <NUM> containing proprioceptive elements <NUM> in the forefoot region <NUM> may be referred to as a first set of holes, and the holes <NUM> containing proprioceptive elements <NUM> in the heel region <NUM> may be referred to as a second set of holes <NUM>. The proprioceptive elements <NUM> in the forefoot region <NUM> of <FIG> may have a density greater than or less than the density of the midsole body <NUM>. In one embodiment, proprioceptive elements <NUM> are provided only in the forefoot region <NUM> and are a foam material that has a greater density than the material of the midsole body <NUM>. Proprioceptive elements are also disposed in holes <NUM> in the heel region <NUM>, and may be configured for impact cushioning as well as proprioception. For example, the proprioceptive elements <NUM> in the heel region <NUM> may be silicone. In some embodiments, a proprioceptive element <NUM> may completely fill a hole <NUM> and act as a plug. For example, proprioceptive elements <NUM> used in the heel region <NUM> for cushioning could be such plugs.

The midsole body <NUM> may be polymeric foam that is compression-molded according to a thermal process, with the holes <NUM> formed during the molding process rather than via a secondary process. All outer surfaces of a molded foam article, such as a molded midsole body <NUM>, may have an outer skin <NUM> that is denser than an interior portion <NUM> of the midsole body <NUM> due to contact with the surfaces of the mold tools. The outer skin <NUM> of the midsole body <NUM> is indicated in <FIG>, and is separated from the interior portion <NUM> by a representative boundary <NUM>. Forming the holes <NUM> during molding via pins, as disclosed herein, will cause the interior walls <NUM> of the holes <NUM> to also have the dense outer skin <NUM>. More particularly, the midsole body <NUM> includes an interior portion <NUM>, and a skin <NUM> that covers the interior portion <NUM> and extends along each of the holes <NUM> from the proximal surface <NUM> to the distal surface <NUM>. In a non-limiting example, the interior portion <NUM> may be an open-cell foam, or a closed-cell foam. In an open-cell foam, air moves out of the cell when the foam is compressed. Accordingly, the compressive stiffness of the foam is unaffected by the air in the cells. In a closed-cell foam, air is trapped in the cell, and compresses when the foam is compressed, thus affecting the compressive stiffness of the foam. The skin <NUM> has a first density, and the interior portion <NUM> has a second density less than the first density. Reference to a second density of the interior portion <NUM> may be numerically different than the second density of the proprioceptive elements <NUM> discussed herein, as first and second densities are relative terms used in comparison to two different components. The denser skin <NUM> forms a cylinder around each hole <NUM>, bordering the hole <NUM> beginning at the interior wall <NUM> and extending into the midsole body <NUM> away from the interior wall <NUM> a short distance, forming an annular cylinder around the hole <NUM>. A skin having a greater thickness will provide greater resistance to compression than a thinner skin. Conversely, a skin with a lesser thickness will allow the foam of the midsole around the holes to compress to a greater extent under a given load than a thicker skin. The cylinder of skin <NUM> around the hole <NUM> is most resistant to compression along its length, as the full length of the stiffer skin <NUM> must be compressed. The midsole body <NUM> thus has a greater compressive stiffness under loading along the center axis CA of a hole <NUM> than under loading transverse to the center axis CA, or than under loading at an oblique angle to the center axis CA (i.e., angles greater than zero degrees and less than <NUM> degrees). An empty hole <NUM>, or a hole containing a proprioceptive element <NUM> of a lesser density than the midsole body <NUM>, will provide cushioning and absorb forces that are not aligned with the center axis of a hole <NUM> by a partial or complete collapse of the foam midsole body <NUM> into the hole <NUM>, as shown in <FIG>. Forces aligned with the center axis CA, however, will be at least partially countered by the resistance of the tunnel-like skin <NUM> at the hole <NUM>, resisting compression.

As further discussed herein, the holes <NUM> are angled relative to a vertical axis V indicated in <FIG> and <FIG>. The angle A of the central axis CA of a hole <NUM> relative to the vertical axis V may be selected so that the central axis CA aligns with an expected direction of loading force on the midsole body <NUM> at the location of the hole <NUM>, such as the expected direction of impact forces during walking or running, or from making a lateral movement, such as a cutting movement during sports. For example, in certain sports, lateral (i.e., sideways) cutting motions are common. Angles of holes <NUM> at the lateral sidewall <NUM> and/or the medial sidewall <NUM> may be selected to coincide with the lateral forces typically resulting from a lateral cutting motion.

In order to provide angled holes <NUM> with an outer skin <NUM> along the walls <NUM> of the midsole body <NUM> bordering the holes <NUM>, the midsole body <NUM> is molded with a cleft <NUM> in the proximal surface <NUM> so that the midsole body <NUM> is in a "split open" position (referred to herein as a molded position), as shown in <FIG>. In the embodiment shown, the cleft <NUM> extends along a longitudinal axis L of the midsole body <NUM>. In other embodiments, a mold could be configured to provide a cleft that extends transversely. With a longitudinally-extending cleft <NUM> as shown in <FIG>, when the cleft <NUM> is closed (as shown in <FIG>), the resulting angled holes angle laterally-outward from the proximal surface <NUM> to the distal surface <NUM>. In the open, molded position of the cleft <NUM> in <FIG>, the central axes CA of the holes <NUM> extend vertically, and the center axes CA of the holes of the first set <NUM> are parallel with the center axes CA of the holes of the second set <NUM>. As shown in <FIG>, a first set <NUM> of holes <NUM> is disposed between a medial periphery <NUM> of the midsole body <NUM> and the cleft <NUM>, and a second set <NUM> of holes <NUM> is disposed between a lateral periphery <NUM> of the midsole body <NUM> and the cleft <NUM>. The proximal openings <NUM> of the first set <NUM> are disposed at a first portion of the proximal surface <NUM>, and the proximal openings <NUM> of the second set <NUM> are disposed at a second portion of the proximal surface <NUM>. The first set <NUM> of holes <NUM> may be referred to as a medial set <NUM>, and the second set <NUM> of holes <NUM> may be referred to as a lateral set <NUM>. The midsole body <NUM> is hinged at the cleft <NUM>. Stated differently, the cleft <NUM> extends downward from the proximal surface <NUM> only partway to the distal surface <NUM> at least in some regions, such that a first portion 32A (e.g., a medial portion) of the midsole body <NUM> with the medial set <NUM> of holes <NUM> is connected to a second portion 32B (e.g., a lateral portion) of the midsole body <NUM> at least at connected portions referred to as a forefoot hinge FH and a heel hinge HH at the bottom of the cleft <NUM>. <FIG> is a schematic depiction of the midsole body <NUM> if pressed even further open at the cleft <NUM> than the molded position of <FIG>, so that the forefoot hinge FH and the heel hinge HH are apparent. The cleft <NUM> may extend completely through the midsole body <NUM> in some areas, such that the medial portion 32A and the lateral portion 32B may be completely split and disconnected from one another at an area rearward of the heel hinge HH, at an area forward of the forefoot hinge FH, and at an area between the forefoot hinge FH and the heel hinge HH, as shown in <FIG>. This allows the distal surface <NUM> to curve upward toward the foremost extent of the midsole body <NUM> at the forefoot portion <NUM> forward of the forefoot hinge FH, the distal surface <NUM> to curve upward toward the rearmost extent rearward of the heel hinge HH, and the distal surface <NUM> to curve upward at the midfoot portion <NUM> between the heel hinge HH and the forefoot hinge FH.

<FIG> show the midsole body <NUM> in the molded position with the cleft <NUM> open. The cleft <NUM> is shown as having an angle A between vertical V and each of its sidewalls 72A, 72B in the open (as molded) position. The sidewalls 72A, 72B are also indicated in <FIG>. The angle A may be, for example <NUM> degrees, so that a total opening between the sidewalls of the cleft <NUM> is <NUM> degrees. Accordingly, when the cleft <NUM> is closed, as shown in <FIG>, the angled holes <NUM> will each extend laterally outward at angle A, which is <NUM> degrees in the embodiment shown. The angle of the holes <NUM> is best shown in the cross-sectional views of <FIG>, <FIG> and <FIG>. The center axes CA of the holes <NUM> of the first set <NUM> angle laterally outward from the proximal surface <NUM> to the distal surface <NUM> such that a distal end <NUM> of each hole <NUM> of the first set <NUM> is nearer to the medial periphery <NUM> than is a proximal end <NUM> of the hole <NUM>. The center axes CA of the holes <NUM> of the second set <NUM> angle laterally outward from the proximal surface <NUM> to the distal surface <NUM> such that a distal end <NUM> of each hole <NUM> of the second set <NUM> is nearer to the lateral periphery <NUM> than is a proximal end <NUM> of the hole <NUM>. The holes <NUM> of the first set <NUM> are parallel in the open (as-molded) position of the cleft <NUM> (see <FIG>), and are nonparallel with the holes <NUM> of the second set <NUM> in the closed position of the cleft <NUM> (see <FIG>).

As shown in <FIG>, the first portion 32A of the midsole body <NUM> is contiguous with the second portion 32B at the proximal surface <NUM> and at the distal surface <NUM> when the cleft <NUM> is closed. In other words, there are no gaps or differences in elevation between the first portion 32A and the second portion 32B at the cleft <NUM> when the cleft is closed. The cleft <NUM> may be kept in the closed position by thermally bonding or adhering the sidewalls 72A, 72B to one another. Alternatively, the bonding of an upper at the proximal surface <NUM> or an outsole at the distal surface <NUM> may serve to retain the cleft <NUM> in the closed position.

In embodiments having a connecting web <NUM>, the web <NUM> may be positioned over midsole body <NUM> with the cleft <NUM> in the open position, and the integral proprioceptive elements <NUM> may be inserted into the holes <NUM> effectively simultaneously simply by moving the connecting web <NUM> toward the proximal surface <NUM> with the proprioceptive elements <NUM> aligned with the holes <NUM>. The web <NUM> may be stretchable such that it is pulled transversely to stretch across the cleft <NUM> during insertion, and retracts to a narrower width corresponding to the narrower width at the proximal surface <NUM> of the midsole body <NUM> with the cleft <NUM> in the closed position. Alternatively or in addition, a portion of the connecting web <NUM> extending over the cleft <NUM> may be folded into the cleft <NUM> prior to closing the cleft <NUM>, such that the web <NUM> is bonded in the cleft <NUM>. In either instance, the web <NUM> with integral proprioceptive elements <NUM> simplifies the insertion process for the proprioceptive elements <NUM>, allowing insertion simultaneously or nearly simultaneously simply by aligning the proprioceptive elements <NUM> with the holes <NUM> when the cleft <NUM> is positioned over the midsole body <NUM>, and then lowering the proprioceptive elements <NUM> into the holes <NUM>. In instances where the holes <NUM> and the corresponding proprioceptive elements <NUM> are a variety of sizes, this saves assembly time and reduces the potential for erroneously inserting the differently-sized proprioceptive elements <NUM> in the wrong holes <NUM>. In other embodiments, however, where no web or other connecting layer (e.g., sockliner, outsole) for the proprioceptive elements <NUM> is used, the proprioceptive elements <NUM> can be individually and separately inserted into the corresponding holes <NUM>, as they will be trapped between the outsole <NUM> and the upper <NUM> or other overlying layer in any event once the article of footwear <NUM> is assembled.

In <FIG>, the outsole <NUM> is shown with a proximal surface <NUM> secured to the distal surface <NUM> of the midsole body <NUM>. In lieu of outsole <NUM>, an outsole 16A with flex grooves <NUM> in a distal surface <NUM> of the outsole 16A may be used, as shown in the sole structure 10A of <FIG>, <FIG>. Only some of the flex grooves <NUM> are labeled in <FIG>. The outsole 16A is shown secured to a midsole body 32C that does not show holes with proprioceptive elements, but could instead be secured to the midsole body <NUM>. The flex grooves <NUM> would extend between adjacent ones of at least some of the proprioceptive elements <NUM> when secured to midsole body <NUM>. In <FIG>, the proximal surface 22A of the midsole body 32C is shown with internal flex grooves <NUM>. The internal flex grooves <NUM> overlie and are aligned with the external flex grooves <NUM>. More specifically, internal flex grooves <NUM> are arranged in a pattern matching the pattern of the external flex grooves <NUM> so that the internal flex grooves <NUM> border either side of centerlines of the external flex grooves <NUM>, as best indicated in <FIG>. In other words, two internal flex grooves <NUM> extend parallel to one another, tracking the grooves <NUM> from above, with a narrow portion of the midsole body 32C between each of the internal flex grooves <NUM> directly overlying the external flex grooves <NUM>. Accordingly, the internal flex grooves <NUM> and the external flex grooves <NUM> allow the midsole body 32C and outsole 16A to function as pleated bellows at the grooves <NUM>, <NUM> such that the sole structure 10A articulates at the external flex grooves <NUM> and the internal flex grooves <NUM> both in dorsiflexion (e.g., along curve <NUM>) and in plantarflexion (e.g., along curve <NUM>) of the sole structure 10A, as best depicted in <FIG>. Curve <NUM> represents a degree of articulation at which at least some of the internal flex grooves <NUM> will close. Curve <NUM> represents a degree of plantar flexion at which at least some of the external flex grooves <NUM> will close. The longitudinally-extending flex grooves <NUM>, <NUM> allow articulation in the transverse direction of the sole structure 10A as well, such as during plantarflexion over a curved ball surface.

<FIG> show a representative mold <NUM> for manufacturing the midsole body <NUM>. <FIG> is a flowchart of a method of manufacturing the midsole body <NUM> using the mold <NUM> of <FIG>. The mold <NUM> includes an upper mold half 90A and a lower mold half 90B. The upper mold half 90A has an upper mold surface 91A in a mold cavity <NUM>, and the lower mold half 90B has a lower mold surface 91B in the mold cavity <NUM>. The mold halves 90A, 90B are movable toward one another to the closed position shown in <FIG>, in which the mold surfaces 91A, 91B together form a mold cavity <NUM>. The mold halves 90A, 90B are movable away from one another to open the mold cavity <NUM> (e.g., by moving mold half 90A upward in <FIG>, moving mold half 90B downward, or both, as will be understood from the present disclosure to those skilled in the art. The upper mold surface 91A includes a protrusion <NUM> that extends toward the lower mold half 90B. The lower mold half 90B also includes a protrusion <NUM>. Both protrusions <NUM>, <NUM> run along a longitudinal axis of the mold <NUM>, which is perpendicular to the plane of the cross-section shown. The protrusion <NUM> forms the cleft <NUM> shown in the midsole body <NUM> in <FIG>, and the protrusion <NUM> molds the distal surface <NUM> of the midsole body <NUM> to the open position. In certain regions, the protrusions <NUM>, <NUM> may touch. Such regions will correspond to the areas where the cleft <NUM> extends completely through the midsole body <NUM>, where the medial portion 32A and the lateral portion 32B are completely split and disconnected from one another (e.g., at an area rearward of the heel hinge HH, at an area forward of the forefoot hinge FH, and at an area between the forefoot hinge FH and the heel hinge HH, as described with respect to <FIG>).

The upper mold half 90A has through-holes 95A, and the lower mold half 90B has blind holes 95B. Alternatively, through-holes 95A may be used in lieu of blind holes 95B. The through-holes and blind holes 95A, 95B are aligned with one another to receive a first set of pins 96A, and a second set of pins 96B, as shown in <FIG>. The pins 96A, 96B extend from a mold tool <NUM> that is translatable toward and away from the mold <NUM>. A single mold tool <NUM> is used. Alternatively, the first and second sets of pins 96A, 96B may be secured to separate mold tools. The pins 96A, 96B and the holes 95A, 95B are arranged in the same pattern (i.e., relative spacing and size), which is identical to the pattern of the holes <NUM> in the midsole body <NUM>.

<FIG> is a flowchart illustrating a method <NUM> of manufacturing an article of footwear, such as the article of footwear <NUM>. In block <NUM>, the method <NUM> includes extending a first set of pins 96A into the midsole cavity <NUM> on a first side of the protrusion <NUM> (i.e., on the medial side), and a second set of pins 96B into the midsole cavity <NUM> on a second side of the protrusion <NUM> (i.e., on the lateral side). The first set of pins 96A forms the first set <NUM> of holes <NUM> in the midsole body <NUM>, the second set of pins 96B forms the second set <NUM> of holes <NUM> in the midsole body <NUM>, and the protrusion <NUM> forms the cleft <NUM> between the first set <NUM> of holes and the second set <NUM> of holes, all shown in <FIG>. Center axes CP1 of the pins of the first set of pins 96A are parallel with center axes CP2 of pins of the second set 96B.

The method <NUM> includes block <NUM>, disposing polymeric material <NUM> into a mold cavity <NUM> of a mold <NUM> for a midsole body <NUM>. For example, the polymeric material <NUM> may be introduced through an injection port <NUM> of the mold <NUM>. The method <NUM> continues with block <NUM>, molding the polymeric material to the shape of the mold surface, thereby forming a midsole body <NUM>. Molding in block <NUM> may include compression, vacuum-forming, and/or thermal processing. In other embodiments, blocks <NUM>, <NUM>, and <NUM> can be performed in a different order than as described.

In block <NUM>, the method <NUM> includes withdrawing the first set of pins 96A and the second set of pins 96B from the midsole body <NUM>. Because the pins 96A, 96B are parallel, the same mold tool <NUM> can be used to form the first and second sets <NUM>, <NUM> of holes <NUM> simultaneously. Additionally, because the holes <NUM> are formed during molding, rather than during a secondary process following molding, the skin <NUM> borders the less dense, interior portion <NUM> of the midsole body <NUM>, providing compression resistance to forces along the central axes of the holes <NUM>, as discussed with respect to <FIG>.

In block <NUM>, the method <NUM> includes removing the midsole body <NUM> from the mold <NUM>. As described with respect to <FIG>, <FIG> and <FIG>, center axes CA of the holes <NUM> of the first set <NUM> of holes are nonparallel with center axes CA of the holes <NUM> of the second set <NUM> of holes when the cleft <NUM> is closed.

In block <NUM>, the method <NUM> may include disposing a first plurality of proprioceptive elements <NUM> in at least some holes <NUM> of the first set <NUM> and a second plurality of proprioceptive elements <NUM> in at least some holes <NUM> of the second set <NUM>. In embodiments having a connecting web <NUM>, this may including placing the connecting web <NUM> above the midsole body <NUM>, and aligning the proprioceptive elements <NUM> with the holes <NUM>. In embodiments in which the proprioceptive elements <NUM> are integrally formed with another layer, such as a sockliner or an outsole, block <NUM> will include placing the layer above (e.g., if the layer is a sockliner) or below (e.g., if the layer is an outsole) the midsole body <NUM>, and aligning the proprioceptive elements <NUM> with the holes <NUM>. In embodiments in which each of the proprioceptive elements <NUM> is disconnected from each of the other proprioceptive elements <NUM>, block <NUM> will include separately aligning and disposing each proprioceptive element <NUM> into a respective hole <NUM> of the correct size.

In one embodiment, a first set of proprioceptive elements <NUM> are disposed in the forefoot region <NUM>, and a second set of proprioceptive elements <NUM> are disposed in the heel region <NUM>. The first plurality of proprioceptive elements may have a first density, and the second plurality of proprioceptive elements may have a second density different than the first density. Additionally, the midsole body <NUM> may have a density at the skin <NUM>, and a different density at the interior portion <NUM>, both of which are different than the densities of the proprioceptive elements <NUM>. The proprioceptive elements <NUM> of the first set <NUM> may be a polymeric foam that has a density greater than or lesser than the midsole body <NUM>. The proprioceptive elements <NUM> of the second set <NUM> may be silicone.

Next, the method <NUM> may include block <NUM>, securing an outsole, such as outsole <NUM> or 16A described herein, to the distal surface <NUM> of the midsole body <NUM>. In some embodiments, securing an outsole may occur later in the method <NUM>, such as after block <NUM> described herein. If block <NUM> is performed following block <NUM>, then the method <NUM> moves to either of blocks <NUM> or <NUM>. Block <NUM> includes securing an upper <NUM>, such as a sock, to the proximal surface <NUM> of the midsole body <NUM>. In other embodiments, the method <NUM> includes block <NUM>, securing an elastic sockliner layer to the proximal surface <NUM> of the midsole body <NUM>. The elastic sockliner layer may be, for example, elastic sockliner layer <NUM> as described with respect to <FIG>, with the elastic sockliner layer spanning across the first set <NUM> of holes <NUM> and the second set <NUM> of holes <NUM>. In the embodiment of <FIG>, a sockliner is not required, however, as the midsole body <NUM> has a thickness sufficient to also serve as a sockliner.

In still other embodiments, the method <NUM> moves from block <NUM> to block <NUM>, in which a distal surface of an inner sock is secured to the proximal surface <NUM> of the midsole body <NUM>, and then in block <NUM>, an outer sock is pulled over the midsole body <NUM> and secured to the distal surface <NUM> of the midsole body <NUM> such that the midsole body <NUM> is disposed inside of the outer sock, and between the inner sock and the outer sock. For example, although <FIG> are illustrated with midsole body <NUM>, a sole structure including midsole body <NUM> can include an inner sock and an outer sock in a like manner. In such an embodiment, following block <NUM>, the method <NUM> continues in block <NUM>, securing an outsole <NUM> to the distal surface of the outer sock, as shown and described with respect to <FIG>.

<FIG> shows another embodiment of a sole structure 210A having a midsole 214A for an article of footwear <NUM>. The sole structure 210A includes a midsole 214A with a midsole body <NUM>. The midsole 214A may be used in the article of footwear <NUM> shown in <FIG> in lieu of midsole <NUM>.

The midsole body <NUM> has perforations <NUM> that extend from the proximal surface <NUM> to the distal surface <NUM>. In <FIG>, the distal surface <NUM> is shown, but it is apparent that the perforations <NUM> extend entirely through the thickness of the midsole body <NUM> from the proximal surface <NUM> to the distal surface <NUM>. In the embodiment shown, the perforations <NUM> define perforated shapes that are circular. The perforated shapes are integral portions <NUM> of the midsole body <NUM> and are surrounded by three equally-spaced perforations <NUM>. The integral portions <NUM> serve as proprioceptive elements <NUM>. The three equally-spaced perforations <NUM> define a perforated hole 234A. As best shown in <FIG>, arms <NUM> span between the main portion <NUM> of the midsole body <NUM> (i.e., the portion surrounding the perforations <NUM>) to secure the integral proprioceptive element <NUM> within the perforated hole 234A. A plurality of proprioceptive elements <NUM> that are disposed in the plurality of perforated holes 234A are thus integral portions of the midsole body <NUM> surrounding the perforations <NUM>. The perforations <NUM> and integral proprioceptive elements <NUM> may be formed during molding of the midsole body <NUM>, or the midsole body <NUM> may be perforated in a secondary process, after molding.

The arms <NUM> enable some degree of translating movement of the proprioceptive element <NUM> relative to the surrounding main portion <NUM> of the midsole body <NUM> along the central axis CA of the proprioceptive element <NUM> when a force is applied at a distal end <NUM> of the proprioceptive element <NUM> toward the proximal surface <NUM>. The proprioceptive elements <NUM> can thus provide tactile feedback to a wearer, as described with respect to proprioceptive elements <NUM>.

In some embodiments, such as is shown in <FIG>, some or all of the integral proprioceptive elements <NUM> are punched out. Stated differently, multiple ones of the perforated shapes (i.e., the integral proprioceptive elements <NUM>) are punched out at the perforations <NUM> such that a plurality of punched through-holes 234B extend from the proximal surface <NUM> to the distal surface <NUM>. The midsole body <NUM> with punched-out holes 234B is referred to as midsole <NUM> and is included in sole structure <NUM> of <FIG>. In <FIG> an outsole <NUM> is removed for clarity in viewing the midsole <NUM>. The midsole body <NUM>, midsole <NUM>, and sole structure <NUM> have many of the same features as midsole body <NUM>, midsole <NUM>, and sole structure <NUM>, and such features are referred to with like reference numbers and are as described with respect to sole structure <NUM>. Each of the punched through-holes 234B can then have a proprioceptive element <NUM> inserted into the through-hole 234B, in the same manner as described with respect to proprioceptive elements <NUM> in through-holes <NUM> of <FIG>. The midsole body <NUM> may have a first density, and the inserted proprioceptive elements <NUM> may have a second density different than the first density, as described with respect to the midsole body <NUM> and sole structure <NUM>. Different proprioceptive elements <NUM> of different densities can be used, and disposed in different regions of the midsole <NUM>.

<FIG> shows many punched through-holes 234B with proprioceptive elements <NUM> disposed therein. <FIG> also shows that some of the integral proprioceptive elements <NUM> are not punched out. Additionally, <FIG> shows two of the punched through-holes 234B without any proprioceptive elements <NUM> therein. In some embodiments, these or other punched through-holes 234B can be left empty (i.e., punched out without a proprioceptive element <NUM> disposed therein in a secondary process). Accordingly, the midsole <NUM> may include a combination of: (i) integral proprioceptive elements <NUM> in perforated holes 234A formed during molding, three-dimensional printing, or otherwise forming of the midsole <NUM> or perforated therein during a secondary process; (ii) proprioceptive elements <NUM> disposed in punched through-holes 234B in a secondary process; and (iii) empty, punched through-holes 234B.

As is evident in the embodiment of <FIG>, the perforated holes 234A are disposed in a bottom portion <NUM>, and in a medial sidewall portion <NUM> of the midsole body <NUM>, in the forefoot region <NUM>, and the midfoot region <NUM>. The heel region <NUM> and the lateral sidewall portion <NUM> in the embodiment shown in <FIG> generally have no perforated holes 234A of other holes, but in other embodiments, perforated holes 234A could be disposed in one or both of these portions as well.

At least some of the perforated holes 234A have different diameters, as shown in <FIG>. The integral proprioceptive elements <NUM> are discoid, as best shown in <FIG>. The proprioceptive elements <NUM> are also discoid in the embodiment of <FIG>. The thickness of the midsole body <NUM> is less than midsole body <NUM>, so the proprioceptive elements <NUM> are less elongated than those in midsole <NUM> when disposed in the punched through-holes <NUM> of midsole <NUM>.

<FIG> shows the midsole body <NUM> taken at lines <NUM>-<NUM> in <FIG>. <FIG>, <FIG>, and <FIG> are cross-sectional views of the midsole body <NUM> of <FIG>. <FIG> is a plan view of the proximal surface <NUM> of the midsole body <NUM> at one of the perforated holes 234A.

<FIG> shows a fragmentary portion of the sole structure <NUM> including the midsole body <NUM>, with an upper <NUM> that includes an outer sock <NUM> secured to the distal surface <NUM>. <FIG> shows the sole structure <NUM> such as when unloaded (e.g., not subjected to the forces of controlling a ball). <FIG> is a longitudinal cross-sectional view. An outsole <NUM> is secured to the distal surface of the outer sock <NUM>. The distal surface of an inner sock <NUM> may be secured at the proximal surface <NUM> of the midsole body <NUM>, as shown in <FIG>, or a relatively thin, elastic sockliner layer, such as a four-way stretch knit material elastic layer <NUM> shown in <FIG>, may be secured so that it overlies the holes 234A, 234B and the proprioceptive elements <NUM>, <NUM>. In either embodiment, the inner sock <NUM> or the elastic sockliner layer <NUM> is stretched by the translating proprioceptive elements <NUM>, <NUM> toward the foot-receiving cavity <NUM>, such as shown and described in <FIG> when subjected to forces along their central axes CA.

The inner sock <NUM> may be secured first by placing the inner sock <NUM> on a last, and then securing the midsole <NUM>, including the midsole body <NUM> and the proprioceptive elements <NUM> to the inner sock <NUM>. The outer sock <NUM> is then pulled over the inner sock <NUM> and midsole <NUM>, and the proximal surface of the outer sock <NUM> is secured to the distal surface <NUM>. The midsole body <NUM> is disposed inside of the outer sock <NUM>, and between the inner sock <NUM> and the outer sock <NUM>.

<FIG> shows forces F due to a ball <NUM> on certain ones of the proprioceptive elements <NUM>, <NUM>, causing these proprioceptive elements <NUM>, <NUM> to be "active" and translate relative to the midsole body <NUM> along the central axis CA of the respective holes 234B, 234A, while inactive ones of the proprioceptive elements <NUM>, <NUM> do not translate in this manner. The active proprioceptive elements <NUM>, <NUM> protrude further at the proximal surface <NUM> than when not under loading, and thus provide tactile feedback of ball position to the foot <NUM> of the wearer. The relatively thin and flexible outsole <NUM>, outer sock <NUM>, and inner sock <NUM> do not interfere with the ability of the proprioceptive elements <NUM>, <NUM> to provide feedback in this manner.

In an alternative embodiment in <FIG>, only a single sock layer <NUM> is used, and the proprioceptive elements <NUM> are integral with a sheet or connecting web <NUM>, similar to connecting web <NUM>. The outsole <NUM> is secured to the webbing <NUM>.

As an alternative to outsole <NUM>, the outsole 16A of <FIG> could be used with the midsole body <NUM>, and the midsole body <NUM> could have internal flex grooves <NUM> at the proximal surface <NUM> (similarly as described with respect to midsole body 32C of <FIG>) to enhance articulation of the sole structure <NUM> both in dorsiflexion and plantarflexion.

<FIG> is a flowchart of a method <NUM> of manufacturing an article of footwear, such as article of footwear <NUM> and may apply to sole structure <NUM>, 210A. The method <NUM> begins with block <NUM>, perforating a midsole body <NUM> such that perforations <NUM> define a plurality of perforated shapes and extend through the midsole body <NUM> from a proximal surface <NUM> to a distal surface <NUM>, creating perforated holes 234A. Perforating the midsole body <NUM> may be done during molding of the midsole body <NUM>, in which case block <NUM> is a molding process. Alternatively, the midsole body <NUM> may be 3D printed, with the perforations created during the printing process by controlled material deposition. In another alternative, perforating the midsole body <NUM> may be a secondary process, in which case a molding process occurs prior to block <NUM>.

The method <NUM> then proceeds with block <NUM>, punching out multiple ones of the perforated shapes at the perforations <NUM> such that a plurality of punched through-holes 234B extend from the proximal surface <NUM> to the distal surface <NUM>. Next, block <NUM> includes disposing proprioceptive elements <NUM> in one or more of the punched through-holes 234B, each proprioceptive element <NUM> disposed in a different one of the punched through-holes. The proprioceptive elements <NUM> may have a density different than a density of the midsole body <NUM>. In some embodiments, such as when manufacturing an article of footwear including sole structure 210A, blocks <NUM> and <NUM> are omitted, so that the midsole body <NUM> includes only the perforated openings 234A, and the integral proprioceptive elements <NUM> are the only proprioceptive elements in the midsole body <NUM>. In some embodiments, block <NUM> occurs, but block <NUM> is omitted, so that all of the punched through-holes 234B remain empty.

In some embodiments, the punched through-holes 234B include a first set of punched through-holes in a forefoot region <NUM> of the midsole body <NUM>, and a second set of punched through-holes in a heel region <NUM> of the midsole body <NUM>. The punched through-holes are not shown in the heel region in <FIG>, but their placement in the heel region <NUM> will be readily understood by a person skilled in the art in light of the present disclosure. In such an embodiment, at least some of the proprioceptive elements <NUM> disposed in the first set of punched through-holes 234B have a different density than at least some of the proprioceptive elements <NUM> disposed in the second set of punched through-holes 234B. For example, the proprioceptive elements <NUM> in the forefoot region <NUM> may be a foam that has a greater or lesser density than the foam of the midsole body <NUM>, and the proprioceptive elements <NUM> in the heel region <NUM> may be silicon proprioceptive elements <NUM> for cushioning rather than or in addition to proprioception.

The method <NUM> then proceeds to block <NUM>, securing a component layer to the proximal surface <NUM> of the midsole body <NUM>. For example, an elastic sockliner layer <NUM> such as in <FIG> or a sock <NUM> (which may be an inner sock or a single sock used without an outer sock) may be secured to the proximal surface <NUM> of the midsole body <NUM>, spanning across the punched through-holes 234B and the perforated holes 234A.

In embodiments having an inner sock <NUM> and an outer sock <NUM>, the method <NUM> proceeds to block <NUM>, securing an outer sock <NUM> to the distal surface <NUM> of the midsole body <NUM> such that the midsole body <NUM> is disposed inside of the outer sock <NUM>, and between the inner sock <NUM> and the outer sock <NUM>.

Next, the method <NUM> proceeds to block <NUM>, securing an outsole <NUM> or 16A to the distal surface <NUM> of the midsole body <NUM>. In embodiments that do not include an outer sock <NUM> or other layer between the midsole body <NUM> and the outsole, the method <NUM> may include completing block <NUM> prior to block <NUM> so that the sole structure <NUM> is complete prior to securing the sockliner layer, the sock <NUM>, or other upper component to the midsole body <NUM>.

<FIG> show another embodiment of a sole structure <NUM> for an article of footwear. The sole structure <NUM> includes a midsole <NUM> with a midsole body <NUM> and proprioceptive elements <NUM>. The sole structure <NUM>, midsole <NUM>, midsole body <NUM>, and proprioceptive elements <NUM> have many of the same features as described with respect to sole structure <NUM> and corresponding components thereof, and such features are referred to with like reference numbers and are as described with respect to sole structure <NUM>.

The midsole body <NUM> has a proximal surface <NUM> and a distal surface <NUM> indicated in <FIG>. The midsole body <NUM> has holes <NUM> that open at the proximal surface <NUM>. In the embodiment shown, the holes <NUM> are in the forefoot region <NUM> and the midfoot region <NUM> at the bottom portion <NUM> of the midsole <NUM>. In other embodiments, the holes <NUM> could also be disposed in a heel region <NUM>, in medial or lateral sidewall portions, or both. A plurality of proprioceptive elements <NUM> are integrally secured to the midsole body <NUM>. In fact, the midsole body <NUM> and the proprioceptive elements <NUM> are a single, unitary component molded integrally with one another. Some of the proprioceptive elements <NUM> are generally cylindrical with rounded ends, and others are frustoconical with rounded ends.

The holes <NUM> are not through-holes, but instead are annular recesses in the proximal surface <NUM> that surround the proprioceptive elements <NUM>, as indicated in <FIG> and <FIG>. The holes <NUM> have different diameters, as is apparent in <FIG>. The holes <NUM> are configured such that the proprioceptive elements <NUM> each have a height greater than a depth of the annular recesses at the proximal surface <NUM>, as shown with respect to proprioceptive elements <NUM> having height H and annular recesses <NUM> having a depth D in <FIG>. Each proprioceptive element <NUM> is disposed in a different one of the holes <NUM>, and is partially surrounded by an interior wall <NUM> of the hole <NUM> when the sole structure is in the relatively unflexed position of <FIG>, without loading. The holes <NUM> at the proximal surface <NUM> may have different depths D, and the proprioceptive elements <NUM> may have different heights H, but in the midsole <NUM>, the height H of the proprioceptive element <NUM> is greater than the depth D of the hole <NUM> for each proprioceptive element <NUM> and hole <NUM> in which it is disposed, where both the height H and the depth D are measured from the bottom of the hole <NUM>. In other embodiments, some of the holes may have depths greater than the heights of the proprioceptive elements that they surround, as illustrated with respect to <FIG>.

The midsole body <NUM> also has annular recesses <NUM> in the distal surface <NUM>, each annular recess <NUM> encircling a different one of the plurality of proprioceptive elements <NUM> from below, and aligned with one of the holes <NUM> in the proximal surface <NUM>. Some of the annular recesses <NUM> are indicated in <FIG> and <FIG>. Each annular recesses <NUM> extends upward from the distal surface <NUM> beyond a lowest extent of the hole <NUM> that it surrounds.

The sole structure <NUM> includes an outsole <NUM> secured to the distal surface <NUM> of the midsole body <NUM> and lining the annular recesses <NUM> of the midsole body <NUM>, as best shown in <FIG>. The outsole <NUM> has a proximal surface <NUM> with annular protrusions <NUM> nested in the annular recesses <NUM> of the midsole body <NUM>. The outsole also has annular recesses <NUM> at a distal surface <NUM>. The annular recesses <NUM> underlie the annular protrusions <NUM> and encircle the annular recesses <NUM> from below. The outsole <NUM> is further secured to distal ends <NUM> of proprioceptive elements <NUM> (i.e., to a distal surface of each proprioceptive element <NUM>).

The outsole <NUM> has external flex grooves <NUM> at a distal surface <NUM> of the outsole <NUM> as best shown in <FIG>. The external flex grooves <NUM> extend along lines connecting center axes CA of adjacent ones of the proprioceptive elements <NUM>, as indicated in <FIG>. Only some of the external flex grooves <NUM> are indicated in <FIG>.

As illustrated by a comparison of <FIG>, each proprioceptive element <NUM> is movable relative to adjacent portions 432A of the midsole body <NUM> along a central axis CA of the proprioceptive element <NUM> in a direction toward the proximal surface <NUM> when under a force toward the proximal surface <NUM> applied at a distal end <NUM> of the proprioceptive element along the central axis CA. As illustrated in <FIG>, the annular recesses <NUM> of the midsole body <NUM> encircling the holes <NUM>, and the protrusions <NUM> and annular recesses <NUM> of the outsole <NUM> enable the sole structure <NUM> to function as bellows between the proprioceptive element <NUM> and the portions 432A of the midsole body <NUM> surrounding the hole <NUM>, articulating to simultaneously decrease the depths of the holes <NUM> and the annular recesses <NUM> while driving the proximal end <NUM> of the proprioceptive element <NUM> in the direction of the axial force, such as further toward a foot-receiving cavity and a foot therein to enhance proprioceptive feedback. The external grooves <NUM> further enable independent articulation of the sole structure <NUM> at adjacent proprioceptive elements <NUM>, such that a distinction between active proprioceptive elements <NUM> and inactive proprioceptive elements <NUM> is more apparent to the wearer. The sole structure <NUM> can articulate both in dorsiflexion (e.g., along curve <NUM> in <FIG>) and in plantarflexion (e.g., along curve <NUM> in <FIG>) similar to sole structure 10A as described with respect to <FIG>.

<FIG> illustrate another embodiment of a sole structure <NUM> with a midsole <NUM> having a midsole body <NUM>. The outsole <NUM> as described with respect to <FIG> is secured to the midsole body <NUM> in the same manner as described with respect to midsole body <NUM>. The sole structure <NUM> is identical in all respects to sole structure <NUM> except that proprioceptive elements <NUM> used in place of proprioceptive elements <NUM> have a height H1 that is less than the depth D of the hole <NUM> (i.e., the annular recess) in which it is disposed, where both the height H1 and the depth D are measured from the bottom of the hole <NUM>. Stated differently, the proximal ends <NUM> of the proprioceptive elements <NUM> are recessed relative to the surrounding portion of the midsole body <NUM> at the proximal surface <NUM>. In other embodiments, some of the holes <NUM> may have depths less than the heights of the proprioceptive elements that they surround. Because the proprioceptive elements <NUM> do not extend beyond (i.e., above) the proximal surface <NUM> in the unloaded position of <FIG>, greater translation along their central axes can occur before pressure of an overlying foot inhibits further translation. Accordingly, the sole structure <NUM> can likewise experience greater articulation than sole structure <NUM>.

<FIG> illustrate another embodiment of a sole structure <NUM> with the midsole <NUM> having the midsole body <NUM> as described with respect to <FIG>. An outsole <NUM> is secured to the midsole body <NUM> in the same manner as described with respect to outsole <NUM>, except that the outsole <NUM> has through-holes <NUM> that are aligned with and underlie the proprioceptive elements <NUM> such that the distal ends <NUM> of the proprioceptive elements <NUM> are exposed at the distal surface 483A of the outsole <NUM> and therefore serve as a portion of the distal surface of the sole structure <NUM>. The sole structure <NUM> functions as described with respect to sole structure <NUM> except that, because the distal ends of the proprioceptive elements <NUM> are exposed, they may modify the traction of the sole structure <NUM> both with respect to the ground and with respect to an object such as a ball. For example, if the proprioceptive elements <NUM> are a material that is softer than the material of the outsole <NUM>, they may increase the grip of the sole structure <NUM> on a ball.

<FIG> and <FIG> show the sole structure <NUM> assembled in an article of footwear <NUM>. The article of footwear <NUM> includes an upper <NUM> secured to the sole structure <NUM>. The upper <NUM> may be any material or materials. The upper <NUM> terminates at a lower periphery <NUM> that is secured to a strobel <NUM>. Both a portion of the lower periphery <NUM> and the strobel <NUM> are secured to the proximal surface <NUM> of the midsole body <NUM>. The strobel <NUM> has holes 621A that are through-holes and are aligned with the proprioceptive elements <NUM> so that the proprioceptive elements <NUM> protrude through the holes 621A.

The article of footwear <NUM> also includes a sockliner <NUM> overlying the midsole body <NUM> and the strobel <NUM>. More specifically, the sockliner <NUM> includes a foam layer <NUM> that has a distal surface <NUM> secured to a proximal surface <NUM> of the strobel <NUM>. The sockliner <NUM> also includes an elastic layer <NUM> that has a distal surface <NUM> secured to a proximal surface <NUM> of the foam layer <NUM>. The sockliner <NUM> is shown in plan view in <FIG>. The elastic layer <NUM> is also referred to herein as an elastic sockliner top layer. The elastic layer <NUM> overlies the plurality of proprioceptive elements <NUM> such that proximal ends <NUM> of the proprioceptive elements contact the distal surface <NUM> of the elastic layer <NUM>. The elastic layer <NUM> is thinner and has greater elastic stretchability than the foam layer <NUM>.

As shown in <FIG>, the foam layer <NUM> is disposed between the elastic layer <NUM> and the midsole body <NUM>. The foam layer <NUM> has holes 633A aligned with the proprioceptive elements <NUM> such that the proprioceptive elements <NUM> extend through the holes 633A of the foam layer <NUM> toward the elastic layer <NUM>. Accordingly, the proprioceptive elements <NUM> extend through the holes 621A of the strobel <NUM> and through the holes 633A of the foam layer <NUM> when interfacing with the elastic layer <NUM>. With only the thin, flexible elastic layer <NUM> between the foot-receiving cavity <NUM> and the proprioceptive elements <NUM>, proprioception is enhanced.

<FIG> is a flowchart of a method <NUM> of manufacturing an article of footwear, such as article of footwear <NUM>. The method <NUM> may apply to footwear that includes any of the sole structures <NUM>, <NUM>, <NUM>, with the exception of some portions of the method applicable only to sole structures <NUM> and <NUM>. The method <NUM> begins with block <NUM>, forming a midsole body such that the midsole body has annular holes at a proximal surface of the midsole body, and annular recesses in a distal surface of the midsole body, with each annular recess encircling a different one of the annular holes from below and extending beyond a lowest extent of the different one of the annular holes toward the proximal surface. The midsole body also has a plurality of proprioceptive elements, each proprioceptive element centered in a different one of the annular holes. Block <NUM> applies to the midsole bodies <NUM> and <NUM> as described herein. Forming the midsole body in block <NUM> may be by molding, such as compression molding, or by <NUM>-D printing.

Next, the method <NUM> moves to block <NUM>, securing an outsole to the distal surface of the midsole body so that the outsole lines the annular recesses of the midsole body. For example, outsole <NUM> or <NUM> may be used. If outsole <NUM> is used, block <NUM> may include block <NUM>, aligning the through-holes <NUM> of the outsole with the proprioceptive elements <NUM> such that the proprioceptive elements are exposed at a distal surface 483A of the outsole, as described with respect to <FIG>.

The method then proceeds to block <NUM>, securing an upper to a strobel, and then to block <NUM>, securing the strobel to the proximal surface of the midsole body. Blocks <NUM> and <NUM> may be carried out, for example with upper <NUM>, strobel <NUM>, and midsole body <NUM> as described with respect to <FIG>. The strobel <NUM> has through-holes 621A that align with the plurality of proprioceptive elements <NUM>. Accordingly, block <NUM> includes block <NUM>, aligning the through-holes 621A of the strobel <NUM> with the proprioceptive elements <NUM>.

Next, the method moves to block <NUM>, securing an elastic sockliner top layer <NUM> to a proximal surface of the sockliner <NUM>, with the elastic sockliner top layer spanning across the holes of the sockliner. For example, elastic layer <NUM> is secured to foam layer <NUM> of the sockliner <NUM> as described.

Next, the method moves to block <NUM>, securing a sockliner to the proximal surface of the strobel. For example, sockliner foam layer <NUM> is secured to the strobel <NUM> in this manner. Additionally, block <NUM> may include block <NUM>, aligning the holes 633A of the sockliner (i.e., holes 633A of sockliner foam layer <NUM>) with the plurality of proprioceptive elements <NUM> such that the proprioceptive elements <NUM> protrude through the the holes of the strobel <NUM> and the holes of the sockliner foam layer <NUM> when interfacing with the elastic sockliner top layer <NUM>.

Claim 1:
An article of footwear (<NUM>), comprising:
a sole structure (<NUM>, 10A, 10B), comprising:
a midsole body (<NUM>, <NUM>) having a proximal surface (<NUM>) and a distal surface (<NUM>);
wherein the midsole body (<NUM>, <NUM>) has a first set of holes (<NUM>) extending through the midsole body (<NUM>, <NUM>) from the proximal surface (<NUM>) to the distal surface (<NUM>), a second set of holes (<NUM>) extending through the midsole body (<NUM>, <NUM>) from the proximal surface (<NUM>) to the distal surface (<NUM>), and a cleft (<NUM>) extending partway through the midsole body (<NUM>, <NUM>) between the first set of holes (<NUM>) and the second set of holes (<NUM>);
wherein center axes (CA) of holes (<NUM>) of the first set are parallel with center axes (CA) of holes (<NUM>) of the second set with the cleft (<NUM>) open, and are nonparallel with the center axes (CA) of the holes (<NUM>) of the second set with the cleft (<NUM>) closed;
a plurality of proprioceptive elements (<NUM>), each proprioceptive element (<NUM>) disposed in a different hole (<NUM>) of the first set or of the second set, and translatable relative to the midsole body (<NUM>, <NUM>) along a central axis (CA) of the respective hole (<NUM>) in a direction toward the proximal surface (<NUM>) under a force along the central axis (CA) at a distal end (<NUM>) of the proprioceptive element (<NUM>);
a connecting web (<NUM>) integral with the plurality of proprioceptive elements (<NUM>) at either proximal ends (<NUM>) or distal ends (<NUM>) of the plurality of proprioceptive elements (<NUM>) such that the connecting web (<NUM>) and the plurality of proprioceptive elements (<NUM>) are a single, unitary component; and
in combination with a sock overlying the connecting web (<NUM>) such that the proximal ends (<NUM>) of the plurality of proprioceptive elements (<NUM>) translate into a foot-receiving cavity (<NUM>) of the sock.