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 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 cushioning component for an article of footwear that includes a fluid-filled chamber and a covering element extending over a portion of the chamber. <CIT> describes that a sole structure for an article of footwear includes a bladder system with a first bladder enclosing a first sealed chamber retaining fluid, and a second bladder overlying and bonded to the first bladder and enclosing a second sealed chamber isolated from the first sealed chamber and retaining fluid. <CIT> describes an article of footwear having an upper and a sole structure secured to the upper. The sole structure includes a first chamber and a second chamber that each enclose a fluid. The first chamber and the second chamber both define a plurality of projections and depressions. <CIT> describes an article of footwear that includes an upper and a sole structure secured to the upper. The sole structure incorporates a sup-port element that includes a fluid-filled chamber.

The claimed invention provides a sole structure as defined in claim <NUM>. Implementations of the disclosure may include one or more of the following optional features.

In some examples, the first cushioning element includes a bladder.

In some implementations, a first side of the first cushioning element includes a substantially planar base and a second side of the first cushioning element includes the plurality of lobes formed on an opposite side from the base. In some configurations, lobes of the plurality of lobes are arranged in a quad-shaped configuration.

Each lobe of the plurality of lobes is hemispherical.

In some configurations, the first surface includes a first socket receiving a first end of the cushioning arrangement including the first cushioning element.

The sole structure includes a cradle defining the first surface of the recess, the cradle including a harder material than the chassis. In some implementations, a length of the recess extends between a first concave end and a second concave end.

The sole structure has a support plate disposed between the first cushioning element and the second cushioning element and including a plurality of receptacles receiving the plurality of lobes of the first cushioning element. The support plate includes a material having a greater hardness than each of the first cushioning element and the second cushioning element.

In some examples, the sole structure also has a cushioning arrangement including a first cushioning element protruding from the first surface and including a first plurality of lobes, and a second cushioning element protruding from the second surface and including a second plurality of lobes contacting the first plurality of lobes. Implementations of the disclosure may include one or more of the following optional features.

In some examples, at least one of the first cushioning element and the second cushioning element includes a fluid-filled bladder.

In some implementations, a first side of the first cushioning element includes a substantially planar first base and the second cushioning element includes a substantially planar second base. Here, the first plurality of lobes is disposed on an opposite side of the first cushioning element than the substantially planar first base and the second plurality of lobes is disposed on an opposite side of the second cushioning element than the substantially planar second base.

In some examples, lobes of the first plurality of lobes and lobes of the second plurality of lobes are arranged in a quad-shaped configuration.

In some implementations, each lobe of the second plurality of lobes is hemispherical.

In some configurations, the first surface includes a first socket receiving the first cushioning element and the second surface includes a second socket receiving the second cushioning element.

In some configurations, a length of the recess extends between a first concave end and a second concave end.

The sole structure includes a support plate disposed between the first cushioning element and the second cushioning element and including a plurality of receptacles receiving lobes of the first cushioning element and lobes of the second cushioning element. The support plate includes a material having a greater hardness than each of the first cushioning element and the second cushioning element.

Referring to <FIG>, an article of footwear <NUM> includes a sole structure <NUM> and an upper <NUM> attached to the sole structure. The footwear <NUM> may further include an anterior end <NUM> associated with a forward-most point of the footwear, and a posterior end <NUM> corresponding to a rearward-most point of the footwear <NUM>. As shown in <FIG>, a longitudinal axis AF of the footwear <NUM> extends along a length of the footwear <NUM> from the anterior end <NUM> to the posterior end <NUM> parallel to a ground surface, 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>. As used herein, a longitudinal direction refers to the direction extending from the anterior end <NUM> to the posterior end <NUM>, while a lateral direction refers to the direction transverse to the longitudinal direction and extending from the lateral side <NUM> to the medial side <NUM>.

The article of footwear <NUM> may be divided into one or more regions. The regions may include a forefoot region <NUM>, a mid-foot region <NUM>, and a heel region <NUM>. The forefoot region <NUM> corresponds to a ball portion of the foot including the metatarsophalangeal (MTP) j oint. 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.

With reference to <FIG> and <FIG>, 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> extending from the anterior end <NUM> to the posterior end <NUM>, and a cushioning arrangement <NUM> disposed within the heel region <NUM>. The midsole <NUM> includes a cradle <NUM> configured to receive and support a lower portion of the cushioning arrangement <NUM> within the chassis <NUM>. The chassis <NUM> is configured to be attached to the upper <NUM> and provides an interface between the upper <NUM> and the cushioning arrangement <NUM>. As described in greater detail below, the cushioning arrangement includes a lower cushioning element <NUM> and an upper cushioning element <NUM> arranged in a stacked configuration in the heel region <NUM>. The cushioning arrangement <NUM> includes a support plate <NUM> interposed between the lower cushioning element <NUM> and the upper cushioning element <NUM>.

With reference to <FIG> and <FIG>, the chassis <NUM> of the midsole <NUM> extends continuously from a first end <NUM> at the anterior end <NUM> to a second end <NUM> at the posterior end <NUM>. An upper portion of the chassis <NUM> includes a footbed <NUM> configured to attach to the upper <NUM> and to provide support and cushioning for a plantar surface of the foot. A lower portion of the chassis <NUM> includes a forefoot support member <NUM> formed in the forefoot region <NUM> and the mid-foot region <NUM>, and a recess <NUM> extending through the mid-foot region <NUM> and the heel region <NUM>. As discussed below, the forefoot support member <NUM> is configured to provide cushioning along the forefoot region <NUM>, while the recess <NUM> is configured to receive the cushioning arrangement <NUM> for supporting the heel region <NUM> of the upper <NUM>.

The footbed <NUM> extends continuously from the first end <NUM> to the second end <NUM> of the chassis <NUM> and defines a top surface <NUM> of the chassis <NUM> configured to face the upper <NUM> when the article of footwear <NUM> is assembled. The footbed <NUM> also includes a lower surface <NUM> formed on an opposite side from the top surface <NUM>, where a distance between the top surface <NUM> and the lower surface <NUM> forms a thickness of the footbed <NUM>. As shown, the forefoot support member <NUM> depends from the lower surface <NUM> of the footbed <NUM> and defines a bottom surface <NUM> of the chassis <NUM>. Here, the forefoot support member <NUM> extends continuously from the first end <NUM> to a first end wall <NUM> formed in the mid-foot region <NUM>. A thickness T<NUM> of the support member <NUM> progressively increases along a direction from the first end <NUM> to the end wall <NUM>.

The recess <NUM> is formed adjacent to the forefoot support member <NUM> and extends at least partially through the heel region <NUM> from the first end wall <NUM> in the mid-foot region <NUM> to a second end wall <NUM> in the heel region <NUM>, adjacent to the second end <NUM>. The first end wall <NUM> faces the second end wall <NUM> to define a length of the recess <NUM>. As shown, each end wall <NUM>, <NUM> may have a concave profile extending across a width of the chassis <NUM> from the lateral side <NUM> to the medial side <NUM>. In use, the concave geometries of the end walls <NUM>, <NUM> allow upper and lower portions of the end walls <NUM>, <NUM> to flex towards each other, which provides a springlike compression of the end walls <NUM>, <NUM> during use. A depth or height of the recess <NUM> is defined by a distance from the bottom surface <NUM> of the chassis <NUM> to the lower surface <NUM> of the footbed <NUM>. The lower surface <NUM> of the footbed <NUM> may include an upper socket <NUM> facing the recess <NUM>. As described in greater detail below, the upper socket <NUM> is configured to interface with or receive an upper portion of the cushioning arrangement <NUM> to secure a position of the cushioning arrangement <NUM> within the recess <NUM>.

As described above, the chassis <NUM> is formed of a resilient polymeric material, 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 chassis <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). Examples of suitable polyurethanes include those discussed below for the barrier layers <NUM>, <NUM>. 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.

The cradle <NUM> is disposed within the recess <NUM> of the chassis <NUM> and extends from the first end wall <NUM> of the forefoot support member <NUM> to the second end wall <NUM> of the chassis <NUM>. The cradle <NUM> includes an inner surface <NUM> that faces the recess <NUM> and is configured to interface with a lower portion of the cushioning arrangement <NUM>. For instance, the inner surface <NUM> may define a lower socket <NUM> configured to receive the lower portion of the cushioning arrangement <NUM>. Thus, the lower surface <NUM> of the footbed <NUM> and the inner surface <NUM> of the cradle <NUM> are arranged on opposite sides of the recess <NUM> and cooperate to define the height of the recess <NUM>. The cradle <NUM> includes one or more materials having a greater hardness than the materials of the chassis <NUM> and the outsole <NUM>. Accordingly, the cradle <NUM> provides a stiffer stabilizing interface between the cushioning arrangement <NUM> and the ground surface.

With continued reference to <FIG> and <FIG>, the cushioning arrangement <NUM> of the midsole <NUM> includes the lower cushioning element <NUM> and the upper cushioning element <NUM> arranged in a stacked configuration within the recess <NUM>. The cushioning arrangement <NUM> further includes the support plate <NUM> interposed between the lower cushioning element <NUM> and the upper cushioning element <NUM>. The cushioning elements <NUM>, <NUM> include resilient and compressible materials, and are configured to provide cushioning in the heel region <NUM>. The support plate <NUM> includes materials having a greater hardness than the cushioning elements <NUM>, <NUM> such that the support plate <NUM> provides a stabilizing interface between the cushioning elements <NUM>, <NUM>.

In the illustrated example, each of the cushioning elements <NUM>, <NUM> is formed as a bladder <NUM>, <NUM> having an interior void filled with a compressible material. In this example, each of the bladders <NUM>, <NUM> has the same configuration and size, where the lower bladder <NUM> is attached to the cradle <NUM> and faces upward while the upper bladder <NUM> is attached to the lower surface <NUM> of the footbed <NUM> and faces downward, as shown in <FIG>. As shown in the cross-sectional views of <FIG> and <FIG>, each of the bladders <NUM>, <NUM> may be formed by an opposing pair of barrier layers <NUM>, <NUM>, which can be joined to each other at a peripheral seam to define an overall shape of the bladders <NUM>, <NUM>. As discussed below, the barrier layers <NUM>, <NUM> include a substantially flat base barrier layer <NUM> attached to the midsole <NUM> and a deformable cushioning barrier layer <NUM> extending into the recess <NUM>.

As used herein, the term "barrier layer" (e.g., barrier layers <NUM>, <NUM>) encompasses both monolayer and multilayer films. In some embodiments, one or both of the barrier layers <NUM>, <NUM> are each produced (e.g., thermoformed or blow molded) from a monolayer film (a single layer). In other embodiments, one or both of the barrier layers <NUM>, <NUM> 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 be 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 the barrier layers <NUM>, <NUM> can independently be transparent, translucent, and/or 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.

The barrier layers <NUM>, <NUM> 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 <NUM>, <NUM> may include two or more sublayers (multilayer film) such as shown in<CIT> and<CIT>. In embodiments where the barrier layers <NUM>, <NUM> include two or more sublayers, examples of suitable multilayer films include microlayer films, such as those disclosed in<CIT>. In further embodiments, the barrier layers <NUM>, <NUM> 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 the barrier layers <NUM>, <NUM> 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 bladders <NUM>, <NUM> can be produced from the barrier layers <NUM>, <NUM> 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, the barrier layers <NUM>, <NUM> can be produced by coextrusion followed by vacuum thermoforming to form the profile of the cushioning arrangement <NUM>, which can optionally include one or more valves (e.g., one way valves) that allows the cushioning arrangement <NUM> to be filled with the fluid (e.g., gas).

The barrier layers <NUM>, <NUM> have a low gas transmission rate to preserve its retained gas pressure. In some embodiments, the barrier layers <NUM>, <NUM> have 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, cushioning arrangement <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 <NUM>, <NUM>). 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.

As previously mentioned, the bladder <NUM>, <NUM> may be generally described as including a base barrier layer <NUM> configured to attach to one of the sockets <NUM>, <NUM>, and a cushioning barrier layer <NUM> configured to extend into the recess <NUM>. The base barrier layer <NUM> of each bladder <NUM>, <NUM> is substantially flat, while the cushioning barrier layer <NUM> is contoured and substantially defines the geometry of the bladder <NUM>, <NUM>. The barrier layers <NUM>, <NUM> are joined together along the peripheral seam to define an outer peripheral profile of the bladders <NUM>, <NUM>.

Interior surfaces of the barrier layers <NUM>, <NUM> are spaced apart from each other to define an interior void filled with a compressible material. The interior voids of the bladders <NUM>, <NUM> can be provided in a fluid-filled (e.g., as provided in footwear <NUM>) or in an unfilled state. The bladders <NUM>, <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. The fluid provided to the bladders <NUM>, <NUM> can result in the bladders <NUM>, <NUM> being pressurized at a first pressure. In some examples, the first pressure ranges from <NUM> psi to <NUM> psi, and more particularly from <NUM> psi to <NUM> psi, and even more particularly from <NUM> psi to <NUM> psi. The second pressure may range from <NUM> psi to <NUM> psi, and more particularly from <NUM> psi to <NUM> psi, and even more particularly from <NUM> psi to <NUM> psi. Alternatively, the fluid provided to the bladders <NUM>, <NUM> can be at atmospheric pressure such that the bladders <NUM>, <NUM> are not pressurized but, rather, simply contain a volume of fluid at atmospheric pressure. In other aspects, the bladders <NUM>, <NUM> can alternatively include other compressible media, such as pellets, beads, ground recycled material, and the like (e.g., foamed beads and/or rubber beads).

With reference to <FIG>, each bladder <NUM>, <NUM> includes a plurality of interconnected hemispherical lobes 146a-146d and an interior depression <NUM> all defined by the cushioning barrier layer <NUM> on a first side of the bladder <NUM>, <NUM>. In the illustrated example, the lobes 146a-146d include four lobes 146a-146d arranged in a quad-shaped configuration. In other words, the lobes 146a-146d may be described as being arranged in a two-by-two configuration, where two of the lobes 146a-146d are arranged along a first side of the bladder <NUM>, <NUM> and another two of the lobes 146a-146d are arranged along an opposite second side of the bladder <NUM>, <NUM>.

As shown, each of the lobes 146a-146d has a hemispherical shape defined by the cushioning barrier layer <NUM> on the first side of the bladder <NUM>, <NUM>. Here, each of the lobes 146a-146d has the same size and shape, such that a radius R<NUM> of each lobe 146a-146d defines a maximum thickness T<NUM>, T<NUM> of the bladder <NUM>, <NUM> (<FIG>). As discussed above, the lobes 146a-146d are arranged in a quad-shaped pattern such that center points of each of the lobes 146a-146d are each positioned at a corner of a theoretical square pattern. Thus, center points of adjacent ones of the lobes 146a-146d are spaced apart from each other by a distance corresponding to a length of each side of the square pattern. As shown, the distances between adjacent ones of the lobes 146a-146d are less than the twice the radius R<NUM> of each of the lobes 146a-146d such that adjacent ones of the lobes 146a-146d overlap or intersect with each other.

With continued reference to <FIG>, the cushioning barrier layer <NUM> defines the interior depression <NUM> formed between the lobes 146a-146d. Generally, the interior depression <NUM> is formed by a portion of the bladder <NUM>, <NUM> having a reduced thickness relative to the lobes 146a-146d. The interior depression <NUM> may be described as including a central portion <NUM> (<FIG>) surrounded by all of the lobes 146a-146d, and a plurality of valleys or channels 150a-150d (<FIG>) extending radially outwardly from the central portion <NUM>. Here, each of the channels 150a-150d is defined where adjacent ones of the hemispherical lobes 146a-146d intersect with each other. The channels 150a-150d may have a concave curvature extending between adjacent ones of the lobes 146a-146d.

Referring to <FIG>, the support plate <NUM> of the present example is a rigid or semirigid (i.e., greater hardness than the cushioning elements <NUM>, <NUM>) member configured to provide a stabilizing interface between the upper and lower bladders <NUM>, <NUM> when the cushioning arrangement <NUM> is assembled. The support plate <NUM> includes upper and lower support surfaces <NUM> formed on opposite sides of the support plate <NUM>. The support surfaces <NUM> each include a plurality of receptacles <NUM> configured to receive one of the lobes 146a-146d of one of the bladders <NUM>, <NUM>. Thus, a first one of the support surfaces <NUM> includes four of the receptacles <NUM> for receiving the lobes 146a-146d of the lower bladder <NUM> and the opposite support surface <NUM> includes four of the receptacles <NUM> for receiving the lobes 146a-146d of the upper bladder <NUM>. In the illustrated example, each of the receptacles <NUM> is a concave recess formed in or on the support surface <NUM> of the support plate <NUM>, which receives a distal end of one of the lobes 146a-146d.

With reference to <FIG>, <FIG> and <FIG>, when the cushioning arrangement <NUM> is assembled, the lobes 146a-146d of the upper bladder <NUM> are arranged directly across the support plate <NUM> from the lobes 146a-146d of the lower bladder <NUM>. Thus, the lobes 146a-146d of the upper and lower bladders <NUM>, <NUM> are aligned with each other across the support plate <NUM> such that an overall thickness T<NUM> of the cushioning arrangement <NUM> is defined by combined thicknesses of the lobes 146a-146d of the lower bladder <NUM>, the support plate <NUM>, and the lobes 146a-146d of the upper bladder <NUM>. Here, the lobes 146a-146d of the lower bladder <NUM> may be described as indirectly contacting the lobes 146a-146d via the support plate <NUM>.

With reference to <FIG>, when the sole structure <NUM> is assembled, the cushioning arrangement <NUM> is received within the recess <NUM> between the footbed <NUM> of the chassis <NUM> and the cradle <NUM>. Particularly, a first end of the cushioning arrangement <NUM>, defined by the base barrier layer <NUM> of the upper cushioning element <NUM> is received within the upper socket <NUM> formed in the lower surface <NUM> of the footbed <NUM>. A second end of the cushioning arrangement <NUM>, which is formed at an opposite end of the cushioning arrangement <NUM> from the first end and defined by the base barrier layer <NUM> of the lower cushioning element <NUM>, is received within the lower socket <NUM> formed on the inner surface <NUM> of the cradle <NUM>. Accordingly, opposite ends of the cushioning arrangement <NUM> are embedded or captured within the upper and lower sockets <NUM>, <NUM> to secure a position of the cushioning arrangement <NUM> within the recess <NUM>.

By arranging the lower and upper bladders <NUM>, <NUM> in the foregoing manner, the thickest portions of the bladders <NUM>, <NUM> (i.e., the lobes 146a-146d) cooperate with each other to provide cushioning in the heel region of the sole structure <NUM>, while the interior depressions <NUM> of the bladders <NUM>, <NUM> are recessed from each other and the support plate <NUM> by a space or gap. Thus, when the cushioning arrangement <NUM> is compressed between the footbed <NUM> and the cradle <NUM>, the pressure within the lobes 146a-146d may increase such that the compressible material (e.g., air) disposed within the lobes 146a-146d is displaced to the lower pressure area of the interior depression <NUM> of the bladder <NUM>, <NUM>. As the compressible material flows from the lobes 146a-146d to the interior depression <NUM>, the pressure within the interior depression <NUM> increases, causing expansion of the cushioning barrier layer <NUM> along the interior depression <NUM>. Thus, the interior depression <NUM> serves as an accumulator for the fluid of the bladder <NUM>, <NUM> when the lobes 146a-146d are compressed, which allows for a greater degree of compression.

During compression, the support plate <NUM> provides a rigid interface between the lobes 146a-146d of the respective bladders <NUM>, <NUM>. In addition to securing a position of each of the lobes 146a-146d, the support plate <NUM> may act as a damper to distribute compressive forces among the lobes 146a-146d of the bladders <NUM>, <NUM>. For instance, when a compressive force is applied directly to one corner of the cushioning arrangement <NUM>, rather than have the entire compressive force be applied through a single opposing pair of the lobes 146a-146d of the lower and upper bladders <NUM>, <NUM>, the support plate <NUM> may transfer at least a portion of the compressive force to adjacent ones of the lobes 146a-146d.

The outsole <NUM> of the sole structure <NUM> extends continuously from the anterior end <NUM> to the posterior end <NUM> of the sole structure <NUM> and defines a ground-contacting surface of the footwear <NUM>. The outsole <NUM> includes an inner surface <NUM> attached to the bottom of the midsole <NUM> and an outer surface <NUM> formed on an opposite side from the inner surface <NUM> and defining the ground-contacting surface of the footwear. Optionally, the outsole <NUM> may be formed as a fragmentary structure including a first portion attached to the midsole <NUM> in a first region <NUM>, <NUM>, <NUM> and a second portion attached to the midsole <NUM> in a second region <NUM>, <NUM>, <NUM>.

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

With particular reference to <FIG>, an article of footwear 10a is provided and includes a sole structure 100a and an upper 200a attached to the sole structure 100a. In view of the substantial similarity in structure and function of the components associated with the article of footwear <NUM> 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.

In the example of the article of footwear 10a shown in <FIG>, the midsole 102a has a substantially similar configuration as the midsole <NUM> discussed above. Particularly, the midsole 102a includes a chassis 106a including the footbed <NUM>, a forefoot support member 124a, and a recess 126a formed in the heel region <NUM>. The midsole <NUM> also includes the cushioning arrangement <NUM> and a cradle 110a.

As shown in <FIG> and <FIG>, the midsole 102a of the present example includes a bottom surface 132a having a laterally extending arch or recess <NUM> in the mid-foot region <NUM>. The outsole 104a of the sole structure 100a includes a first fragment 164a attached to the bottom surface 132a on first side of the recess <NUM> and a second segment 164b attached to the bottom surface on a second side of the recess <NUM>. Thus, the portion of the bottom surface 132a including the recess <NUM> is exposed between the first and second fragments 164a, 164b of the outsole <NUM>.

As shown in <FIG>, the second fragment 164b of the outsole <NUM> may include a depression <NUM> formed in the outer surface <NUM>. The depression <NUM> is aligned with the cushioning arrangement <NUM> and may include a peripheral profile corresponding in shape to the peripheral profile of the cushioning arrangement <NUM>. The depression <NUM> provides the heel portion of the outsole 104a with a trampoline-like structure between the cushioning arrangement <NUM> and the ground surface, which provides an added degree of cushioning and resiliency in the heel region <NUM>.

With particular reference to <FIG>, a cushioning arrangement 108a is provided and includes the upper cushioning element <NUM> and the lower cushioning element <NUM>. In view of the substantial similarity in structure and function of the components associated with the cushioning arrangement <NUM> with respect to the cushioning arrangement 108a, 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.

In the example of the cushioning arrangement 108a not in accordance with the claimed invention shown in <FIG>, the upper and lower cushioning elements <NUM>, <NUM> are again provided as upper and lower bladders <NUM>, <NUM> with distal ends of the lobes 146a-146b of the upper bladder <NUM> aligned with distal ends of the lobes 146a-146d of the lower bladder <NUM>. In this example, the support plate <NUM> is omitted such that distal ends of the lobes 146a-146d of the bladders <NUM>, <NUM> are in direct contact with each other. Here, the distal ends of the lobes 146a-146d of the lower and upper bladders <NUM>, <NUM> are convex such that the lobes 146a-146d of the upper bladder <NUM> and the lobes 146a-146d of the lower bladder <NUM> are attached or bonded to each other in a point-contact relationship.

In contrast to the example of the cushioning arrangement <NUM> described previously, where the lobes 146a-146d are received within concave receptacles <NUM> of the support plate <NUM> to distribute compressive forces, the direct, point-contact relationship between the lobes 146a-146d of the bladders <NUM>, <NUM> in the current example provides localized compression. For instance, a compressive force applied at one of the lobes 146a-146d of the upper bladder <NUM> is transferred directly to the corresponding lobe 146a-146d of the lower bladder <NUM> through the respective distal ends. As the respective lobes 146a-146d are deformed under the compressive force, the interface between the lobes 146a-146d transitions from a point-contact to an area-contact. Meanwhile, the compressible material (e.g., air) within the compressed lobes 146a-146d is displaced to the interior depression <NUM> and the other lobes 146a-146d until pressures within the interior voids of the bladders <NUM>, <NUM> reaches equilibrium.

With particular reference to <FIG>, a cushioning arrangement 108b not in accordance with the claimed invention is provided and includes a lower cushioning element 112a and an upper cushioning element 114a. In view of the substantial similarity in structure and function of the components associated with the cushioning arrangement <NUM> with respect to the cushioning arrangement 108b, 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.

In the example of the cushioning arrangement 108b not in accordance with the claimed invention shown in <FIG>, an upper cushioning element 114a is provided in direct contact with the lower cushioning element 112a, similar to the arrangement discussed above with respect to the cushioning arrangement 108a of <FIG>. However, in the illustrated example, the cushioning barrier layers 144a of the cushioning elements 112a, 114a define a first pair of the hemispherical lobes 146b, 146c discussed above at opposite corners of the cushioning element 112a, 114a and a pair of truncated lobes 146e, 146f at the other two corners of the cushioning element 112a, 114a.

As shown, the truncated lobes 146e, 146f include receptacles <NUM> configured to mate with the distal ends of the hemispherical lobes 146b, 146c of the opposing bladder 112a, 114a when the bladders 112a, 114a are assembled. Here, the receptacles 156a are similar to the receptacles <NUM> formed in the support plate <NUM> discussed above. For instance, the receptacles 156a have a concave shape corresponding to the convex shape of the distal ends of the lobes 146b, 146c. Thus, when the cushioning arrangement 108b is assembled, the truncated lobes 146e, 146f of each of the cushioning elements 112a, 114a are aligned and received within the receptacles 156a of the lobes 146e, 146f of the other cushioning element 112a, 114a in a ball-and-socket configuration.

With particular reference to <FIG>, an article of footwear 10b is provided and includes a sole structure 100b, which is not in accordance with the claimed invention, and the upper <NUM> attached to the sole structure 100b. In view of the substantial similarity in structure and function of the components associated with the article of footwear <NUM> with respect to the article of footwear 10b, 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.

As shown in <FIG> and <FIG>, the article of footwear 10b includes a sole structure 100b having a midsole 102b and an outsole 104b. The midsole 102b includes a chassis 106b having the footbed <NUM> formed in an upper portion and a forefoot support member 124b and recess 126b formed on a bottom portion. The midsole 102b further includes a cushioning arrangement 108c received within the recess 126b of the chassis 106b, between the footbed <NUM> and the outsole 104b.

With reference to <FIG>, cross-sections of the sole structure 100b are provided to illustrate the construction of the cushioning arrangement 108c. Here, the cushioning arrangement 108c includes the lower cushioning element <NUM> and an upper cushioning element 114b with a support plate 116b interposed between the cushioning elements <NUM>, 114b.

In this example, the upper cushioning element 114b has a substantially similar configuration to the upper cushioning element <NUM> discussed above. Accordingly, the upper cushioning element 114b is configured as a bladder 114b having a base barrier layer 142b and a cushioning barrier layer 144b defining a plurality of lobes <NUM>-146j and an interior depression 148b. The interior depression 148b includes a central portion 150b and a plurality of channels <NUM>-152j extending radially outwardly from the central portion 150b. Thus, the channels <NUM>-152j of the interior depression 148b extend between adjacent ones of the lobes <NUM>-148j. While the upper bladder 114b has a substantially similar geometry as the lower bladder <NUM>, the upper bladder 114b has different dimensions than the lower bladder <NUM>. Particularly, the lobes <NUM>-148j have a radius R<NUM> that is smaller than the radius R146a of the lobes 146a-146d of the lower bladder <NUM>. Additionally or alternatively, adjacent ones of the lobes <NUM>-146j of the upper bladder 114b may be spaced apart by a distance that is less than the distance between adjacent ones of the lobes 146a-146d of the lower bladder <NUM>.

The support plate 116b of the cushioning arrangement 108c includes a pair of support surface 154a, 154b formed on opposite sides of the support plate 116b. Unlike the support plate <NUM> described above, which is substantially flat and includes the receptacles <NUM>, the support plate 116b of the current example is contoured such that the upper support surface 154a mates with the cushioning barrier layer 144b of the upper bladder 114b and the lower support surface 154b mates with the cushioning barrier layer <NUM> of the lower bladder <NUM>. Thus, the support plate 116b may include a central hub <NUM> configured to interface with the central portions <NUM>, 150b of the bladders <NUM>, 114b and an undulated peripheral rim <NUM> configured to mate with the lobes 146a-146d, <NUM>-146j and channels 152a-152d, <NUM>-152j.

Referring to <FIG>, <FIG>, and <FIG>, the cushioning arrangement 108c includes the upper bladder 114b and the lower bladder <NUM> arranged in a stacked configuration with the support plate 116b interposed therebetween. As in the previous examples, the upper bladder 114b and the lower bladder <NUM> are arranged such that the cushioning barrier layers <NUM>, 144b face each other. However, in the current example, the lower bladder <NUM> is rotated relative to the longitudinal axis A<NUM> and the upper bladder 114b such that the lobes 146a-146d of the lower bladder <NUM> are offset (i.e., not vertically aligned) from the lobes <NUM>-146j of the upper bladder 114b. As shown in <FIG>, the lobes 146a-146d of the lower bladder <NUM> are received within the channels <NUM>-152j of the upper bladder 114b. Likewise, the lobes <NUM>-146j of the upper bladder 114b are received within the channels 152a-152d of the lower bladder <NUM>.

As provided above, the central hub <NUM> of the support plate 116b is received within the central portions <NUM>, 150b of the bladders <NUM>, 114b. As shown in <FIG>, the central hub <NUM> is disposed between the opposing (i.e., facing) portions of the cushioning barrier layers <NUM>, 144b forming the central portions <NUM>, 150b of the bladders <NUM>, 114b. Thus, the central hub <NUM> fills a space between the central portions <NUM>, 150b of the bladders <NUM>, 114b.

As shown in <FIG>, <FIG>, <FIG>, and <FIG> the undulated peripheral rim <NUM> of the support plate 116b is interposed between the lobes 146a-146d, <NUM>-146j and channels 152a-152d, <NUM>-152j of the respective bladders <NUM>, 114b. The peripheral rim <NUM> may be described as including first undulations 172a-172d and second undulations <NUM>-172j alternatingly arranged around the central hub <NUM>. The first undulations 172a-172d are configured to receive corresponding lobes 146a-146d of the lower bladder <NUM> and to be received within the channels <NUM>-152j of the upper bladder 114b. The second undulations <NUM>-172j are configured to receive the corresponding lobes <NUM>-146j of the upper bladder 114b and to be received within the channels 152a-152d of the lower bladder <NUM>. Thus, the undulations 172a-172d, <NUM>-172j function as receptacles 172a-172d, <NUM>-172j for the corresponding lobes 146a-146d, <NUM>-146j of the bladders <NUM>, 114b.

A diameter of the outer periphery <NUM> of the support plate 116b may also be undulated such that portions of the outer periphery <NUM> corresponding to the first undulations 172a-172d terminate at the distal ends of the lobes 146a-146d of the lower bladder <NUM> (<FIG> and <FIG>) and portions of the outer periphery <NUM> corresponding to the second undulations <NUM>-172j terminate at the distal ends of the lobes <NUM>-146j of the upper bladder 114b (<FIG> and <FIG>). Thus, the peripheral rim <NUM> of the support plate 116b fills a space formed between inner portions of the bladders <NUM>, 114b, while the outer portions of the bladders <NUM>, 114b are exposed and unrestricted.

With continued reference to <FIG>, the cushioning arrangement 108c is disposed within the recess <NUM> of the chassis <NUM> such that a first end of the cushioning arrangement 108c formed by the base barrier layer 142b of the upper bladder 114b is received within the upper socket <NUM> of the footbed <NUM> and a second end of the cushioning arrangement 108c formed by the base barrier layer <NUM> of the lower bladder <NUM> is received within a lower socket 140b formed in the inner surface 160b of the outsole 104b. Thus, in this example, cradle <NUM> is omitted and the cushioning arrangement 108c is attached directly to the outsole 104b.

As shown, the cushioning arrangement 108c is oriented within the recess <NUM> such that a first pair of opposing lobes 146a, 146c of the lower bladder <NUM> are aligned with the longitudinal axis A10c and the second pair of opposing lobes 146b, 146d of the lower bladder <NUM> are aligned across the longitudinal axis A10c. Conversely, the upper bladder 114b is oriented such that a first pair of adjacent lobes <NUM>, 146i are aligned with the longitudinal axis A<NUM> along the lateral side <NUM> and a second pair of adjacent lobes <NUM>, 146j are aligned with the longitudinal axis A<NUM> along the medial side <NUM>.

When the heel region <NUM> of the sole structure 100b is compressed, the compression forces applied to the cushioning arrangement 108c are distributed among the inner portions of the bladders <NUM>, 114b. Particularly, the support plate 116b distributes the compression forces among the inner portions of the lobes 146a-146d, <NUM>-146j. Because the support plate 116b fills the spaces formed between the inner portions of the bladders <NUM>, 114b, the interior depressions <NUM>, 148b of the bladders <NUM>, 114b do not deform to accommodate the pressure increase within the bladders <NUM>, 114b. In this example, the increased pressure within the compressed bladders <NUM>, 114b is accommodated by the exposed outer portions of the lobes 146a-146d, <NUM>-146j. Thus, the rotated and stacked configuration of the cushioning arrangement 108c may result in a cushioning arrangement 108c with a firmer feel than the cushioning arrangements discussed above, as deformation of the cushioning barrier layers <NUM>, 144b is restricted by the support plate 116b.

Optionally, the midsole <NUM> may include a pair of braces 176a, 176b surrounding openings of the recess 126c on opposite sides <NUM>, <NUM> of the sole structure 100b. The braces 176a, 176b may be formed of a material having a greater hardness than the material of the chassis <NUM>, such that the braces 176a, 176b provide added strength around the openings of the recess 126b.

With particular reference to FIGS. 23A and <FIG>, a cushioning arrangement 108d is provided and includes the upper cushioning element 114b and the lower cushioning element <NUM> described above. In view of the substantial similarity in structure and function of the components associated with the cushioning arrangement <NUM> with respect to the cushioning arrangement 108d, 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.

The cushioning arrangement 108d not in accordance with the claimed invention of <FIG> is substantially similar to the cushioning arrangement 108b previously described. However, in this configuration, the support plate 116b is omitted from the cushioning arrangement 108c such that the cushioning barrier layers <NUM>, 144b mate directly with each other. As shown in <FIG>, the direct relationship between the bladders <NUM>, 114b results in line-contact between the lobes 146a-146d, <NUM>-146j and the corresponding channels <NUM>-152j, 152a-152d. Additionally, the central portions <NUM>, 150b of the bladders <NUM>, 114b are spaced apart from each other. Accordingly, the cushioning arrangement 108d may have a softer feel than a cushioning arrangement 108b having the same interior void pressure, as deformation of the barrier layers <NUM>, 144b of the cushioning arrangement 108d is not restricted by the support plate 116b.

With particular reference to <FIG>, a cushioning arrangement 108e not in accordance with the claimed invention is provided and includes the upper cushioning element <NUM> and the lower cushioning element <NUM>. In view of the substantial similarity in structure and function of the components associated with the cushioning arrangement <NUM> with respect to the cushioning arrangement 108e, 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.

The cushioning arrangement 108e not in accordance with the claimed invention of <FIG> is substantially similar to the cushioning arrangement 108d previously described. However, in this configuration, the bladders <NUM>, <NUM> are the same size as each other and are configured such that an inner region (i.e., radially inwardly of the distal ends of the lobes 146a-146d) of the cushioning barrier layers <NUM> are in facing contact with each other. Thus, the bladders <NUM>, <NUM> have a surface-contact bonding area, which provides greater stability and a firmer feel in comparison to the line-contact bonding of the cushioning arrangement 108d.

With particular reference to <FIG>, an article of footwear 10c is provided and includes a sole structure 100c and the upper <NUM> attached to the sole structure 100c. In view of the substantial similarity in structure and function of the components associated with the article of footwear <NUM> with respect to the article of footwear 10c, 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.

As shown in <FIG> and <FIG>, the article of footwear 10c includes a sole structure 100c having a midsole 102c and an outsole 104c. The midsole 102c includes a chassis 106c having the footbed <NUM> formed in an upper portion and a forefoot support member 124c and recess 126c formed on a lower portion. The midsole 102b further includes a cushioning arrangement 108f received within the recess 126c of the chassis 106c, between the footbed 122c and the outsole 104c. In this example, the midsole 102c includes a cradle 110c extending across a lower portion of the recess 126c between the cushioning arrangement 108f and the outsole 104c. The cradle 110c includes a lower socket 140c configured to receive an end of the cushioning arrangement 108f.

The cushioning arrangement 108f of the present example includes the lower cushioning element <NUM> formed as a bladder <NUM>, as previously described, and an upper cushioning element 114c including a resilient polymeric material. As shown, the upper cushioning element 114c is formed as a foam cushioning element 114c attached to and extending from the lower surface <NUM> of the footbed <NUM>. Here, the upper cushioning element 114c extends from the lower surface <NUM> to a substantially planar distal end surface <NUM> facing the lower bladder <NUM>. In the illustrated example, the upper cushioning element 114c is integrally formed with the footbed 122c of the chassis <NUM>. Thus, the upper cushioning element 114c and the footbed 122c may include the same foam material. However, in other examples, the upper cushioning element 114c may be formed separately from the footbed 122c and/or include different resilient materials than the footbed 122c.

When the sole structure <NUM> is assembled, the distal ends of the lobes 146a-146d of the lower bladder <NUM> form respective point-contacts with the planar distal end <NUM> of the upper cushioning element 114c. Thus, when the heel region <NUM> is compressed during use, the lobes 146a-146d of the lower bladder <NUM> are compressed by the resilient distal end <NUM> of upper cushioning element <NUM>.

Claim 1:
A sole structure (<NUM>; 100a; 100b; 100c) for an article of footwear (<NUM>; 10a; 10b; 10c), the sole structure (<NUM>; 100a; 100b; 100c) comprising:
a chassis (<NUM>; 106a; 106b; 106c) including a recess (<NUM>; 126a; 126b; 126c) formed between a first surface and a second surface facing the first surface;
a cushioning arrangement (<NUM>; 108a to 108f) including a first cushioning element (<NUM>; 112a) protruding from the first surface and including a plurality of lobes (146a-146d, <NUM>-146j) and a second cushioning element (<NUM>; 114a; 114b; 114c) protruding from the second surface to a distal end of the second cushioning element (<NUM>; 114a; 114b; 114c); and
a support plate (<NUM>; 116b) disposed between the first cushioning element (<NUM>; 112a) and the second cushioning element (<NUM>; 114a; 114b; 114c) and including a plurality of receptacles (<NUM>; 156a; 172a-172d, <NUM>-172j) receiving the plurality of lobes (146a-146d, <NUM>-146j) of the first cushioning element (<NUM>; 112a),
wherein each lobe (146a-146d, <NUM>-146j) of the plurality of lobes (146a-146d, <NUM>-146j) is hemispherical, and
wherein the support plate (<NUM>; 116b) includes a material having a greater hardness than each of the first cushioning element (<NUM>; 112a) and the second cushioning element (<NUM>; 114a; 114b; 114c).