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 may be 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 additionally or alternatively incorporate a fluid-filled bladder to provide cushioning to the foot by compressing resiliently under an applied load to attenuate ground-reaction forces. Sole structures may also include a comfort-enhancing insole or a sockliner located within a void proximate to the bottom portion of the upper and a strobel attached to the upper and disposed between the midsole and the insole or sockliner.

Midsoles employing bladders typically include a bladder formed from two barrier layers of polymer material that are sealed or bonded together. The bladders may contain air, and are designed with an emphasis on balancing support for the foot and cushioning characteristics that relate to responsiveness as the bladder resiliently compresses under an applied load. <CIT> describes a bladder for an article of footwear. <CIT> describes a sole structure for an article of footwear.

Referring to <FIG>, an article of footwear <NUM> includes a sole structure <NUM> and an upper <NUM> attached to the sole structure <NUM>. The article of footwear <NUM>, and components thereof, may be described as including an anterior end <NUM> associated with a forward-most point of the footwear <NUM>, and a posterior end <NUM> corresponding to a rearward-most point of the footwear <NUM>. As shown in the bottom view of <FIG>, a longitudinal axis A<NUM> of the footwear <NUM> extends along a length of the footwear <NUM> from the anterior end <NUM> to the posterior end <NUM>, and generally divides the footwear <NUM> into a lateral side <NUM> and a medial side <NUM>. Accordingly, the lateral side <NUM> and the medial side <NUM> respectively correspond with opposite sides of the footwear <NUM> and extend from the anterior end <NUM> to the posterior end <NUM>.

The article of footwear <NUM> may be divided into one or more regions along the longitudinal axis A<NUM>. The regions 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 regions of the foot, including a calcaneus bone. In the illustrated example, the article of footwear also includes a posterior region <NUM> disposed adjacent to the heel region <NUM> at the posterior end <NUM> of the footwear. As will be discussed in greater detail below, the posterior region <NUM> is not directly associated with a corresponding region of the foot, but instead includes components of the footwear <NUM> that extend beyond the calcaneus bone and the calcaneal ("Achilles") tendon.

With reference to FIGS. <NUM>-2B, the sole structure <NUM> includes a midsole <NUM> configured to provide cushioning characteristics to the sole structure <NUM>, and an outsole <NUM> configured to provide a ground-engaging surface of the article of footwear <NUM>. Unlike conventional sole structures, the midsole <NUM> of the sole structure <NUM> may be formed compositely and include a plurality of subcomponents for providing desired forms of cushioning and support throughout the sole structure <NUM>. For example, the midsole <NUM> includes a chassis <NUM> and a bladder <NUM>, where the chassis <NUM> is configured to be attached to the upper <NUM> and provides an interface between the upper <NUM>, the bladder <NUM>, and the outsole <NUM>.

As best shown in <FIG>, the midsole <NUM> of the present disclosure includes a footbed <NUM> configured to receive, support, and cushion the plantar surface of the foot, and a bolster <NUM> extending from the footbed at the posterior end <NUM>. In the illustrated example, the footbed <NUM> extends along each of the forefoot region <NUM>, the mid-foot region <NUM>, and the heel region <NUM>, while the bolster <NUM> is formed in the posterior region <NUM>. The bolster <NUM> extends continuously around the footbed <NUM> in the heel region <NUM> from the lateral side <NUM> to the medial side <NUM>. As shown in <FIG>, the bolster <NUM> has maximum width W<NUM> at the posterior end <NUM>. The width W<NUM> of the bolster <NUM> tapers as the bolster <NUM> wraps around the heel region <NUM> to each of the lateral side <NUM> and the medial side <NUM>. Thus, unlike conventional sole structures that only extend beneath the foot, the sole structure <NUM> of the present example extends beyond the heel of the foot to provide posterior stability.

In the illustrated example, the midsole <NUM>, and more particularly, the bolster <NUM> of the midsole <NUM>, is formed as a composite structure including the chassis <NUM> and at least a portion of the bladder <NUM>. As shown in <FIG> and described in greater detail below, the bladder <NUM> may extend at least partially into the bolster <NUM> so that when the article of footwear <NUM> is assembled, the bladder <NUM> is positioned closer to the posterior end <NUM> than the upper <NUM>. In other words, an end of the bladder <NUM> extends beyond the end of the upper <NUM> at the posterior end <NUM> of the article of footwear <NUM>. However, in some examples, the sole structure <NUM> may be formed without the bladder <NUM>, where the footbed <NUM> and/or the bolster <NUM> are formed of elastomeric components.

The bladder <NUM> of the midsole <NUM> includes an opposing pair of barrier layers 118a, 118b, which can be joined to each other at discrete locations to define a chamber <NUM>, a web area <NUM>, and a peripheral seam <NUM>. In the illustrated embodiment, the barrier layers 118a, 118b include a first, upper barrier layer 118a and a second, lower barrier layer 118b. Alternatively, the chamber <NUM> can be produced from any suitable combination of one or more barrier layers.

In some implementations, the upper barrier layer 118a and the lower barrier layer 118b cooperate to define a geometry (e.g., thicknesses, width, and lengths) of the chamber <NUM>. For example, the web area <NUM> and the peripheral seam <NUM> may cooperate to bound and extend around the chamber <NUM> to seal the fluid (e.g., air) within the chamber <NUM>. Thus, the chamber <NUM> is associated with an area of the bladder <NUM> where interior surfaces of the upper and lower barrier layers 118a, 118b are not joined together and, thus, are separated from one another.

As shown in <FIG>, <FIG>, <FIG>, a space formed between opposing interior surfaces of the upper and lower barrier layers 118a, 118b defines an interior void of the chamber <NUM>. Similarly, exterior surfaces of the upper and lower barrier layers 118a, 118b define an exterior profile of the chamber <NUM>. Thicknesses T<NUM> of the bladder <NUM> are defined by the distance between the upper and lower barrier layers 118a, 118b of the bladder <NUM>, as discussed in greater detail below.

Referring to <FIG>, the chamber <NUM> includes a plurality of segments <NUM>, <NUM> that cooperate to provide characteristics of responsiveness and support to the midsole <NUM>. Particularly, the segments <NUM>, <NUM> may be described as including a pair of cushions <NUM> that are connected (i.e., in fluid communication) with each other by one or more conduits <NUM>. Each of the cushions <NUM> includes a tubular body extending from a first terminal end 130a to a second terminal end 130b disposed at an opposite end of the tubular body from the first terminal end 130a. The cushion <NUM> defines a substantially circular cross section that extends along a longitudinal axis A<NUM>. As shown, the thickness T<NUM> of the chamber <NUM> increases continuously along the longitudinal axis A<NUM> from a first thickness T<NUM>-<NUM> at the first terminal end 130a to a second thickness T<NUM>-<NUM> at the second terminal end 130b. Thus, the thickness of the chamber <NUM> may be described as tapering along the direction from the second terminal end 130b to the first terminal end 130a.

The first terminal end 130a and the second terminal end 130b of each cushion <NUM> are substantially dome-shaped, and each includes compound curvatures associated with the respective upper and lower barrier layers 118a, 118b. For example, the first terminal end 130a of each cushion <NUM> is formed where an end portion of the upper barrier layer 118a converges with and is joined to the lower barrier layer 118b at the peripheral seam <NUM> to enclose an anterior end of the cushion <NUM>. Referring still to <FIG>, the second terminal end 130b of each cushion <NUM> is formed where another end portion of the upper barrier layer 118a converges with and is joined to the lower barrier layer 118b at the peripheral seam <NUM> to enclose the opposite end of the cushion <NUM>.

As provided above, each of the cushions <NUM> defines a respective longitudinal axis A<NUM> that extends from the first terminal end 130a to the second terminal end 130b. As best shown in <FIG>, the cushions <NUM> are spaced apart from each other along a direction transverse to the longitudinal axes A<NUM> of each of the cushions <NUM>. More particularly, when the bladder <NUM> is assembled within the sole structure <NUM>, the cushions <NUM> are spaced apart from each other along a lateral direction of the article of footwear <NUM>, substantially perpendicular to the longitudinal axis A<NUM> of the article of footwear <NUM>. Furthermore, the longitudinal axes A<NUM> of the cushions <NUM> converge with each other and with the longitudinal axis A<NUM> of the article of footwear <NUM> along the direction from the posterior end <NUM> to the anterior end <NUM>. Accordingly, a lateral distance D1 between the cushions <NUM> is greater at the second terminal ends 130b than at the first terminal ends 130a.

With continued reference to <FIG>, the chamber <NUM> further includes at least one conduit <NUM> extending between and fluidly coupling the cushions <NUM>. In the illustrated example, the chamber <NUM> includes a plurality of the conduits <NUM> connecting the cushions <NUM> to each other. The conduits <NUM> each extend along respective longitudinal axes A<NUM> that are transverse to the longitudinal axes A<NUM> of the cushions <NUM>. As best shown in <FIG> and <FIG>, the conduits <NUM> include a first conduit <NUM> extending between the cushions <NUM> adjacent to the first terminal ends 130a, a second conduit <NUM> extending between the cushions <NUM> adjacent to the second terminal ends 130b, and a third conduit <NUM> disposed between the first conduit <NUM> and the second conduit <NUM> and connecting intermediate portions of the cushion <NUM>. Accordingly, the first conduit <NUM> and the second conduit <NUM> are disposed on opposite sides of the third conduit <NUM>.

As best shown in <FIG>, <FIG>, and <FIG>, the conduits <NUM> are defined by the cooperation of the upper barrier layer 118a and the lower barrier layer 118b. As shown in <FIG>, the upper barrier layer 118a and the lower barrier layer 118b are formed to provide a plurality of semi-cylindrically shaped conduits <NUM>, each having a substantially similar third thickness T<NUM>-<NUM> that is less than the first thickness T<NUM>-<NUM> and the second thickness T<NUM>-<NUM> of the cushions <NUM>. A profile of each of the conduits <NUM> is defined by the upper barrier layer 118a, whereby the upper barrier layer 118a is molded to define a curved upper portion of each conduit <NUM> while the lower barrier layer 118b is provided as a substantially flat lower portion of each of the conduits <NUM>. Although the lower barrier layer 118b is initially provided in a substantially flat state, the lower barrier layer 118b may bulge from the web area <NUM> when the chamber <NUM> is pressurized and the lower barrier layer 118b is biased apart from the upper barrier layer 118a, as illustrated in <FIG>.

With reference to <FIG>, the web area <NUM> is formed at a bonded region of the upper barrier layer 118a and the lower barrier layer 118b, and extends between and connects each of the segments <NUM>, <NUM> of the chamber <NUM>. Particularly, the web area <NUM> includes an anterior portion extending between and connecting the first terminal ends 130a of the respective cushions <NUM>, and defines a first terminal edge at an anterior end of the bladder <NUM>. A posterior portion of the web area <NUM> extends between and connects the second terminal ends 130b of the cushions <NUM> and forms a second terminal edge at a posterior end of the bladder <NUM>. Intermediate portions of the web area <NUM> extend between and connect adjacent ones of the conduits <NUM> and the cushions <NUM>. Accordingly, the intermediate portions of the web area <NUM> may be completely surrounded by the chamber <NUM>. In the illustrated example, the web area <NUM> is disposed vertically intermediate with respect to the thickness T<NUM> of the bladder <NUM>.

In the illustrated example, the web area <NUM> and the cushions <NUM> of the chamber <NUM> cooperate to define an upper pocket 132a on a first side of the bladder <NUM> associated with the upper barrier layer 118a, and a lower pocket 132b on a second side of the bladder <NUM> associated with the lower barrier layer 118b. Here, the conduits <NUM> may be disposed within the upper pocket 132a to form an alternating series of bulges and recesses along a length of the upper pocket 132a. As described in greater detail below, the chassis <NUM> may include one or more features configured to mate with the upper pocket 132a when the sole structure <NUM> is assembled. For instance, the chassis <NUM> may include protrusions and indentations configured to engage the bulges and recesses formed by the conduits <NUM> of the bladder <NUM>.

As used herein, the term "barrier layer" (e.g., barrier layers 118a, 118b) encompasses both monolayer and multilayer films. In some embodiments, one or both of barrier layers 118a, 118b are each produced (e.g., thermoformed or blow molded) from a monolayer film (a single layer). In other embodiments, one or both of barrier layers 118a, 118b are each produced (e.g., thermoformed or blow molded) from a multilayer film (multiple sublayers). In either aspect, each layer or sublayer can have a film thickness ranging from about <NUM> micrometers to about <NUM> millimeter. In further embodiments, the film thickness for each layer or sublayer can range from about <NUM> micrometers to about <NUM> micrometers. In yet further embodiments, the film thickness for each layer or sublayer can range from about <NUM> micrometer to about <NUM> micrometers.

One or both of barrier layers 118a, 118b can independently be transparent, translucent, and/or opaque. For example, the upper barrier layer 118a may be transparent, while the lower barrier layer 118b is opaque. As used herein, the term "transparent" for a barrier layer and/or a fluid-filled chamber means that light passes through the barrier layer in substantially straight lines and a viewer can see through the barrier layer. In comparison, for an opaque barrier layer, light does not pass through the barrier layer and one cannot see clearly through the barrier layer at all. A translucent barrier layer falls between a transparent barrier layer and an opaque barrier layer, in that light passes through a translucent layer but some of the light is scattered so that a viewer cannot see clearly through the layer.

Barrier layers 118a, 118b can each be produced from an elastomeric material that includes one or more thermoplastic polymers and/or one or more cross-linkable polymers. In an aspect, the elastomeric material can include one or more thermoplastic elastomeric materials, such as one or more thermoplastic polyurethane (TPU) copolymers, one or more ethylene-vinyl alcohol (EVOH) copolymers, and the like.

Examples of suitable isocyanates for producing the polyurethane copolymer chains include diisocyanates, such as aromatic diisocyanates, aliphatic diisocyanates, and combinations thereof. Examples of suitable aromatic diisocyanates include toluene diisocyanate (TDI), TDI adducts with trimethyloylpropane (TMP), methylene diphenyl diisocyanate (MDI), xylene diisocyanate (XDI), tetramethylxylylene diisocyanate (TMXDI), hydrogenated xylene diisocyanate (HXDI), naphthalene <NUM>,<NUM>-diisocyanate (NDI), <NUM>,<NUM>-tetrahydronaphthalene diisocyanate, para-phenylene diisocyanate (PPDI), <NUM>,<NUM>' - dimethyldipheny1-<NUM>, <NUM>' -diisocyanate (DDDI), <NUM>,<NUM> '-dibenzyl diisocyanate (DBDI), <NUM>-chloro-<NUM>,<NUM>-phenylene diisocyanate, and combinations thereof. In some embodiments, the copolymer chains are substantially free of aromatic groups.

In another aspect, the polymeric layer can be formed of one or more of the following: EVOH copolymers, poly (vinyl chloride), polyvinylidene polymers and copolymers (e.g., polyvinylidene chloride), polyamides (e.g., amorphous polyamides), amide-based copolymers, acrylonitrile polymers (e.g., acrylonitrile-methyl acrylate copolymers), polyethylene terephthalate, polyether imides, polyacrylic imides, and other polymeric materials known to have relatively low gas transmission rates. Blends of these materials as well as with the TPU copolymers described herein and optionally including combinations of polyimides and crystalline polymers, are also suitable.

The barrier layers 118a, 118b may include two or more sublayers (multilayer film) such as shown in <CIT> and <CIT>. In embodiments where the barrier layers 118a, 118b include two or more sublayers, examples of suitable multilayer films include microlayer films, such as those disclosed in <CIT>. In further embodiments, barrier layers 118a, 118b may each independently include alternating sublayers of one or more TPU copolymer materials and one or more EVOH copolymer materials, where the total number of sublayers in each of barrier layers 118a, 118b includes at least four (<NUM>) sublayers, at least ten (<NUM>) sublayers, at least twenty (<NUM>) sublayers, at least forty (<NUM>) sublayers, and/or at least sixty (<NUM>) sublayers.

The chamber <NUM> can be produced from the barrier layers 118a, 118b using any suitable technique, such as thermoforming (e.g. vacuum thermoforming), blow molding, extrusion, injection molding, vacuum molding, rotary molding, transfer molding, pressure forming, heat sealing, casting, low-pressure casting, spin casting, reaction injection molding, radio frequency (RF) welding, and the like. In an aspect, barrier layers 118a, 118b can be produced by co-extrusion followed by vacuum thermoforming to produce an inflatable chamber <NUM>, which can optionally include one or more valves (e.g., one way valves) that allows the chamber <NUM> to be filled with the fluid (e.g., gas).

The chamber <NUM> can be provided in a fluid-filled (e.g., as provided in footwear <NUM>) or in an unfilled state. The chamber <NUM> can be filled to include any suitable fluid, such as a gas or liquid. In an aspect, the gas can include air, nitrogen (N<NUM>), or any other suitable gas. In other aspects, the chamber <NUM> can alternatively include other media, such as pellets, beads, ground recycled material, and the like (e.g., foamed beads and/or rubber beads). The fluid provided to the chamber <NUM> can result in the chamber <NUM> being pressurized. Alternatively, the fluid provided to the chamber <NUM> can be at atmospheric pressure such that the chamber <NUM> is not pressurized but, rather, simply contains a volume of fluid at atmospheric pressure.

The chamber <NUM> desirably has a low gas transmission rate to preserve its retained gas pressure. In some embodiments, the chamber <NUM> has a gas transmission rate for nitrogen gas that is at least about ten (<NUM>) times lower than a nitrogen gas transmission rate for a butyl rubber layer of substantially the same dimensions. In an aspect, the chamber <NUM> has a nitrogen gas transmission rate of <NUM> cubic-centimeter/square-meter•atmosphere•day (cm<NUM>/m<NUM>•atm•day) or less for an average film thickness of <NUM> micrometers (based on thicknesses of barrier layers 118a, 118b). In further aspects, the transmission rate is <NUM><NUM>/m<NUM>•atm•day or less, <NUM><NUM>/m<NUM>•atm•day or less, or <NUM><NUM>/m<NUM>•atm•day or less.

In some implementations, the upper and lower barrier layers 118a, 118b are formed by respective mold portions each defining various surfaces for forming depressions and pinched surfaces corresponding to locations where the web area <NUM> and/or the peripheral seam <NUM> are formed when the upper barrier layer 118a and the lower barrier layer 118b are joined and bonded together. In some implementations, adhesive bonding joins the upper barrier layer 118a and the lower barrier layer 118b to form the web area <NUM> and the peripheral seam <NUM>. In other implementations, the upper barrier layer 118a and the lower barrier layer 118b are joined to form the web area <NUM> and the peripheral seam <NUM> by thermal bonding. In some examples, one or both of the barrier layers 118a, 118b are heated to a temperature that facilitates shaping and melding. In some examples, the barrier layers 118a, 118b are heated prior to being located between their respective molds. In other examples, the mold may be heated to raise the temperature of the barrier layers 118a, 118b. In some implementations, a molding process used to form the fluid-filled chamber <NUM> incorporates vacuum ports within mold portions to remove air such that the upper and lower barrier layers 118a, 118b are drawn into contact with respective mold portions. In other implementations, fluids such as air may be injected into areas between the upper and lower barrier layers 118a, 118b such that pressure increases cause the barrier layers 118a, 118b to engage with surfaces of their respective mold portions.

In the illustrated example, the chassis <NUM> extends continuously from the anterior end <NUM> to the posterior end <NUM>, and is configured to receive and support the bladder <NUM> therein. As shown, the chassis <NUM> is formed as a composite structure including a cushioning element <NUM> and a cradle <NUM> received at least partially within the cushioning element <NUM>. While the cushioning element <NUM> and the cradle <NUM> of the illustrated example are shown as separate components that cooperate to form the chassis <NUM>, in some examples, the chassis <NUM> may be formed as a unitary body.

The cushioning element <NUM> is formed of an elastomeric material, and extends continuously from a first end <NUM> at the anterior end <NUM> to a second end <NUM> at the posterior end <NUM>. The cushioning element <NUM> includes a top side <NUM> and a bottom side <NUM> formed on an opposite side of the cushioning element <NUM> from the top side <NUM>, whereby a distance from the top side <NUM> to the bottom side <NUM> defines an overall thickness T<NUM> of the cushioning element <NUM>. The cushioning element <NUM> further includes a peripheral wall <NUM> extending from the top side <NUM> to the bottom side <NUM>, and defining an outer periphery of the cushioning element <NUM>.

With reference to <FIG>, the top side <NUM> of the cushioning element <NUM> forms an upper surface of the footbed <NUM> extending from the forefoot region <NUM> though the heel region <NUM>. As shown, an upper receptacle <NUM> is formed in the top side <NUM> of the cushioning element <NUM> in the mid-foot region <NUM>. The upper receptacle <NUM> is configured to receive components of the tensioning system <NUM> therein. For instance, in the illustrated example the tensioning system <NUM> includes a tensioning device <NUM> and a capsule <NUM> for supporting the tensioning device <NUM>. Here, the receptacle <NUM> of the cushioning element <NUM> has a shape corresponding to an exterior shape of the capsule <NUM>, such that the capsule <NUM> is partially encapsulated within the upper receptacle <NUM> when the sole structure <NUM> is assembled. In the illustrated example, the upper receptacle <NUM> includes an aperture <NUM> formed through the peripheral wall <NUM> of the cushioning element <NUM>, which provides access to controls of the tensioning device <NUM> from the exterior of the article of footwear <NUM> when the article of footwear <NUM> is assembled.

Referring now to <FIG>, the bottom side <NUM> of the cushioning element <NUM> includes a lower receptacle <NUM> configured to receive the bladder <NUM> therein. In the illustrated example, the receptacle includes an upper central spine <NUM> disposed between a pair of upper channels <NUM>. Generally, the upper central spine <NUM> is configured to at least partially mate with the upper pocket 132a formed by the upper barrier layer 118a of the bladder <NUM>. As shown, the upper central spine <NUM> includes a plurality of ribs <NUM> arranged in series along a direction of the longitudinal axis A<NUM>. Each of the ribs <NUM> extends from the upper central spine <NUM> to a distal end <NUM>. Here, the ribs <NUM> are each configured to be received between adjacent ones of the conduits <NUM> of the bladder <NUM>. Accordingly, sides of the ribs <NUM> may be concave to receive corresponding convex portions of the conduits <NUM>. As best shown in the cross sectional view of <FIG>, the ribs <NUM> may extend fully between the conduits <NUM>, such that the distal ends <NUM> of the ribs <NUM> face and contact the web area <NUM> when the sole structure <NUM> is assembled.

With continued reference to <FIG> and <FIG>, the lower receptacle <NUM> extends along the heel region <NUM> and at least partially into the posterior region <NUM>. For example, the upper central spine <NUM> of the receptacle <NUM> is disposed within the heel region <NUM>, while the upper channels <NUM> extend beyond the heel region <NUM> and into the posterior region <NUM>. Thus, the upper central spine <NUM> is positioned within the footbed <NUM> of the sole structure <NUM>, while the upper channels <NUM> extend at least partially into the bolster <NUM>. When the sole structure <NUM> is assembled, the cushions <NUM> of the bladder <NUM> are received within the upper channels <NUM> such that the second terminal ends 130b of the cushions <NUM> also extend partially into the posterior region <NUM> of the sole structure <NUM>. As such, the second terminal ends 130b of the cushions <NUM> cooperate with the second end <NUM> of the cushioning element <NUM> to form a portion of the bolster <NUM> at the posterior end <NUM> of the sole structure <NUM>.

As best shown in <FIG> and <FIG>, the cradle <NUM> cooperates with the cushioning element <NUM> to form the chassis <NUM>. Particularly, the cradle <NUM> is configured to be received within the lower receptacle <NUM> of the cushioning element <NUM> and forms a bottom portion of the chassis <NUM> in the heel region <NUM> and the posterior region <NUM>. Accordingly, when the sole structure <NUM> is assembled, the bladder <NUM> is interposed between the cushioning element <NUM> and the cradle <NUM>. In the illustrated example, the cradle <NUM> extends from a first end <NUM> in the heel region <NUM> to a second end <NUM> in the posterior region <NUM>. Here, the second end <NUM> cooperates with the second end <NUM> of the cushioning element <NUM> and the second terminal ends 130b of the cushions <NUM> to form the bolster <NUM> of the sole structure <NUM>.

The cradle <NUM> may be described as including a top side <NUM> and a bottom side <NUM> formed on an opposite side of the cradle <NUM> from the top side <NUM>. The top side <NUM> of the cradle <NUM> includes a lower central spine <NUM> disposed between a pair of lower channels <NUM>. Here, the lower central spine <NUM> is configured to face or oppose the upper central spine <NUM> and the lower channels <NUM> are configured to oppose or face the upper channels <NUM> when the sole structure <NUM> is assembled. Particularly, the lower central spine <NUM> mates with the lower pocket 132b of the bladder <NUM> and the lower channels <NUM> receive lower portions of the cushions <NUM> of the bladder <NUM> (e.g., the lower barrier layer 118b).

As shown in <FIG> and <FIG>, the bottom side <NUM> of the cradle <NUM> may include a cavity <NUM> formed on an opposite side from the lower central spine <NUM>. The cavity <NUM> may be ellipsoidal in shape, and extends along a central portion of the cradle <NUM> from the first end <NUM> to the second end <NUM>. When the sole structure <NUM> is assembled and the cradle <NUM> is received within the lower receptacle <NUM>, the bottom side <NUM> of the cradle <NUM> is flush with the bottom side <NUM> of the cushioning element <NUM> to form a substantially continuous ground-facing surface <NUM> along the bottom of the midsole <NUM> for attaching the outsole <NUM>.

Optionally, the midsole <NUM> may further include a cover <NUM> for the upper receptacle <NUM>. As shown in <FIG> and <FIG>, the cover <NUM> is disposed above the tensioning device <NUM> and the capsule <NUM> on the top side <NUM> of the cushioning element <NUM> to provide a resilient interface between the tensioning device <NUM> and the plantar surface of the foot. Here, a top side of the cover <NUM> is flush with the top side <NUM> of the cushioning element <NUM> to form a substantially continuous foot-supporting surface of the midsole <NUM> along the footbed <NUM>.

As described above, the cushioning element <NUM>, the cradle <NUM>, and the cover <NUM> include resilient polymeric materials, such as foam or rubber, to impart properties of cushioning, responsiveness, and energy distribution to the foot of the wearer. Example resilient polymeric materials for the cushioning element <NUM> and cradle <NUM> may include those based on foaming or molding one or more polymers, such as one or more elastomers (e.g., thermoplastic elastomers (TPE)). The one or more polymers may include aliphatic polymers, aromatic polymers, or mixtures of both; and may include homopolymers, copolymers (including terpolymers), or mixtures of both.

In further aspects, the one or more polymers may include one or more polyamide copolymers (e.g., polyamide-polyether copolymers) and/or one or more polyurethanes (e.g., crosslinked polyurethanes and/or thermoplastic polyurethanes). Alternatively, the one or more polymers may include one or more natural and/or synthetic rubbers, such as butadiene and isoprene.

When the resilient polymeric material is a foamed polymeric material, the foamed material may be foamed using a physical blowing agent which phase transitions to a gas based on a change in temperature and/or pressure, or a chemical blowing agent which forms a gas when heated above its activation temperature. For example, the chemical blowing agent may be an azo compound such as azodicarbonamide, sodium bicarbonate, and/or an isocyanate.

With reference to <FIG>, the outsole <NUM> extends continuously along the length of the sole structure <NUM>. In the illustrated example, the outsole <NUM> includes a plantar portion <NUM> extending along the ground-facing surface <NUM> of the midsole <NUM>, and optional side portions <NUM>, <NUM> extending from the plantar portion <NUM> on opposite sides <NUM>, <NUM> of the article of footwear <NUM>. The outsole <NUM> and the components <NUM>, <NUM>, <NUM> of the outsole <NUM> may be described as including an inner surface <NUM> facing the midsole <NUM> and an exterior surface <NUM> formed on an opposite side from the inner surface <NUM>.

As best shown in <FIG>, <FIG>, the plantar portion <NUM> of the outsole <NUM> substantially conforms to the ground-facing surface <NUM> of the midsole <NUM> such that the outsole <NUM> extends into the cavity <NUM> of the cradle <NUM> in the heel region <NUM>. Here, the exterior surface <NUM> of the outsole <NUM> is spaced apart from the ground surface in the heel region <NUM>. As discussed above, the cavity <NUM> of the cradle <NUM> is disposed on an opposite side of the cradle <NUM> from the lower central spine <NUM>, which mates with the lower pocket 132b of the bladder <NUM> and abuts the web area <NUM>. Accordingly, the web area <NUM> of the bladder <NUM> is disposed above the cavity <NUM> and provides a trampoline-like structure across the heel region <NUM>.

The side portions <NUM>, <NUM> include a lateral side portion <NUM> extending from the plantar portion <NUM> along a lateral side <NUM> of the midsole <NUM>, and a medial side portion <NUM> extending from the plantar portion <NUM> along a medial side <NUM> of the midsole <NUM>.

The upper <NUM> forms an enclosure having a plurality of components that cooperate to define an interior void <NUM> and an ankle opening <NUM>, which cooperate to receive and secure a foot for support on the sole structure <NUM>. For example, the upper <NUM> includes a pair of quarter panels <NUM> in the mid-foot region <NUM> on opposite sides of the interior void <NUM>. A throat <NUM> extends across the top of the upper <NUM> and defines an instep region extending between the quarter panels <NUM> from the ankle opening <NUM> to the forefoot region <NUM>. In the illustrated example, the throat <NUM> is enclosed with a material panel extending between the opposing quarter panels in the instep region to cover the interior void <NUM>. Here, the material panel covering the throat <NUM> may be formed of a material having a higher modulus of elasticity than the material forming the quarter panels <NUM>.

The upper <NUM> of the article of footwear <NUM> includes heel side panels <NUM> extending through the heel region <NUM> along the lateral and medial sides <NUM>, <NUM> of the ankle opening <NUM>. A heel panel <NUM> wraps around the posterior end <NUM> of the footwear <NUM> and connects the heel side panels <NUM>. Uppermost edges of the throat <NUM>, the heel side panels <NUM>, and the heel panel <NUM> cooperate to form a collar <NUM>, which defines the ankle opening <NUM> of the interior void <NUM>.

Optionally, the upper <NUM> may include a plurality of tensioning straps <NUM> arranged in series along the throat <NUM>. As shown in <FIG>, each of the tensioning straps <NUM> extends across the throat <NUM> from a first end on the lateral side <NUM> to a second end on the medial side <NUM>. In the illustrated example, the tensioning straps <NUM> are provided as passive tensioning elements. In other words, the tensioning straps <NUM> are not actively adjusted, but instead provide continuous tensioning over the throat <NUM> of the upper <NUM>. The tensioning straps <NUM> may include an elastomeric material configured to provide continuous tension across the throat <NUM> of the upper.

The upper <NUM> may be formed from one or more materials that are stitched or adhesively bonded together to define the interior void <NUM>. Suitable materials of the upper <NUM> may include, but are not limited to, textiles, foam, leather, and synthetic leather. The example upper <NUM> may be formed from a combination of one or more substantially inelastic or non-stretchable materials and one or more substantially elastic or stretchable materials disposed in different regions of the upper <NUM> to facilitate movement of the article of footwear <NUM> between the tightened state and the loosened state. The one or more elastic materials may include any combination of one or more elastic fabrics such as, without limitation, spandex, elastane, rubber or neoprene. The one or more inelastic materials may include any combination of one or more of thermoplastic polyurethanes, nylon, leather, vinyl, or another material/fabric that does not impart properties of elasticity.

The article of footwear <NUM> further includes a support system <NUM> connecting the sole structure <NUM> to the upper <NUM> and providing reinforcement and support to the upper <NUM>. As shown, the support system includes a buttress or brace <NUM> connecting the sole structure <NUM> to the upper <NUM> at the posterior end <NUM>, and an optional toe clip <NUM> connecting the sole structure <NUM> to the upper <NUM> at the anterior end <NUM>.

With reference to <FIG>, the brace <NUM> includes a stanchion <NUM> formed at a first end and a heel clip <NUM> formed at a second end. Generally, the stanchion <NUM> is attached to and extends upwardly from the bolster <NUM> at the posterior end <NUM> of the sole structure <NUM>. The stanchion <NUM> includes a base portion <NUM> attached to the bolster <NUM> and a neck portion <NUM> extending upwardly from the base portion <NUM> to a distal end <NUM> adjacent to the heel panel <NUM> of the upper <NUM>. However, because the bolster <NUM> projects beyond the heel panel <NUM> at the posterior end <NUM> of the article of footwear <NUM>, the neck portion <NUM> spans a gap between the bolster <NUM> and the heel panel <NUM> at the posterior end <NUM>.

With continued reference to <FIG>, the heel clip <NUM> is connected to the stanchion <NUM> at the distal end <NUM> of the neck portion <NUM>, and is attached to the heel panel <NUM> of the upper <NUM>. Accordingly, the neck portion <NUM> extends between and connects the base portion <NUM> attached to the bolster <NUM> and the heel clip <NUM> attached to the heel panel <NUM>. The heel clip <NUM> is arcuate and extends around the heel panel <NUM> from a first end 316a adjacent to the heel side panel <NUM> on the lateral side <NUM> to a second end 316b adjacent to the heel side panel <NUM> on the medial side <NUM>.

The support system <NUM> includes a heel counter <NUM> disposed between the heel clip <NUM> and the heel panel <NUM> of the upper <NUM>. As shown in <FIG>, the heel counter <NUM> is spaced apart from the sole structure <NUM> at the posterior end <NUM>. Accordingly, the heel counter <NUM> is not directly connected to the sole structure <NUM>, but is instead only indirectly connected to the bolster <NUM> of the sole structure <NUM> via the neck portion <NUM> of the stanchion <NUM>. The heel counter <NUM> is formed of a resilient polymeric material, and may provide additional cushioning and support around the upper <NUM> at the posterior end <NUM>.

Referring to <FIG>, the tensioning system <NUM> includes the tensioning device <NUM> disposed within the capsule <NUM> in the sole structure <NUM>. The tensioning system <NUM> further includes a cable <NUM> and a plurality of cable guides <NUM> configured to route the cable <NUM> through the sole structure <NUM> and along the upper <NUM>. Here, the tensioning system <NUM> includes one or more cable guides <NUM> attached to the upper <NUM> for routing the cable <NUM> and distributing a tension of the cable <NUM> along the upper <NUM>.

The cable <NUM> may be highly lubricous and/or may be formed from one or more fibers having a low modulus of elasticity and a high tensile strength. For instance, the fibers may include high modulus polyethylene fibers having a high strength-to-weight ratio and a low elasticity. Additionally or alternatively, the cable <NUM> may be formed from a molded monofilament polymer and/or a woven steel with or without other lubrication coating. In some examples, the cable <NUM> includes multiple strands of material woven together.

In some examples, the tensioning system <NUM> may include one or more cable guides <NUM>. The cable guides <NUM> may be formed of a rigid, low-friction material (e.g., high density polyethylene, etc.) and have an arcuate inner surface for receiving the tensioning element <NUM>. In some examples, the inner (i.e., cable-contacting) surfaces of the cable guides <NUM> are lined or coated with a low friction material, such as a lubricous polymer (e.g., polytetrafluoroethylene, etc.), that facilitates movement of the cable <NUM> therein. By coating the cable guides <NUM> with a low friction material, the number of turns taken by each lacing pattern can be increased without incurring a detrimentally high (e.g., function impairing) level of friction throughout the cable path.

With reference to <FIG>, the cable <NUM> includes a tensioning element <NUM> that cooperates with the cable guides <NUM> and the tensioning device <NUM> to move the article of footwear <NUM> between the tightened state and the relaxed state. The tensioning element <NUM> is movable in a tightening direction DT to move the article of footwear <NUM> into the tightened state, and in a loosening direction DL to allow the article of footwear <NUM> to transition to a relaxed state. In the illustrated example, the tightening force FT may be applied to the tensioning element <NUM> by a powered tensioning device <NUM> disposed in the sole structure.

As best shown in <FIG>, the tensioning element <NUM> may be described as including a lateral tensioning strand <NUM> and a medial tensioning strand <NUM>, which extend along opposite sides of the upper <NUM> and are connected to each other within the tensioning device <NUM>.

With reference to <FIG>, the lateral tensioning strand <NUM> of the tensioning element <NUM> includes a first end <NUM> attached at the bite line <NUM> on the lateral side <NUM> and is routed along the quarter panel <NUM> on the lateral side <NUM> of the upper <NUM>. Referring to <FIG>, the medial tensioning strand <NUM> of the tensioning element <NUM> includes a second end <NUM> attached at the bite line <NUM> on the medial side <NUM> and is routed along the quarter panel <NUM> on the medial side <NUM> of the upper <NUM>. Each of the tensioning strands <NUM>, <NUM> is routed from its respective side of the upper <NUM> to the tensioning device <NUM> between the sole structure <NUM> and a strobel of the upper <NUM>, and connects to the other of the tensioning strands <NUM>, <NUM> within the tensioning device <NUM>.

As shown in <FIG>, on the lateral side <NUM> of the article of footwear <NUM>, the lateral tensioning strand <NUM> includes a first end <NUM> of the tensioning element <NUM> attached at the bite line <NUM> of the article of footwear <NUM> at a point adjacent to the forefoot region <NUM>. From the first end <NUM>, the lateral tensioning strand <NUM> is alternatingly routed between the bite line <NUM> and the throat <NUM> along a series of the cable guides <NUM> arranged along the lateral side quarter panel <NUM>. The lateral tensioning strand <NUM> is then routed from one of the cable guides <NUM> adjacent to the bite line <NUM> in the heel region <NUM> to the tensioning device <NUM>. The portion of the lateral tensioning strand <NUM> extending from the lateral side <NUM> of the upper <NUM> to the tensioning device <NUM> is routed between the top side <NUM> of the cushioning element <NUM> and a strobel of the upper <NUM>.

As shown in <FIG>, on the medial side <NUM> of the article of footwear <NUM>, the medial tensioning strand <NUM> includes a second end <NUM> of the tensioning element <NUM> attached at the bite line <NUM> of the article of footwear <NUM> at a point adjacent to the forefoot region <NUM>. From the second end <NUM>, the medial tensioning strand <NUM> is alternatingly routed between the bite line <NUM> and the throat <NUM> along a series of the cable guides <NUM> arranged along the medial side quarter panel <NUM>. The medial tensioning strand <NUM> is then routed from one of the cable guides <NUM> adjacent to the bite line <NUM> in the heel region <NUM> to the tensioning device <NUM>. The portion of the medial tensioning strand <NUM> extending from the medial side <NUM> of the upper <NUM> to the tensioning device <NUM> is routed between the top side <NUM> of the cushioning element <NUM> and a strobel of the upper <NUM>.

In the illustrated example, the tensioning device <NUM> is a powered tensioning device, whereby the tensioning element <NUM> is moved in the loosening direction DL and the tightening direction DT by extending and retracting the tensioning element <NUM> from the tensioning device <NUM>. Accordingly, the tensioning device <NUM> may include a powered spool (not shown) for simultaneously winding and unwinding each of the lateral tensioning strand <NUM> and the medial tensioning strand <NUM>. As shown in <FIG>, the tensioning device <NUM> may include actuators <NUM> for powering the spool in a tightening direction and a loosening direction. The actuators <NUM> are configured as buttons <NUM> on the lateral side of the tensioning device <NUM>. The buttons <NUM> extend through respective openings in the capsule <NUM> and are exposed through the aperture <NUM> in the lateral side of the cushioning element <NUM>.

Claim 1:
An article of footwear (<NUM>) comprising:
an upper (<NUM>) extending from a first end in a forefoot region (<NUM>) to a second end in a heel region (<NUM>) and including heel side panels (<NUM>) and a heel panel (<NUM>) wrapping around a posterior end (<NUM>) of the footwear (<NUM>) and connecting the heel side panels (<NUM>);
a sole structure (<NUM>) attached to the upper (<NUM>) and including a posterior end extending beyond the second end of the upper (<NUM>), the sole structure (<NUM>) including a bladder (<NUM>) having a first portion disposed between the second end of the upper (<NUM>) and the posterior end of the sole structure (<NUM>), the sole structure (<NUM>) including a footbed (<NUM>) and a bolster (<NUM>) extending from the footbed (<NUM>) at the posterior end; and
a support system (<NUM>) connecting the sole structure (<NUM>) to the upper (<NUM>), the support system (<NUM>) including
a buttress (<NUM>) including a stanchion (<NUM>) formed at a first end and a heel clip (<NUM>) formed at a second end, the stanchion including a base portion (<NUM>) attached to the bolster (<NUM>) and a neck portion (<NUM>) extending upwardly from the base portion (<NUM>) to a distal end (<NUM>) adjacent to the heel panel (<NUM>) of the upper (<NUM>), the neck portion (<NUM>) spanning a gap between the bolster (<NUM>) and the heel panel (<NUM>) at the posterior end (<NUM>) of the sole structure (<NUM>); the heel clip (<NUM>) being connected to the stanchion (<NUM>) at the distal end (<NUM>) of the neck portion (<NUM>), and being attached to the heel panel (<NUM>) of the upper (<NUM>)); and
a heel counter (<NUM>) disposed between the heel clip (<NUM>) and the heel panel (<NUM>) of the upper (<NUM>) and being spaced apart from the sole structure (<NUM>) at the posterior end (<NUM>).