Patent Description:
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 enhance 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 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.

<CIT> describes a method of making a cushioning member. The method includes forming a first barrier member from a first material, the first barrier member including a first compartment and a second compartment. The method further includes forming a second barrier member from a second material different than the first material. The first compartment is provided with a first quantity of particulate matter and the second compartment is provided with a second quantity of particulate matter. The method further includes covering the first compartment with the second barrier member and covering the second compartment with the second barrier member.

The drawings described herein are for illustrative purposes only of selected configurations.

It will be apparent to those of ordinary skill in the art that specific details need not be employed, that example configurations may be embodied in many different forms.

In contrast, when an element is referred to as being "directly on," "directly engaged to," "directly connected to," "directly attached to," or "directly coupled to" another element or layer, there is no intervening elements or layers present.

The invention relates to a sole structure as specified in appended independent claim <NUM>. Additional embodiments of the invention are disclosed in the dependent claims.

With reference to <FIG> and <FIG>, an article of footwear <NUM> is provided. As shown in <FIG>, the article of footwear <NUM> includes an upper <NUM> and a sole structure <NUM> attached to the upper <NUM>, which is not part of the claimed invention, but useful to understand the claimed invention. The article of footwear <NUM> may be divided into one or more portions. The portions may include a forefoot region <NUM>, a mid-foot region <NUM>, and a heel region <NUM>. The forefoot region <NUM> may correspond with toes and joints connecting metatarsal bones with phalanx 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 upper <NUM> includes interior surfaces that define an interior void <NUM> that receives and secures a foot for support on the sole structure <NUM>. An ankle opening <NUM> located 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 facilitate entry and removal of the foot from and to the interior void <NUM>. 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 while concurrently accommodating 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 additionally include a tongue portion <NUM> that extends between the interior void <NUM> and the fasteners <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 for the upper may include, but are not limited to, 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 to the foot while disposed within the interior void <NUM>.

With continued reference to <FIG> and <FIG>, the sole structure <NUM> is shown as including a midsole <NUM>, an outsole <NUM>, and a cushioning member <NUM>. As shown in <FIG>, the midsole <NUM> is generally disposed between the outsole <NUM> and the upper <NUM> and supports the cushioning member <NUM> relative to the upper <NUM>. Namely, the midsole <NUM> may support the cushioning member <NUM> between the outsole <NUM> and a lower substrate <NUM> of the upper <NUM>. The substrate <NUM> may be attached to the upper <NUM> via stitching <NUM> (<FIG>) or, alternatively, may be integrally formed with a material of the upper <NUM>. For example, if the upper <NUM> or a portion of the upper <NUM> is formed from a knit material, the knit material may likewise form the substrate <NUM> and, as such, the substrate <NUM> that opposes the midsole <NUM> and the cushioning member <NUM> may be integrally formed with the upper <NUM>.

If the substrate <NUM> is separately formed from the upper <NUM>, the substrate <NUM> may be attached to the upper <NUM> via stitching <NUM>. Regardless of whether the substrate <NUM> is integrally formed with the upper <NUM> or, alternatively, is a separate component that is attached to the upper <NUM>, the substrate <NUM> is disposed generally between the midsole <NUM> and the upper <NUM> and is formed from a flexible material. Forming the substrate <NUM> from a flexible material allows the substrate <NUM> to stretch and move when loaded by a wearer's foot during use. Allowing the substrate <NUM> to flex and move in response to a load received by a wearer's foot during use allows the wearer's foot to depress the midsole <NUM> and/or the cushioning member <NUM>, thereby providing the wearer with a degree of comfort and cushioning during use of the article of footwear <NUM>, as will be described in greater detail below.

The midsole <NUM> may be formed from a polymer material such as, for example, a foamed polymer material. Namely, the foamed polymer material may be ethyl-vinyl-acetate or polyurethane. Regardless of the particular construction of the midsole <NUM>, the midsole <NUM> extends generally from an anterior end <NUM> of the upper <NUM> to a posterior end <NUM> of the upper <NUM>. Further, the midsole <NUM> may extend between a medial side <NUM> of the upper <NUM> and a lateral side <NUM> of the upper <NUM>. In so doing, a portion of the midsole <NUM> may extend onto an outer surface <NUM> of the upper <NUM> proximate to a junction of the upper <NUM> and the midsole <NUM>. For example, the midsole <NUM> may include a projection <NUM> that extends at least partially around a perimeter of the midsole <NUM> and extends from the midsole <NUM> to cover a portion of the outer surface <NUM> of the upper <NUM>. The projection <NUM> may be integrally formed with the midsole <NUM> when the material of the midsole is formed into the shape shown in <FIG>.

With particular reference to <FIG> and <FIG>, the midsole <NUM> is shown as including a forefoot cavity <NUM>, a mid-foot cavity <NUM>, and a heel cavity <NUM>. As shown in <FIG> and <FIG>, the cavities <NUM>, <NUM>, <NUM> are disposed along a length of the sole structure <NUM> such that the forefoot cavity <NUM> is disposed in the forefoot region <NUM>, the mid-foot cavity <NUM> is disposed in the mid-foot region <NUM>, and the heel cavity <NUM> is disposed in the heel region <NUM>. The cavities <NUM>, <NUM>, <NUM> are formed in a first surface <NUM> of the midsole <NUM> that opposes the substrate <NUM> of the upper <NUM>. The first surface <NUM> is recessed from an upper surface <NUM> of the midsole <NUM> to provide clearance for a portion of the cushioning member <NUM> when the cushioning member <NUM> is disposed within the midsole <NUM>, as will be described in greater detail below. In the illustrated example, the forefoot cavity <NUM> has an anterior end disposed between a ball portion and a toe portion of the forefoot region.

The midsole <NUM> additionally includes a second surface <NUM> located on an opposite side of the midsole <NUM> than the first surface <NUM>. The second surface <NUM> opposes the outsole <NUM> and provides a surface to which the outsole <NUM> may be attached.

The cavities <NUM>, <NUM>, <NUM> are each associated with a first aperture and a second aperture of the midsole <NUM> that permit insertion of the cushioning member <NUM> into the midsole <NUM> and visibility of the cushioning member <NUM> at the outsole <NUM>, respectively, once the cushioning member <NUM> is inserted into the midsole <NUM>. Specifically, the forefoot cavity <NUM> defines a first aperture <NUM> at a junction of the forefoot cavity <NUM> and the first surface <NUM>. The first aperture <NUM> defines an opening to the forefoot cavity <NUM> at the first surface <NUM> and generally defines a shape of the forefoot cavity <NUM> at the first surface <NUM>. The forefoot cavity <NUM> additionally includes a second aperture <NUM> disposed at an opposite end of the forefoot cavity <NUM> than the first aperture <NUM> and formed through a bottom wall <NUM> of the midsole <NUM> within the forefoot cavity <NUM>. In one configuration, the bottom wall <NUM> and, thus, the second aperture <NUM> may extend in a plane that is substantially parallel to a plane defined by the first surface <NUM>.

As described, the opening to the forefoot cavity <NUM> at the first surface <NUM> is generally defined by the shape and size of the first aperture <NUM> and, further, a bottom portion of the forefoot cavity <NUM> disposed at an opposite end of the forefoot cavity <NUM> than the first aperture <NUM> is generally defined by the bottom wall <NUM>. The forefoot cavity <NUM> is further defined by a series of side surfaces <NUM> that extend from the bottom wall <NUM> to a junction of the first aperture <NUM> and the first surface <NUM> around a perimeter of the forefoot cavity <NUM>. Accordingly, the side surfaces <NUM> cooperate with one another to encircle and define a shape of the forefoot cavity <NUM> between the bottom wall <NUM> and the first aperture <NUM>.

The mid-foot cavity <NUM> is disposed generally between the forefoot cavity <NUM> and the heel cavity <NUM> along a longitudinal axis (F) of the sole structure <NUM> (<FIG>). The mid-foot cavity <NUM> includes a first aperture <NUM> that defines an opening to the mid-foot cavity <NUM> at the first surface <NUM>. The mid-foot cavity <NUM> further includes a second aperture <NUM> disposed at an opposite end of the mid-foot cavity <NUM> than the first aperture <NUM> and formed through a bottom wall <NUM> of the midsole <NUM>. As with the bottom wall <NUM> associated with the forefoot cavity <NUM>, the bottom wall <NUM> associated with the mid-foot cavity <NUM> defines a bottom of the mid-foot cavity <NUM> and, thus, defines a bottom surface of the mid-foot cavity <NUM>. Side surfaces <NUM> extend between the first aperture <NUM> and the bottom wall <NUM> to define the overall shape of the mid-foot cavity <NUM>. As such, the side surfaces <NUM> cooperate with the bottom wall <NUM> to define the overall shape of the mid-foot cavity <NUM> between the first aperture <NUM> and the bottom wall <NUM>.

The heel cavity <NUM> is disposed closer to the posterior end <NUM> than the forefoot cavity <NUM> and the mid-foot cavity <NUM> and includes a first aperture <NUM> formed in the first surface <NUM> of the midsole <NUM>. The first aperture <NUM> defines an opening to the heel cavity <NUM> and generally defines a shape of a perimeter of the heel cavity <NUM> at the first surface <NUM>. The heel cavity <NUM> additionally includes a second aperture <NUM> disposed at an opposite end of the heel cavity <NUM> than the first aperture <NUM> and formed through a bottom wall <NUM> of the heel cavity of the midsole <NUM>. As with the forefoot cavity <NUM> and the mid-foot cavity <NUM>, the bottom wall <NUM> is disposed at an opposite end of the heel cavity <NUM> than the first aperture <NUM> and serves to define a bottom surface of the heel cavity <NUM>. Side surfaces <NUM> extend from the bottom wall <NUM> to the first aperture <NUM> and cooperate to define a perimeter of the heel cavity <NUM>.

As described, each of the forefoot cavity <NUM>, the mid-foot cavity <NUM>, and the heel cavity <NUM> include respective side surfaces <NUM>, <NUM>, <NUM> that define a shape of each cavity <NUM>, <NUM>, <NUM>. As shown in <FIG>, one or more of the side surfaces <NUM>, <NUM>, <NUM> may taper in a direction from the respective first apertures <NUM>, <NUM>, <NUM> to the respective bottom walls <NUM>, <NUM>, <NUM>. By providing the side surfaces <NUM>, <NUM>, <NUM> with a taper that extends from the respective first apertures <NUM>, <NUM>, <NUM> to the respective bottom walls <NUM>, <NUM>, <NUM>, a cross-sectional area of the cavities <NUM>, <NUM>, <NUM> is generally reduced in a direction extending from the first surface <NUM> of the midsole <NUM> to the second surface <NUM> of the midsole <NUM>. As shown in <FIG>, the degree to which the side surfaces <NUM>, <NUM>, <NUM> taper in the direction extending from the first surface <NUM> to the second surface <NUM> may vary amongst the cavities <NUM>, <NUM>, <NUM>. For example, the forefoot cavity <NUM> may include side surfaces <NUM> having a more gradual taper than either of the side surfaces <NUM>, <NUM> of the mid-foot cavity <NUM> and the heel cavity <NUM>, respectively. Further, the side surfaces <NUM> of the heel cavity <NUM> may include less of a taper than either of the side surfaces <NUM>, <NUM> of the forefoot cavity <NUM> and the mid-foot cavity <NUM>, respectively.

With particular reference to <FIG>, the forefoot cavity <NUM>, the mid-foot cavity <NUM>, and the heel cavity <NUM> are shown as being formed into the material of the midsole <NUM> at spaced apart locations along the longitudinal axis (F) of the sole structure <NUM>. Accordingly, a first wall <NUM> of the midsole <NUM> may extend between the forefoot cavity <NUM> and the mid-foot cavity <NUM> and a second wall <NUM> may extend between the mid-foot cavity <NUM> and the heel cavity <NUM>. Accordingly, the first wall <NUM> may serve to separate the forefoot cavity <NUM> from the mid-foot cavity <NUM> while the second wall <NUM> serves to separate the mid-foot cavity <NUM> from the heel cavity <NUM> in a direction extending along the longitudinal axis (F) of the sole structure <NUM>. As will be described in greater detail below, the walls <NUM>, <NUM> help to maintain a desired position of the cushioning member <NUM> relative to the midsole <NUM> and, thus, help to provide a desired cushioning effect to a foot of a wearer during use of the article of footwear <NUM>.

With particular reference to <FIG> and <FIG>, the cushioning member <NUM> is shown as including a first barrier member <NUM>, a second barrier member <NUM>, and a quantity of particulate matter <NUM> contained within the cushioning member <NUM>. In one configuration, the second barrier member <NUM> is attached to the first barrier member <NUM> to contain the particulate matter <NUM> generally between the second barrier member <NUM> and the first barrier member <NUM>. For example, the cushioning member <NUM> may include a first compartment <NUM>, a second compartment <NUM>, and a third compartment <NUM> each respectively incorporating a first quantity of particulate matter <NUM>, a second quantity of particulate matter <NUM>, and a third quantity of particulate matter <NUM>.

The first barrier member <NUM> and the second barrier member <NUM> may be formed from flexible materials that allow the first barrier member <NUM> and the second barrier member <NUM> to stretch and move during use of the article of footwear <NUM> when the sole structure <NUM> is subjected to a force from a foot of a wearer. In one configuration, the first barrier member <NUM> and the second barrier member <NUM> are formed from different materials. For example, the first barrier member <NUM> may be formed from a polymer material such as thermoplastic polyurethane (TPU). Forming the first barrier member <NUM> from TPU allows the first barrier member <NUM> to be formed from an impermeable material and, in some configurations, allows the first barrier member <NUM> to be formed from an optically clear and/or translucent material.

The second barrier member <NUM> may be formed from a flexible material such as, for example, spandex. Forming the second barrier member <NUM> from a flexible material such as spandex also allows the second barrier member <NUM> to be permeable. Forming the second barrier member <NUM> from a permeable material permits fluid communication through the second barrier member <NUM> into the first compartment <NUM>, the second compartment <NUM>, and the third compartment <NUM>, thereby permitting air circulation from an area external to the cushioning member <NUM> into the compartments <NUM>, <NUM>, <NUM>.

The second barrier member <NUM> may be attached to the first barrier member <NUM> via an adhesive <NUM>. The adhesive <NUM> may be a hot melt adhesive and may surround a perimeter of each of the first compartment <NUM>, the second compartment <NUM>, and the third compartment <NUM>. As such, the adhesive <NUM> joins the material of the second barrier member <NUM> to the material of the first barrier member <NUM> between each of the compartments <NUM>, <NUM>, <NUM>, thereby defining an interior void within each compartment <NUM>, <NUM>, <NUM> between the second barrier member <NUM> and the first barrier member <NUM>.

Attaching the second barrier member <NUM> to the first barrier member <NUM> around a perimeter of each compartment <NUM>, <NUM>, <NUM> such that the adhesive <NUM> completely surrounds each compartment <NUM>, <NUM>, <NUM> creates a web member <NUM> in areas where the second barrier member <NUM> is attached to the first barrier member <NUM>. The web member <NUM> may extend between each compartment <NUM>, <NUM>, <NUM> as well as around an outer perimeter of the cushioning member <NUM>, as shown in <FIG>. The web member <NUM> may include a thickness that is substantially equal to a depth of the first surface <NUM> of the midsole <NUM> relative to the upper surface <NUM> of the midsole <NUM>. Further, the overall shape of the cushioning member <NUM> as defined by the web member <NUM> at a perimeter of the cushioning member <NUM> may include a shape that is substantially equal to a shape of the first surface <NUM>, as formed into the upper surface <NUM>. Accordingly, when the cushioning member <NUM> is inserted into the midsole, an upper surface <NUM> of the cushioning member <NUM> is substantially flush with the upper surface <NUM> of the midsole <NUM>, thereby providing a uniform surface that receives the substrate <NUM>. Providing a uniform surface that opposes the substrate <NUM> provides a degree of comfort to a foot of a wearer by preventing the wearer from feeling a transition or junction between the midsole <NUM> and the cushioning member <NUM>.

With particular reference to <FIG>, the cushioning member <NUM> is shown as including varying amounts of particulate matter <NUM> disposed within the compartments <NUM>, <NUM>, <NUM>. For example, the first compartment <NUM>, the second compartment <NUM>, and the third compartment <NUM> are each shown as including different amounts of the particulate matter <NUM>. Namely, the first compartment <NUM> disposed with the forefoot cavity <NUM> and, thus, the forefoot region <NUM> of the sole structure <NUM>, includes less particulate matter <NUM> than the second compartment <NUM> and the third compartment <NUM>. Conversely, the third compartment <NUM> received by the heel cavity <NUM> of the midsole <NUM> and, thus, located in the heel region <NUM> of the sole structure <NUM>, receives a greater amount of particulate matter <NUM> than the second compartment <NUM> and the first compartment <NUM>. While the compartments <NUM>, <NUM>, <NUM> are described and shown as receiving different amounts of particulate matter <NUM>, each compartment <NUM>, <NUM>, <NUM> may receive approximately the same amount of particulate matter <NUM>. Further, one or more of the compartments <NUM>, <NUM>, <NUM> may receive a volume of particulate matter <NUM> that creates a bulge <NUM> in the outer surface <NUM> of the cushioning member <NUM> (<FIG>). For example, the second compartment <NUM> and the third compartment <NUM> of the cushioning member <NUM> may each include a bulge <NUM> that extends from a nominal plane defined by the second barrier member <NUM> at a location of the second compartment <NUM> and the third compartment <NUM>. Namely, the bulges <NUM> extend from a nominal plane defined by the web member <NUM>.

Regardless of the amount of particulate matter <NUM> disposed within the respective compartments <NUM>, <NUM>, <NUM>, the particulate matter <NUM> may be used to enhance the functionality and cushioning characteristics that the material of the midsole <NUM> provides. For example, the particulate matter <NUM> contained within the compartments <NUM>, <NUM>, <NUM> may include foam beads having a substantially spherical shape. Further, the foam beads defining the particulate matter <NUM> may have approximately the same size and shape or, alternatively, may have at least one of a different size and shape. Regardless of the particular size and shape of the particulate matter <NUM>, the particulate matter <NUM> cooperates with the outsole <NUM> and the midsole <NUM> to provide the article of footwear <NUM> with a cushioned and responsive performance during use.

The cushioning member <NUM> may be inserted into the midsole <NUM> such that the first compartment <NUM> is received by the forefoot cavity <NUM>, the second compartment <NUM> is received by the mid-foot cavity <NUM>, and the third compartment <NUM> is received by the heel cavity <NUM>. Once the cushioning member <NUM> is disposed within the midsole <NUM>, the surface <NUM> of the cushioning member <NUM> is substantially flush with the upper surface <NUM> of the midsole <NUM> at the web member <NUM> that defines a perimeter of the cushioning member <NUM>. As such, the second barrier member <NUM> cooperates with the material of the midsole <NUM> at the upper surface <NUM> of the midsole <NUM> to provide a generally uniform surface against which the substrate <NUM> resides when the sole structure <NUM> is attached to the upper <NUM>.

The outsole <NUM> may be formed from a transparent or translucent material and may include one or more discreet portions that are separate from one another. The outsole <NUM> may be formed from a durable material such as, for example, rubber and may be attached to the second surface <NUM> of the midsole <NUM>. The individual portions of the outsole <NUM> may be attached to the second surface <NUM> of the midsole <NUM> proximate to the second apertures <NUM>, <NUM>, <NUM>, respectively associated with the forefoot cavity <NUM>, the mid-foot cavity <NUM>, and the heel cavity <NUM>. The portions of the outsole <NUM> may be separated from one another along a length of the sole structure <NUM> in a direction substantially parallel to the longitudinal axis (L). While the outsole <NUM> is described and shown as including individual portions that are spaced apart from one another, the outsole <NUM> could alternatively have a unitary construction that extends generally across the entire second surface <NUM> of the midsole <NUM> such that the outsole <NUM> extends continuously between the anterior end <NUM> and the posterior end <NUM> and between the medial side <NUM> and the lateral side <NUM>. Regardless of the particular construction of the outsole <NUM> (i.e., unitary or discrete portions), the outsole <NUM> may include treads <NUM> that extend from the outsole <NUM> to provide increased traction with a ground surface during use of the article of footwear <NUM>.

Forming the outsole <NUM> from a transparent or translucent material allows the cavities <NUM>, <NUM>, <NUM> to be viewed from the outsole <NUM> when the outsole <NUM> is attached to the midsole <NUM> at the second surface <NUM>. Further, because the compartments <NUM>, <NUM>, <NUM> substantially fill the respective cavities <NUM>, <NUM>, <NUM> of the midsole <NUM>, the compartments <NUM>, <NUM>, <NUM> and, thus, the particulate matter <NUM> disposed therein is likewise visible at the second apertures <NUM>, <NUM>, <NUM> of the midsole <NUM> through the material of the outsole <NUM>. Accordingly, the particulate matter <NUM> residing within the respective compartments <NUM>, <NUM>, <NUM> of the cushioning member <NUM> is visible through the outsole <NUM> at the second apertures <NUM>, <NUM>, <NUM> associated with the respective cavities <NUM>, <NUM>, <NUM>.

The sole structure <NUM> may be attached to the upper <NUM> via a suitable adhesive <NUM> (<FIG>). For example, the adhesive <NUM> may extend between and attach the projection <NUM> of the midsole <NUM> to the outer surface <NUM> of the upper <NUM>. Further, the adhesive <NUM> may attach the web member <NUM> of the cushioning member <NUM> to the midsole <NUM> at a junction of the web member <NUM> and the first surface <NUM> of the midsole <NUM>.

With reference to <FIG>, an article of footwear 10a is provided and includes an upper <NUM> and a sole structure 14a attached to the upper <NUM>. In view of the substantial similarity in structure and function of the components associated with the article of footwear 10a with respect to the article of footwear 10a, like reference numerals are used hereinafter and in the drawings to identify like components while like reference numerals containing letter extensions are used to identify those components that have been modified.

With continued reference to <FIG>, the sole structure 14a is shown as including a midsole 32a, an outsole 34a, and a cushioning member 36a. As shown in <FIG>, the midsole 32a is generally disposed between the outsole 34a and the upper <NUM> and supports the cushioning member 36a relative to the upper <NUM>. Namely, the midsole 32a may support the cushioning member 36a between the outsole 34a and the lower substrate <NUM> of the upper <NUM>.

As with the example described above, the midsole 32a of <FIG> is shown as including a ball cavity 54a, a mid-foot cavity 56a, and a heel cavity 58a. Here, the midsole 32a also includes a toe cavity <NUM> disposed in the toe region <NUM>T. As shown in <FIG>, the cavities 54a, 56a, 58a, <NUM> are disposed along a length of the sole structure 14a such that the toe cavity <NUM> is disposed in a toe region <NUM>T of the forefoot region <NUM> adj acent to the anterior end <NUM> of the upper <NUM>, the ball cavity 54a is disposed in a ball region <NUM>B of the forefoot region <NUM> adjacent to the toe cavity <NUM>, the mid-foot cavity 56a is disposed in the mid-foot region <NUM>, and the heel cavity 58a is disposed in the heel region <NUM> adjacent to the posterior end <NUM>. The cavities 54a, 56a, 58a, <NUM> are formed in a first surface <NUM> of the midsole 32a that opposes the substrate <NUM> of the upper <NUM>. The first surface <NUM> is recessed from an upper surface <NUM> of the midsole 32a to provide clearance for a portion of the cushioning member 36a when the cushioning member 36a is disposed within the midsole 32a, as will be described in greater detail below.

The cavities 54a, 56a, 58a, 116a are each associated with a first aperture and a second aperture of the midsole 32a that permit insertion of the cushioning member 36a into the midsole 32a and visibility of the cushioning member 36a at the outsole 34a, respectively, once the cushioning member 36a is inserted into the midsole 32a.

Specifically, the ball cavity 54a defines a second aperture 66a at a junction of the ball cavity 54a and the first surface <NUM>. The first aperture 66a defines an opening to the ball cavity 54a at the first surface <NUM> and generally defines a shape of the ball cavity 54a at the first surface <NUM>. The ball cavity 54a additionally includes a second aperture 68a disposed at an opposite end of the ball cavity 54a than the first aperture 66a and formed through a bottom wall 70a of the midsole 32a.

As described, the opening to the ball cavity 54a at the first surface <NUM> is generally defined by the shape and size of the first aperture 66a and, further, a bottom portion of the ball cavity 54a disposed at an opposite end of the ball cavity 54a than the first aperture 66a is generally defined by the bottom wall 70a. The ball cavity 54a is further defined by a series of side surfaces 72a that extend from the bottom wall 70a to a junction of the first aperture 66a and the first surface <NUM> around a perimeter of the ball cavity 54a. Accordingly, the side surfaces 72a cooperate with one another to define a shape of the ball cavity 54a between the bottom wall 70a and the first aperture 66a.

The mid-foot cavity 56a is disposed generally between the ball cavity 54a and the heel cavity 58a along a longitudinal axis (F) of the sole structure 14a (<FIG>). The mid-foot cavity 56a includes a first aperture 74a that defines an opening to the mid-foot cavity 56a at the first surface <NUM>. However, unlike the example above, the bottom end of the mid-foot cavity 56a is enclosed by a bottom wall 78a of the midsole 32a such that the mid-foot cavity 54a terminates Side surfaces 80a extend between the first aperture 74a and the bottom wall 78a to define the overall shape of the mid-foot cavity 56a. As such, the side surfaces 80a cooperate with the bottom wall 78a to define the overall shape of the mid-foot cavity 56a between the first aperture 74a and the bottom wall <NUM>.

The heel cavity 58a is disposed closer to the posterior end <NUM> than the ball cavity 54a and the mid-foot cavity 56a and includes a first aperture 82a formed in the first surface <NUM> of the midsole 32a. The first aperture 82a defines an opening to the heel cavity 58a and generally defines a shape of a perimeter of the heel cavity 58a at the first surface <NUM>. The heel cavity 58a additionally includes a second aperture 84a disposed at an opposite end of the heel cavity 58a than the first aperture 82a and formed through a bottom wall <NUM> of the third cavity of the midsole 32a. As with the ball cavity 54a and the mid-foot cavity 56a, the bottom wall <NUM> is disposed at an opposite end of the heel cavity 58a than the first aperture 82a and serves to define a bottom surface of the heel cavity 58a. Side surfaces 88a extend from the bottom wall <NUM> to the first aperture 82a and cooperate to define a perimeter of the heel cavity 58a.

The toe cavity <NUM> is disposed in the toe region <NUM>T between the ball cavity 54a and the anterior end <NUM> and includes a first aperture <NUM> formed in the first surface <NUM> of the midsole 32a. The first aperture <NUM> defines an opening to the toe cavity <NUM> and generally defines a shape of a perimeter of the toe cavity <NUM> at the first surface <NUM>. The toe cavity <NUM> additionally includes a second aperture <NUM> disposed at an opposite end of the toe cavity <NUM> than the first aperture <NUM> and formed through a bottom wall <NUM> of the toe cavity <NUM> of the midsole 32a. The bottom wall <NUM> is disposed at an opposite end of the toe cavity <NUM> than the first aperture <NUM> and serves to define a bottom surface of the toe cavity <NUM>. Side surfaces 124a extend from the bottom wall <NUM> to the first aperture <NUM> and cooperate to define a perimeter of the toe cavity.

As described, each of the ball cavity 54a, the mid-foot cavity 56a, the heel cavity 58a, and the toe cavity <NUM> include respective side surfaces 72a, 80a, 88a, <NUM> that define a shape of each cavity <NUM>, <NUM>, <NUM>, <NUM>. As shown in <FIG>, one or more of the side surfaces 72a, 80a, 88a, <NUM> may taper in a direction from the respective first apertures 66a, 74a, 82a, <NUM> to the respective bottom walls 70a, 78a, 86a, <NUM>. By providing the side surfaces 72a, 80a, 88a, <NUM> with a taper that extends from the respective first apertures 66a, 74a, 82a to the respective bottom walls 70a, <NUM>, <NUM>, a cross-sectional area of the cavities 54a, 56a, 58a, 116a is generally reduced in a direction extending from the first surface <NUM> of the midsole 32a to the second surface <NUM> of the midsole 32a.

With particular reference to <FIG> and <FIG>, the toe cavity <NUM>, the ball cavity 54a, the mid-foot cavity 56a, and the heel cavity 58a are shown as being formed into the material of the midsole 32a at spaced apart locations along the longitudinal axis (F) of the sole structure 14a. Accordingly, a first wall 90a of the midsole 32a may extend between the toe cavity <NUM> and the ball cavity 54a, a second wall 92a may extend between the ball cavity 54a and the mid-foot cavity 56a, and a third wall 93a may extend between the mid-foot cavity 56a and the heel cavity 58a.

One or more of the cavities 54a, 56a, 58a, <NUM> may include structural features configured to modify physical properties of the midsole 32a. For example, in the illustrated example, the heel cavity 58a is surrounded by one or more pillars <NUM> projecting downwardly around the posterior end <NUM>. Adjacent ones of the pillars <NUM> are spaced apart from each other and are configured to interface with the outsole 34a when the sole structure 14a is assembled, thereby providing support to the article of footwear 10a in the heel region <NUM>. As shown in <FIG>, the particulate matter <NUM> is able to migrate from the heel cavity 58a and into a peripheral region <NUM> surrounding the pillars <NUM> to provide cushioning between the outsole 34a and the midsole 32a at the posterior end <NUM>.

With continued reference to <FIG> and <FIG>, the cushioning member 36a is shown as including a first barrier member 94a, a second barrier member 96a, and a quantity of particulate matter <NUM> contained within the cushioning member 36a. In one configuration, the second barrier member 96a is attached to the first barrier member 94a to contain the particulate matter <NUM> generally between the second barrier member 96a and the first barrier member 94a. For example, the cushioning member 36a may include a first compartment 100a, a second compartment 102a, and a third compartment 104a each respectively incorporating a first quantity of particulate matter <NUM>, a second quantity of particulate matter <NUM>, and a third quantity of particulate matter <NUM>.

Unlike the example of <FIG>, where all of the particulate matter <NUM> is distributed among the three compartments 100a, 102a, 104a, in the example of <FIG> the cushioning member 36a is configured as a hybrid cushioning member 36a, where a first portion of the particulate matter <NUM> is contained within the compartments 100a, 102a, 104a formed by joining the first barrier layer 94a and the second barrier layer 96a, and a second portion of the particulate matter is disposed directly within one of the cavities 54a, 56a, 58a, 116a and sealed within the cavity by the second barrier layer 96a. For instance, as shown in the examples of <FIG>, the cushioning member 36a may form a series of three compartments in the toe region <NUM>T, the ball region <NUM>B, and the mid-foot region <NUM>, while particulate matter in the heel region <NUM> is disposed directly within the heel cavity 58a formed in the heel region <NUM>. Here the second barrier layer 96a extends over the heel cavity 58a to enclose the particulate matter <NUM> therein.

While the shape and configuration of the cushioning member 36a may be different from that of the cushioning member <NUM> of <FIG>, the cushioning member 36a may be formed using similar materials and methods to those described above with respect to the cushioning member <NUM>. That is, the first barrier member 94a and the second barrier member 96a may be formed from flexible materials that allow the first barrier member 94a and the second barrier member 96a to stretch and move during use of the article of footwear 10a when the sole structure 14a is subjected to a force from a foot of a wearer. The second barrier member 96a may be attached to the first barrier member 94a via the adhesive <NUM>. Attaching the second barrier member 96a to the first barrier member 94a around a perimeter of each compartment 100a, 102a, 104a such that the adhesive <NUM> completely surrounds each compartment 100a, 102a, 104a creates the web member <NUM> in areas where the second barrier member 96a is attached to the first barrier member 94a.

With particular reference to <FIG> and <FIG>, the cushioning member 36a is shown as including varying amounts of particulate matter <NUM> disposed within the compartments 100a, 102a, 104a. For example, the first compartment 100a, the second compartment 102a, and the third compartment 104a are each shown as including different amounts of the particulate matter <NUM>. Namely, the first compartment 100a disposed with the toe cavity <NUM> and, thus, the toe region <NUM>T of the sole structure 14a, includes less particulate matter <NUM> than the second compartment 102a and the third compartment 104a. Conversely, the third compartment 104a received by the mid-foot cavity 54a of the midsole 32a and, thus, located in the mid-foot region <NUM> of the sole structure 14a, receives a greater amount of particulate matter <NUM> than the second compartment 102a and the first compartment 100a. While the compartments 100a, 102a, 104a are described and shown as receiving different amounts of particulate matter <NUM>, each compartment 100a, 102a, 104a may receive approximately the same amount of particulate matter <NUM>. Further, one or more of the compartments 100a, 102a, 104a may receive a volume of particulate matter <NUM> that creates a bulge <NUM> in the outer surface <NUM> of the cushioning member 36a (<FIG>). For example, the second compartment 102a and the third compartment 104a of the cushioning member 36a may each include a bulge <NUM> that extends from a nominal plane defined by the second barrier member 96a at a location of the second compartment 102a and the third compartment 104a. Namely, the bulges <NUM> extend from a nominal plane defined by the web member <NUM>.

As provided above, the compartments 100a, 102a, 104a are configured to be received within each of the toe cavity <NUM>, the ball cavity 54a, and the mid-foot cavity 56a. However, the heel cavity 58a does not receive a corresponding chamber of the cushioning member 36a. Instead, the particulate matter <NUM> is provided directly to the heel cavity 58a. Here, the particulate matter <NUM> is contained in the lateral direction by the side surfaces <NUM> of the heel cavity 58a, while the second aperture 84a on the bottom of the heel cavity 58a is enclosed by a portion of the outsole 34a and the first aperture 82a on the top of the heel cavity 58a is enclosed by a portion of the second barrier member 96a.

With reference to <FIG> and <FIG>, the cushioning member 36a includes the first barrier layer 94a forming a lower portion of the cushioning member 36a including the compartments 100a, 102a, 104a. The second barrier member 96a includes a first portion <NUM> extending over each of the compartments 100a, 102a, 104a and joined to the first barrier member 94a to form the web member <NUM> in the forefoot region <NUM> and the mid-foot region <NUM>. Additionally, the second barrier member 96a includes a second portion <NUM> extending beyond the first barrier member 94a and through the heel region <NUM> to cover the heel cavity 58a. Thus, unlike the first portion <NUM>, which is attached to the first barrier member 94a along the web member <NUM>, the second portion <NUM> of the second barrier member 96a is attached directly to the midsole 32a and surrounds an outer periphery of the first aperture 82a of the heel cavity 58a. In some examples, the second portion <NUM> is attached to first surface <NUM> of the midsole 32a such that the portion of the upper surface <NUM> of the cushioning member 36a formed by the second portion <NUM> is substantially flush with the upper surface <NUM> of the midsole 32a.

The outsole 34a may be formed from a transparent or translucent material and may include one or more discreet portions that are separate from one another. The outsole 34a may be formed from a durable material such as, for example, rubber and may be attached to the second surface <NUM> of the midsole 32a. The individual portions of the outsole 34a may be attached to the second surface <NUM> of the midsole 32a proximate to the second apertures <NUM>, 68a, 84a, respectively associated with the toe cavity <NUM>, the ball cavity 54a, and the heel cavity 58a. The portions of the outsole 34a may be separated from one another along a length of the sole structure 14a in a direction substantially parallel to the longitudinal axis (F). While the outsole 34a is described and shown as including individual portions that are spaced apart from one another, the outsole 34a could alternatively have a unitary construction that extends generally across the entire second surface <NUM> of the midsole 32a such that the outsole 34a extends continuously between the anterior end <NUM> and the posterior end <NUM> and between the medial side <NUM> and the lateral side <NUM>. Regardless of the particular construction of the outsole 34a (i.e., unitary or discrete portions), the outsole 34a may include treads <NUM> that extend from the outsole 34a to provide increased traction with a ground surface during use of the article of footwear 10a.

Incorporation of the cushioning member <NUM>, 36a into the article of footwear <NUM>, 10a provides a degree of comfort and cushioning to a foot of a wearer during use. For example, and as described above, the substrate <NUM>, 38a and the second barrier member <NUM>, 96a of the cushioning member <NUM>, 36a are formed from flexible materials. Accordingly, when a force is applied to the substrate <NUM>, 38a during use of the article of footwear <NUM>, 10a by a foot of a wearer, the force causes the substrate <NUM>, 38a and the material of the second barrier member <NUM>, 96a to flex and stretch, thereby allowing the foot of the wearer to engage and displace the particulate matter <NUM> disposed within the cavities <NUM>, 54a, <NUM>, 56a, <NUM>, 58a, <NUM>. In so doing, the particulate matter <NUM> exerts a force on the material of the first barrier member <NUM>, 94a, thereby causing the first barrier member <NUM>, 94a to likewise flex and stretch. Such movement of the first barrier member <NUM>, 94a compresses a material of the midsole <NUM>, 32a generally surrounding the compartments <NUM>, 100a, <NUM>, 102a, <NUM>, 104a or cavities <NUM>, 54a, <NUM>, 56a, <NUM>, 58a, <NUM> which, in turn, absorbs forces associated with a walking or running movement.

Flexing and stretching of the materials of the substrate <NUM>, 38a, the first barrier member <NUM>, 94a, and the second barrier <NUM>, 96a along with compression of the material of the midsole <NUM>, 32a provides a degree of cushioning and comfort to a wearer while wearing the article of footwear <NUM>, 10a. Further, interaction between a foot of a wearer with the particulate matter <NUM>-permitted by the generally flexible nature of the material of the substrate <NUM>, 38a and the second barrier member <NUM>, 96a-likewise provides cushioning to the foot of the wearer. Further, because the particulate matter <NUM> is permitted to move relative to and within each cavity <NUM>, 54a, <NUM>, 56a, <NUM>, 58a, <NUM>, the particulate matter <NUM> conforms to a shape of the wearer's foot and, thus, provides a degree of tailored cushioning that is specific to the shape of the wearer's foot. Further yet, because the particulate matter <NUM> is permitted to move relative to and within the first compartment <NUM>, 100a, the second compartment <NUM>, 102a, the third compartment <NUM>, 104a, and/or the heel cavity 58a, the shape of the substrate <NUM>, 38a and the second barrier member <NUM>, 96a is dynamic and is largely based on the applied loads at the substrate <NUM>, 38a at any given time. In other words, the support provided by the particulate matter <NUM> disposed within the cavities <NUM>, 54a, <NUM>, 56a, <NUM>, 58a, <NUM> moves and shifts in response to the applied forces at the substrate <NUM>, 38a. In so doing, the effective shape of the substrate <NUM>, 38a and the second barrier member <NUM>, 96a is constantly changing as the wearer applies forces at different locations of the substrate <NUM>, 38a, thereby causing the particulate matter <NUM> to shift and move relative to within the cavities <NUM>, 54a, <NUM>, 56a, <NUM>, 58a, <NUM>. As such, the cushioning member <NUM>, 36a provides the sole structure <NUM>, 14a and, thus, the article of footwear <NUM>, 10a with cushioning and support that dynamically responds to an applied force and automatically conforms to a shape of the wearer's foot, thereby providing the wearer with a tailored and personal cushioning system.

With respect to the example of the sole structure 14a in <FIG>, providing the particular matter directly to one of the cavities (e.g., the heel cavity 58a) provides the particulate matter <NUM> with an increased degree of freedom in comparison to the particulate matter <NUM> enclosed within a compartment of a cushioning member <NUM>, 36a. For example, in instances where one of the cavities is formed with structural features, such as pillars or cross-members, the particulate matter <NUM> will be unconstrained within the cavity and free to migrate around the interior structures.

With particular reference to <FIG>, a method of making the cushioning member <NUM> will be described in detail. While the illustrated method is provided with respect to the cushioning member <NUM> of <FIG>, it will be appreciated that the method may also be applied to forming the cushioning member 36a of <FIG>. As will be described in detail below, the method of forming the cushioning member <NUM> shown in <FIG> utilizes a thermoforming process to form the first barrier member <NUM> and, further, uses a heat press to attach the second barrier member <NUM> to the first barrier member <NUM> following insertion of the particulate matter <NUM> into the first compartment <NUM>, the second compartment <NUM>, and the third compartment <NUM>.

As shown in <FIG>, a tool <NUM> may be used to form a sheet of material <NUM> into the first barrier member <NUM>. For example, and as described above, the first barrier member <NUM> may be formed from thermoplastic polyurethane (TPU). Accordingly, the sheet of material <NUM> may be a sheet of TPU material. The tool <NUM> may include a forefoot cavity <NUM>, a mid-foot cavity <NUM>, and a heel cavity <NUM>. The forefoot cavity <NUM> may include an arcuate surface <NUM> that provides the first compartment <NUM> with the shape shown in <FIG>. Similarly, the mid-foot cavity <NUM> may correspond with the second compartment <NUM> and the heel cavity <NUM> may correspond with the third compartment <NUM>, whereby the mid-foot cavity <NUM> includes an arcuate surface <NUM> that conforms to the shape of the second compartment <NUM> and the heel cavity <NUM> includes an arcuate surface <NUM> that conforms to the shape of the third compartment <NUM>. The tool <NUM> may additionally include a series of vacuum ports <NUM> that are attached to a vacuum <NUM> (<FIG>).

In operation, the sheet of material <NUM> may be placed adjacent to the tool <NUM> such that the sheet of material <NUM> opposes the forefoot cavity <NUM>, the mid-foot cavity <NUM>, and the heel cavity <NUM>. Heat may be applied to the sheet of material <NUM> before and/or during application of a vacuum force on the sheet of material <NUM> via the vacuum ports <NUM>. For example, the sheet of material <NUM> may be heated by an external heat source (not shown) and/or via heating elements (not shown) disposed within the tool <NUM> to heat the sheet of material <NUM> at the same time the sheet of material <NUM> is drawn into the cavities <NUM>, <NUM>, <NUM> via the vacuum <NUM> and vacuum ports <NUM>.

As shown in <FIG>, forming the sheet of material <NUM> such that the material <NUM> is drawn into the cavities <NUM>, <NUM>, <NUM> forms the respective compartments <NUM>, <NUM>, <NUM> of the cushioning member <NUM>. Specifically, the material of the sheet of material <NUM> engages the arcuate surfaces <NUM>, <NUM>, <NUM> to form the sheet of material <NUM> into the various compartments <NUM>, <NUM>, <NUM> of the cushioning member <NUM>. The heat and pressure applied to the sheet of material <NUM> (i.e. by the vacuum (<NUM>) and the internal heat source and/or the external heat source) causes the sheet of material <NUM> to conform generally to the shape of the tool <NUM> at the cavities <NUM>, <NUM>, <NUM>, thereby forming the first barrier member <NUM> of the cushioning member <NUM>. Once the sheet of material <NUM> is formed into the shape of the first barrier member <NUM>, the material of the first barrier member <NUM> is permitted to cool, thereby causing the material of the first barrier member <NUM> to retain the shape of the tool <NUM>, as defined by the arcuate surfaces <NUM>, <NUM>, <NUM> of the cavities <NUM>, <NUM>, <NUM>, respectively.

Once the sheet of material <NUM> is formed into the shape of the first barrier member <NUM>, as described above, the compartments <NUM>, <NUM>, <NUM> may be filled with particulate matter <NUM>. As described above, the particulate matter <NUM> may include foam beads having the same and/or different shapes to provide the cushioning member <NUM> with the ability to provide cushioning for the article of footwear <NUM> once the second barrier member <NUM> is attached to the first barrier member <NUM> and the cushioning member <NUM> is inserted in the midsole <NUM>.

The particulate matter <NUM> may be inserted into the compartments <NUM>, <NUM>, <NUM>, by depositing the particulate matter <NUM> into each compartment <NUM>, <NUM>, <NUM> via a series of hoppers.

Specifically, a first hopper <NUM> may be aligned with the first compartment <NUM>, a second hopper <NUM> may be aligned with the second compartment <NUM>, and a third hopper <NUM> may be aligned with the third compartment <NUM> such that when the hoppers <NUM>, <NUM>, <NUM> release particulate matter <NUM>, the particulate matter <NUM> is received by the respective compartments <NUM>, <NUM>, <NUM>. In one configuration, the hoppers <NUM>, <NUM>, <NUM> may be gravity fed such that when a valve or other metering device (none shown) associated with the respective hoppers <NUM>, <NUM>, <NUM> is open, particulate matter <NUM> disposed within the hoppers <NUM>, <NUM>, <NUM> is automatically dispensed from the hoppers <NUM>, <NUM>, <NUM> and is received by the compartments <NUM>, <NUM>, <NUM> of the first barrier member <NUM>. Once a predetermined quantity of particulate matter <NUM> is received by the first compartment <NUM>, the second compartment <NUM>, and the third compartment <NUM>, the valves associated with the hoppers <NUM>, <NUM>, <NUM> may be closed to prevent further particulate matter <NUM> from being received by any of the compartments <NUM>, <NUM>, <NUM>.

With particular reference to <FIG>, the compartments <NUM>, <NUM>, <NUM> are shown as being substantially filled with particulate matter <NUM>. At this point, the adhesive <NUM> may be applied at regions surrounding the compartments <NUM>, <NUM>, <NUM> to allow the first barrier member <NUM> to be attached to the second barrier member <NUM>. As described above, and in one configuration, the adhesive <NUM> may be a hot melt adhesive. The hot melt adhesive may be placed on the first barrier member <NUM> at areas surrounding the compartments <NUM>, <NUM>, <NUM> and at raised portions <NUM> of the tool <NUM>. The raised portions <NUM> may generally mimic a shape of the first wall <NUM> and the second wall <NUM> of the midsole <NUM> to allow the cushioning member <NUM> to be matingly received by the cavities <NUM>, <NUM>, <NUM> of the midsole <NUM>, as shown in <FIG>.

Once the adhesive <NUM> is disposed on the first barrier member <NUM> in areas surrounding the first compartment <NUM>, the second compartment <NUM>, and the third compartment <NUM>, a sheet of material <NUM> may be placed between the first barrier member <NUM> and a heat source <NUM>. The sheet of material <NUM> may be positioned on the adhesive <NUM> such that the sheet of material <NUM> opposes and covers the first compartment <NUM>, the second compartment <NUM>, and the third compartment <NUM>. Once the sheet of material <NUM> is properly placed relative to the first barrier member <NUM>, the heat source <NUM> may be activated, thereby causing the adhesive <NUM> to bond with the sheet of material <NUM> and seal the first compartment <NUM>, the second compartment <NUM>, and the third compartment <NUM>.

Once the sheet of material <NUM> is attached to the first barrier member <NUM>, the sheet of material <NUM> closes the first compartment <NUM>, the second compartment <NUM>, and the third compartment <NUM> and, thus, forms the second barrier member <NUM>. As shown in <FIG>, the second barrier member <NUM> may define bulges <NUM> depending on the quantity of the particulate matter <NUM> disposed within the respective compartments <NUM>, <NUM>, <NUM>, as described above. Regardless of the quantity of particulate matter <NUM> received by the respective compartments <NUM>, <NUM>, <NUM>, once the sheet of material <NUM> is attached to the first barrier member <NUM> and, thus, forms the second barrier member <NUM>, the cushioning member <NUM> may be inserted into the midsole <NUM> such that the first compartment <NUM> is received by the ball cavity <NUM> of the midsole <NUM>, the second compartment <NUM> is received by the mid-foot cavity <NUM> of the midsole <NUM>, and the third compartment <NUM> is received by the heel cavity <NUM> of the midsole <NUM>.

As described above, the cushioning member <NUM> may be formed via a thermoforming process. In so doing, the first compartment <NUM>, the second compartment <NUM>, and the third compartment <NUM> receive a predetermined quantity of particulate matter <NUM> and, further, may result in the second barrier member <NUM> forming bulges <NUM> at an outer surface <NUM> that opposes the substrate <NUM> once installed in the article of footwear <NUM>. While the quantity of particulate matter <NUM> disposed within the first compartment <NUM>, the second compartment <NUM>, and/or the third compartment <NUM> may result in one or more bulges <NUM> being formed at the second barrier member <NUM>, the bulges <NUM> are limited by the amount of particulate matter <NUM> that can be deposited in the various compartments <NUM>, <NUM>, <NUM> via the hoppers <NUM>, <NUM>, <NUM> without having the particulate matter <NUM> spill over edges of the first barrier member <NUM>. Accordingly, the degree to which the bulges <NUM> extend from the cushioning member <NUM> is limited to the quantity of particulate matter <NUM> that can be stacked in the compartments <NUM>, <NUM>, <NUM> without the particulate matter <NUM> spilling over edges of the first barrier member <NUM>.

The bulges <NUM> could be increased by first attaching the second barrier member <NUM> to the first barrier member <NUM>, thereby closing the compartments <NUM>, <NUM>, <NUM> prior to insertion of the particulate matter <NUM> into the compartments <NUM>, <NUM>, <NUM>. Inserting the particulate matter <NUM> into the compartments <NUM>, <NUM>, <NUM> after the second barrier member <NUM> is attached to the first barrier member <NUM> requires use of a different process than the thermoforming process described above.

As will be described in greater detail below, a compression molding process could be used in place of the thermoforming process in an effort to first join the second barrier member <NUM> to the first barrier member <NUM> before inserting the particulate matter <NUM> into the compartments <NUM>, <NUM>, <NUM>. First attaching the second barrier member <NUM> to the first barrier member <NUM> before filling the compartments <NUM>, <NUM>, <NUM> with particulate matter <NUM> allows one or more of the compartments <NUM>, <NUM>, <NUM> to be overfilled with particulate matter <NUM> relative to the amount of particulate matter <NUM> capable of being inserted into the compartments <NUM>, <NUM>, <NUM> when the cushioning member <NUM> is formed via the thermoforming process described above and shown in <FIG>.

With reference to <FIG>, a compression molding process for use in making the cushioning member <NUM> not in accordance with the claimed invention will be described in detail.

The compression molding process may utilize a mold <NUM> including an upper mold half <NUM> and a lower mold half <NUM>. The lower mold half <NUM> may include a ball cavity <NUM>, a mid-foot cavity <NUM>, and a heel cavity <NUM>. The ball cavity <NUM> may include an arcuate surface <NUM> used to form the first compartment <NUM> of the first barrier member <NUM>. Similarly, the mid-foot cavity <NUM> may include an arcuate surface <NUM> used to form the second compartment <NUM> of the first barrier member <NUM> and the heel cavity <NUM> may include an arcuate surface <NUM> used to form the third compartment <NUM> of the first barrier member <NUM>. The cavities <NUM>, <NUM>, <NUM> and associated arcuate surfaces <NUM>, <NUM>, <NUM> may be identical to the cavities <NUM>, <NUM>, <NUM> and arcuate surfaces <NUM>, <NUM>, <NUM>, respectively, of the tool <NUM> used to form the first barrier member <NUM> via the thermoforming process shown in <FIG>.

The upper mold half <NUM> may include projections that extend into the respective cavities <NUM>, <NUM>, <NUM>. Specifically, the upper mold half <NUM> may include a first projection <NUM>, a second projection <NUM>, and a third projection <NUM> that are respectively received by the ball cavity <NUM>, the mid-foot cavity <NUM>, and the heel cavity <NUM>. The projections <NUM>, <NUM>, <NUM> may mimic a shape of the respective arcuate surfaces <NUM>, <NUM>, <NUM> and may be spaced apart from the arcuate surfaces <NUM>, <NUM>, <NUM> by a thickness of a sheet of TPU material used to form the first barrier member <NUM>, as will be described in greater detail below.

In operation, a sheet of material <NUM> such as a sheet of TPU material may be inserted between the upper mold half <NUM> and the lower mold half <NUM>. The sheet of material <NUM> may be attached to the lower mold half <NUM> via a pair of posts <NUM> extending from the lower mold half <NUM> and through a portion of the sheet of material <NUM>.

Once the sheet of material <NUM> is disposed between the upper mold half <NUM> and the lower mold half <NUM> (<FIG>), the mold halves <NUM>, <NUM> may be brought towards one another or, alternatively, one of the mold halves <NUM>, <NUM> may be moved toward the other of the mold halves <NUM>, <NUM> until the mold halves <NUM>, <NUM> are moved into the position shown in <FIG>. Namely, the upper mold half <NUM> and/or the lower mold half <NUM> may be moved from the position shown in <FIG> to the position shown in <FIG> to form the sheet of material <NUM> from a substantially plainer shape (<FIG>) to the shape of the first barrier member <NUM> (<FIG>). When the mold halves <NUM>, <NUM> are positioned in the configuration shown in <FIG>, the posts <NUM> may be received within respective apertures <NUM> of the upper mold half <NUM>, thereby defining a relative spacing between the upper mold half <NUM> and the lower mold half <NUM>. In one configuration, the spacing is approximately equal to a thickness of the sheet of material <NUM> to prevent compression of the sheet of material <NUM> between the projections <NUM>, <NUM>, <NUM> and the respective arcuate surfaces <NUM>, <NUM>, <NUM> of the cavities <NUM>, <NUM>, <NUM>.

Engaging the sheet of material <NUM> with the posts <NUM> maintains a position of the sheet of material <NUM> at the posts <NUM> relative to the lower mold half <NUM>. Accordingly, when the upper mold half <NUM> engages the sheet of material <NUM> at the projections <NUM>, <NUM>, <NUM>, the material of the sheet of material <NUM> is stretched and formed into the shape defined by the arcuate surfaces <NUM>, <NUM>, <NUM>. Deformation of the sheet of material <NUM> by the upper mold half <NUM> forms the sheet of material <NUM> into the shape shown in <FIG>.

As shown in <FIG>, the sheet of material <NUM> is formed into a shape that defines the compartments <NUM>, <NUM>, <NUM> but includes additional material at the location where the posts <NUM> engage the sheet of material <NUM> relative to the shape of the first barrier member <NUM> shown in <FIG>. Accordingly, the sheet of material <NUM> depicted in <FIG> is a partially formed first barrier member <NUM>. The additional material defines a flange <NUM> that extends generally around a perimeter of the sheet of material <NUM> and surrounds the compartments <NUM>, <NUM>, <NUM> formed by the mold <NUM>. The flange <NUM> may additionally include a pair of apertures <NUM> formed by the posts <NUM> during formation of the sheet of material <NUM> into the configuration shown in <FIG>. As will be described in greater detail below, the flange along with the apertures <NUM> may be removed from the sheet of material <NUM> to form the first barrier member <NUM> via a die-cutting process, for example.

Once the sheet of material <NUM> is formed into the configuration shown in <FIG>, a sheet of material <NUM> used to form the second barrier member <NUM> may be attached to sheet of material <NUM>. As described above, the second barrier member <NUM> may be formed from a flexible material such as spandex. Further, the second barrier member <NUM> is described as being attached to the first barrier member <NUM> via an adhesive <NUM>. As shown in <FIG>, the adhesive <NUM> may be provided in the form of a sheet of adhesive material <NUM> such as, for example, a sheet of hot melt adhesive. Finally, a blocking element <NUM> may be positioned between the adhesive <NUM> and the sheet of material <NUM> that forms the first barrier member <NUM> to form areas between the adhesive <NUM> and the first barrier member <NUM> that are not joined. Forming areas between the adhesive <NUM> and the first barrier member <NUM> that are not joined likewise forms areas between the first barrier member <NUM> and the second barrier member <NUM> that are not joined. As will be described in greater detail below, the areas where the first barrier member <NUM> is separated from the second barrier member <NUM> via the blocking element <NUM> provides an area where particulate matter <NUM> is permitted to be inserted into the first compartment <NUM>, the second compartment <NUM>, and the third compartment <NUM>.

The sheet of material <NUM> may be placed in a tool <NUM> (<FIG>) that generally conforms to the shape of the first material <NUM> after formation of the sheet of material <NUM> into the configuration shown in <FIG>. The tool <NUM> may be identical to the tool <NUM> described above with respect to the thermoforming process. Alternatively, the tool <NUM> may be identical to the tool <NUM> with the exception of the tool <NUM> failing to include the vacuum ports <NUM> associated with the tool <NUM>. Regardless of the particular configuration of the tool <NUM>, the tool <NUM> may include a forefoot cavity <NUM>, a mid-foot cavity <NUM>, and a heel cavity <NUM> that respectively receive the first compartment <NUM>, the second compartment <NUM>, and the third compartment <NUM> defined by the sheet of material <NUM> after formation by the mold <NUM>.

After the sheet of material <NUM> is inserted into the tool <NUM> such that the first compartment <NUM> is received by the forefoot cavity <NUM>, the second compartment <NUM> is received by the mid-foot cavity <NUM>, and the third compartment <NUM> is received by the heel cavity <NUM>, the blocking element <NUM> may be positioned over the sheet of material <NUM>, the sheet of adhesive material <NUM> may be placed on the blocking element <NUM>, and the sheet of material <NUM> forming the second barrier member <NUM> may be placed on top of the sheet of adhesive <NUM>. Accordingly, the blocking element <NUM> is disposed between the sheet of adhesive <NUM> and the sheet of material <NUM> forming the first barrier member <NUM>, the sheet of adhesive <NUM> is disposed between the sheet of material <NUM> forming the second barrier member <NUM> and the blocking element <NUM>, and the sheet of material <NUM> that forms the second hairier member <NUM> is disposed on the sheet of adhesive material <NUM> and includes an exposed outer surface <NUM>.

With particular reference to <FIG>, the sheet of adhesive is shown as including a first aperture <NUM>, a second aperture <NUM>, and a third aperture <NUM>. The first aperture <NUM> includes a shape that corresponds to a shape of the first compartment <NUM> to allow the adhesive <NUM> to completely surround the first compartment <NUM>. Similarly, the second aperture <NUM> includes a shape that corresponds to a shape of the second compartment <NUM> to allow the adhesive <NUM> of the sheet of adhesive material <NUM> to completely surround the second compartment <NUM> while the third aperture <NUM> includes a shape that corresponds to a shape of the third compartment <NUM> to allow the adhesive <NUM> of the sheet of adhesive material <NUM> to completely surround the third compartment <NUM>.

The sheet of adhesive material <NUM> may additionally include a fourth aperture <NUM>, a fifth aperture <NUM>, and a sixth aperture <NUM>. The fourth aperture <NUM>, the fifth aperture <NUM>, and the sixth aperture <NUM> may respectively correspond to a first compartment <NUM>, a second compartment <NUM>, and a third compartment <NUM> of a first barrier member <NUM> of an additional cushioning member <NUM>. For example, the sheet of adhesive material <NUM> may be used to simultaneously form a pair of cushioning members <NUM>. As shown in <FIG>, the sheet of adhesive material <NUM> and the related apertures <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> are sized and positioned to accommodate cushioning members <NUM> for use with different articles of footwear <NUM>. Namely, the apertures <NUM>, <NUM>, <NUM> are used to form a cushioning member <NUM> for use with a right-foot article of footwear <NUM> while the apertures <NUM>, <NUM>, <NUM> are used to form a cushioning member <NUM> for use with a left-foot article of footwear <NUM>. While the sheet of adhesive material <NUM> and the related apertures <NUM>-<NUM> are described and shown as being used to form a cushioning member <NUM> for use with a right-foot article of footwear <NUM> and a cushioning member <NUM> for use with a left-foot article of footwear <NUM>, respectively, the apertures <NUM>-<NUM> could be formed through the sheet of adhesive material <NUM> and positioned such that a pair of cushioning members <NUM> having the same configuration are formed. Namely, a pair of cushioning members <NUM> could be formed for use with a right-foot article of footwear <NUM> or, alternatively, a pair of cushioning members <NUM> could be formed for use with a left-foot article of footwear <NUM>.

Finally, while a pair of cushioning members <NUM> are described as being formed simultaneously via the sheet of adhesive material <NUM>, the sheet of adhesive material <NUM> could only include three apertures total such that only one cushioning member <NUM> is formed. Namely, the sheet of adhesive material <NUM> could include apertures <NUM>, <NUM>, <NUM> for use in making a cushioning member <NUM> for a right-foot article of footwear <NUM> or, alternatively could only include apertures <NUM>, <NUM>, <NUM> for use in making a cushioning member <NUM> for use with a left-foot article of footwear <NUM>. While the sheet of adhesive material <NUM> could be used to form a pair of cushioning members <NUM> for the same or different footed articles of footwear or, alternatively, could be configured for making a single cushioning member <NUM>, the sheet of adhesive material <NUM> will be described and shown hereinafter as including six apertures <NUM>-<NUM> that are used to form a pair of cushioning members <NUM> that are respectively configured for use in a right-foot article of footwear <NUM> and a left-foot article of footwear <NUM>.

While not specifically shown, the tool <NUM> could include two sets of cavities <NUM>, <NUM>, <NUM> that respectively receive portions of the same sheet of material <NUM> or individual sheets of material <NUM> to position the compartments <NUM>, <NUM>, <NUM> relative to the apertures of the sheet of adhesive material <NUM>. In this manner, the tool <NUM> could support a pair of first compartments <NUM>, a pair of second compartments <NUM>, and a pair of third compartments <NUM> of the same or different sheets of material <NUM> relative to the sheet of adhesive material <NUM> to simultaneously join the pairs of compartments <NUM>, <NUM>, <NUM> to the sheet of material <NUM> via the adhesive <NUM>.

The blocking element <NUM> may be formed from a material that resists bonding to the adhesive <NUM> of the sheet of adhesive material <NUM>. For example, the blocking element <NUM> may be formed from Kevlar® that inhibits bonding between the adhesive <NUM> of the sheet of adhesive material <NUM> and the sheet of material <NUM> that forms the first barrier member <NUM>.

Regardless of the material used to form the blocking element <NUM>, the blocking element <NUM> may include a series of projections <NUM> extending from a main body <NUM>. The projections <NUM> may be disposed along a length of the main body <NUM> such that each projection <NUM> is aligned with a respective aperture <NUM>-<NUM> of the sheet of adhesive material <NUM>.

As described, the sheet of adhesive material <NUM> is positioned such that the apertures <NUM>-<NUM> are aligned with respective compartments <NUM>, <NUM>, <NUM> formed by one or more sheets of material <NUM> to simultaneously form a pair of cushioning members <NUM>. Accordingly, aligning the projections <NUM> with the apertures <NUM>-<NUM> such that one projection <NUM> is aligned with each of the respective apertures <NUM>-<NUM> likewise aligns the projections <NUM> with the compartments <NUM>, <NUM>, <NUM> of a pair of first barrier members <NUM> used to form a pair of cushioning members <NUM>. Accordingly, when the blocking element <NUM> is disposed between the sheet of adhesive material <NUM> and the sheet(s) of material <NUM> forming the first barrier members <NUM>, the blocking element <NUM> is positioned such that the projections <NUM> are respectively aligned with the compartments <NUM>, <NUM>, <NUM> of each barrier member <NUM>.

Once the blocking element <NUM>, the sheet of adhesive material <NUM>, and the sheet of material <NUM> forming the second barrier members <NUM> are stacked on the sheet(s) of material <NUM> forming the first barrier members <NUM>, a heating device <NUM> may be used to apply heat to surface <NUM>. Heating the sheet of material <NUM> that forms the second barrier members <NUM> activates the adhesive <NUM> of the sheet of adhesive material <NUM>, thereby bonding the sheet of material <NUM> forming the second barrier members <NUM> to the sheet of material <NUM> forming the first barrier members <NUM> at every location with the exception of the locations of the blocking element <NUM>. Namely, the sheet of adhesive material <NUM> is not bonded to the sheet(s) of material <NUM> forming the first barrier members <NUM> at the location of the projections <NUM> and the main body <NUM> of the blocking element <NUM>.

Once the sheet of material <NUM> that forms the second barrier members <NUM> is attached to the sheet(s) of material <NUM> that forms the first barrier members <NUM>, the assembly includes the configuration shown in <FIG>. At this point, the sheet of material <NUM> forming the second barrier members <NUM> is attached to the sheet(s) of material <NUM> forming the first barrier members <NUM> but does not include particulate matter <NUM>. As such, the configuration shown in <FIG> is a pre-filled barrier member devoid of particulate matter <NUM>.

As described above with respect to <FIG>, the sheet of adhesive material <NUM> and blocking element <NUM> are used to form a pair of cushioning members <NUM>. The pair of cushioning members <NUM> may be separated from one another and formed into the shape of the cushioning member <NUM> shown above with respect to <FIG> by subjecting the sheet of material <NUM> forming the pair of second barrier members <NUM> and the sheet(s) of material <NUM> forming the first barrier members <NUM> to a die-cutting process, as shown in <FIG>. Namely, the joined sheets of material <NUM>, <NUM> may be inserted into a die-cutting tool <NUM> having an upper die <NUM> and a lower die <NUM>. Specifically, the configuration shown in <FIG> may be inserted into a cavity <NUM> of the lower mold <NUM> to properly position the joined sheets of material <NUM>, <NUM> relative to a cutting mechanism <NUM> associated with the upper die <NUM>. While not specifically illustrated, the cutting mechanism <NUM> includes a shape defining the outer perimeter of the cushioning member <NUM> shown in <FIG>. Further, while only one cutting mechanism <NUM> is shown in cross-section in <FIG>, a pair of cutting mechanisms <NUM> could be used if a pair of cushioning members <NUM> are being simultaneously cut from the joined sheets of material <NUM>, <NUM>.

In operation, when the upper die <NUM> and, thus, the cutting mechanism(s) <NUM>, are translated toward the lower die <NUM>, the cutting mechanism <NUM> engages an outer perimeter of the joined sheets of material <NUM>, <NUM>, thereby separating the pre-filled cushioning members <NUM> from one another and forming the pre-filled cushioning members <NUM> into the shape shown in <FIG>. At this point, the pair of pre-filled cushioning members <NUM> are separated from one another and may be filled with a predetermined quantity of particulate matter <NUM>.

With particular reference to <FIG>, the compartments <NUM>, <NUM>, <NUM> are shown as receiving an injection nozzle <NUM> at respective ports <NUM> associated with the compartments <NUM>, <NUM>, <NUM>. The ports <NUM> are formed at locations of the projections <NUM> of the blocking element <NUM>. Namely, and as described above, the projections <NUM> prevent the adhesive material <NUM> of the sheet of adhesive material <NUM> from joining the second barrier member <NUM> to the first barrier member <NUM> at the locations of the projections <NUM>. Accordingly, the ports <NUM> are formed at the locations of the projections <NUM> of the blocking element <NUM>, thereby allowing the nozzles <NUM> to be inserted into the respective compartments <NUM>, <NUM>, <NUM>.

In operation, the nozzles <NUM> are inserted into the respective ports <NUM> of the compartments <NUM>, <NUM>, <NUM> and are in fluid communication with the interiors of the compartments <NUM>, <NUM>, <NUM>. Note that the views shown in <FIG> are partial cut-away views, whereby a portion of the second barrier member <NUM> is removed to show the first compartment <NUM>, the second compartment <NUM>, and the third compartment <NUM> of the first barrier member <NUM>.

Once the nozzles <NUM> are disposed within the ports <NUM> such that the nozzles <NUM> are disposed between the second barrier member <NUM> and the first barrier member <NUM>, particulate matter <NUM> may be injected into the nozzles <NUM> via fluid pressure. For example, air pressure may be used to direct particulate matter <NUM> disposed within a hopper <NUM> (<FIG>) into the nozzles <NUM>. While the nozzles <NUM> are described and shown as being associated with a common hopper <NUM>, the nozzles <NUM> could alternatively be associated with individual hoppers that supply the nozzles <NUM> with particulate matter <NUM>.

As shown in <FIG>, the nozzles <NUM> may include an inner diameter that is substantially equal to an outer diameter of the particulate matter <NUM> or, alternatively, is slightly larger than the outer diameter of the particulate matter <NUM> to prevent bunching and clogging of the particulate matter <NUM> within the nozzles <NUM>. The particulate matter <NUM> may be injected into the compartments <NUM>, <NUM>, <NUM> via the nozzles <NUM> and, further, because the particulate matter <NUM> is injected under fluid pressure such as air pressure, the particulate matter <NUM> disposed within the compartments <NUM>, <NUM>, <NUM> may overfill one or more of the compartments <NUM>, <NUM>, <NUM>. Accordingly, the compartments <NUM>, <NUM>, <NUM> may include a larger quantity of particulate matter <NUM> as compared to a quantity of particulate matter received within the compartments <NUM>, <NUM>, <NUM> when the compartments <NUM>, <NUM>, <NUM> are filled with particulate matter <NUM>, as described above with respect to the thermoforming process of <FIG>. Namely, because the particulate matter <NUM> is injected into the compartments <NUM>, <NUM>, <NUM> under fluid pressure and, further, because the second barrier member <NUM> is attached to the first barrier member <NUM> and each barrier member <NUM>, <NUM> is formed from a flexible material, the particulate matter <NUM> may be overfilled in each of the compartments <NUM>, <NUM>, <NUM>, thereby resulting in a greater bulge <NUM> at one or more of the compartments <NUM>, <NUM>, <NUM>. The bulges are shown in <FIG> as extending from a surface of the second barrier member <NUM>.

Once a desired quantity of particulate matter is disposed within each compartment <NUM>, <NUM>, <NUM>, the ports <NUM> may be closed by joining the first barrier member <NUM> and the second barrier member <NUM> at the ports <NUM>. For example, the first barrier member <NUM> and the second barrier member <NUM> may be locally subjected to a welding process such as radio frequency (RF) welding at each port location. As shown in <FIG>, one or more welding apparatuses <NUM> may be used to join the first barrier member <NUM> and the second barrier member <NUM> at the location of the ports <NUM>, thereby closing the ports <NUM> and containing the particulate matter <NUM> within the compartments <NUM>, <NUM>, <NUM>.

As shown in <FIG>, a formed and filled cushioning member <NUM> is illustrated and includes a similar configuration as the cushioning member <NUM> formed via the thermoforming process described and shown above with respect to <FIG>. However, the cushioning members <NUM> shown in <FIG> may include a greater quantity of particulate matter <NUM> in one or more of the compartments <NUM>, <NUM>, <NUM> and, thus, may include a greater bulge <NUM> at the second barrier member <NUM>. Finally, the location of the ports <NUM> where RF welding is used to join the first barrier member <NUM> and the second barrier member <NUM> may be visible at the web member <NUM> when compared to the web member <NUM> formed via the thermoforming process of <FIG>.

The cushioning member <NUM> formed via the thermoforming process of <FIG> or via the compression molding process of <FIG>, may be incorporated in the midsole <NUM>, as shown in <FIG>, which is not part of the claimed invention, but useful to understand the claimed invention. Namely, the first compartment <NUM> may be aligned with the ball cavity <NUM> of the midsole <NUM>, the second compartment <NUM> may be aligned with the mid-foot cavity <NUM> of the midsole <NUM>, and the third compartment <NUM> may be aligned with the heel cavity <NUM> of the midsole <NUM> such that the compartments <NUM>, <NUM>, <NUM> are respectively received by the cavities <NUM>, <NUM>, <NUM>. Once the cushioning member <NUM> is inserted into the midsole <NUM>, the midsole <NUM> may be attached to the upper <NUM>. At this point, the cushioning member <NUM> may be used to provide a degree of comfort and cushioning to a foot of a wearer during use of the article of footwear <NUM>.

Claim 1:
A sole structure (14a) for an article of footwear, the sole structure (14a) comprising:
a midsole (32a) including a plurality of cavities (<NUM>, 54a, 56a, 58a) including a first cavity (58a) and a second cavity (56a);
a first quantity of particulate matter (<NUM>) disposed directly within the first cavity (58a); and
a cushioning member (36a) including a first portion (<NUM>) having at least one compartment (100a, 102a, 104c) containing a second quantity of particulate matter (<NUM>) and disposed within the second cavity (56a), and a second portion (<NUM>) extending from the first portion (<NUM>) and covering the first cavity (58a).