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 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 an article of footwear having a sole structure incorporating a plate and chamber.

An aspect of the disclosure in line with the claimed invention provides a structure for an article of footwear. The sole structure includes a cushioning element including a first material, and comprising a recess in a heel region of the sole structure. The sole structure further includes a cradle including a second material, attached to the cushioning element, and including a top plate disposed against the cushioning element, a first end support, and a second end support that cooperate to define a receptacle disposed beneath the top plate, wherein the top plate extends from the first end support to the second end support and defines an upper portion of the receptacle, the first end support comprising a first distal end and disposed adjacent to and facing an end wall of the recess, the first distal end of the first end support including a lip extending outwardly therefrom, the second end support disposed at a posterior end of the sole structure. The sole structure also includes a bladder disposed within the cradle between the first end support and the second end support (pair of supports), the cradle configured to be received within the recess, the receptacle configured to receive the bladder therein, and an upper barrier layer of the bladder contacting the top plate. The sole structure includes an outsole disposed adjacent to the top plate on an opposite side of the cradle from the cushioning element. Each of the first end support and the second end support contacts the outsole.

This aspect of the disclosure may include one or more of the following optional features. In one implementation, a lower barrier layer of the bladder contacts the outsole.

In another configuration, the receptacle extends continuously through the cradle from a first side to a second side. Here, each of the supports includes a concave surface facing the bladder. Optionally, the concave surface of each of the supports is spaced apart from the bladder.

In some examples, the bladder contacts the cushioning element through the cradle. In such an example, the cradle includes an opening. The cushioning element includes an upper dock engaging the bladder through the opening of the cradle. In one aspect, the upper dock may include a plurality of ribs extending through a plurality of openings of the cradle to engage bladder. In some configurations, the plate has a greater hardness than the cushioning element.

Another aspect of the disclosure provides a sole structure for an article of footwear. The sole structure includes a cushioning element, a cradle and a bladder. The cradle is received by the cushioning element and defines a receptacle extending continuously through the cradle from a first side of the sole structure to a second side of the sole structure. The bladder is disposed within the receptacle and contacts the cradle. A portion of the bladder contacts the cushioning element.

This aspect of the disclosure may include one or more of the following optional features. In one example, the sole structure includes an outsole disposed on an opposite side of the cradle from the cushioning element. Optionally, a lower barrier layer of the bladder contacts the outsole.

In some examples, the cradle includes a plate contacting an upper barrier layer of the bladder. Here, the cradle may include a first end support extending from the plate at a first end of the cradle and a second end support extending from the plate at a second end of the cradle.

In some examples, the cushioning element includes an upper dock engaging the bladder through the cradle. In such an example, the plate includes at least one opening formed therethrough and a portion of the cushioning element extends through the at least one opening so as to engage the bladder.

In some implementations, the cushioning element includes an upper dock engaging the bladder through an opening in the cradle. In some examples, the upper dock includes a plurality of ribs and the cradle includes a plurality of openings, wherein the plurality of ribs extend through a corresponding one of the plurality of openings in the cradle to engage bladder. In some configurations, the cradle has a greater hardness than the cushioning element. Optionally, the cradle has a hardness of <NUM> Shore A and the cushioning element has a hardness of <NUM> to <NUM> Shore C.

Another aspect of the disclosure provides an article of footwear including a sole structure and an upper attached to the sole structure and including at least one tessellation panel configured to define a tessellation zone along the upper. This aspect of the disclosure may include one or more of the following optional features. In some examples, the tessellation panel is aligned with a support member of the sole structure. In other implementations, the tessellation panel includes a first edge aligned with an end of the support member of the sole structure in a mid-foot region.

Referring to FIGS. <NUM>-<NUM>, an article of footwear <NUM> is provided, which includes a sole structure <NUM> and an upper <NUM> attached to the sole structure <NUM>. The article of footwear <NUM> may be divided into one or more regions. The regions may include a forefoot region <NUM>, a mid-foot region <NUM>, and a heel region <NUM>. The forefoot region <NUM> corresponds to the phalanges and the metatarsophalangeal joint (i.e., "the ball") of the foot. The mid-foot region <NUM> may correspond with an arch area of the foot, and the heel region <NUM> may correspond with rear portions of the foot, including a calcaneus bone. The footwear <NUM> may further include an anterior end <NUM> associated with a forward-most point of the forefoot region <NUM>, and a posterior end <NUM> corresponding to a rearward-most point of the heel region <NUM>. 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>, as shown in <FIG>. Accordingly, the lateral side <NUM> and the medial side <NUM> respectively correspond with opposite sides of the footwear <NUM> and extend through the regions <NUM>, <NUM>, <NUM>.

With reference to <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> may be described as including a bladder <NUM> and a chassis <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>.

Generally, the bladder <NUM> of the sole structure <NUM> is supported within the heel region <NUM> of the chassis <NUM> and is configured to attenuate forces associated with impacts in the heel region <NUM>. Referring to <FIG>, the bladder <NUM> of the midsole <NUM> includes an opposing pair of barrier layers <NUM>, <NUM>, which are 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 <NUM>, <NUM> include a first, upper barrier layer <NUM> and a second, lower barrier layer <NUM>. Alternatively, the chamber <NUM> can be produced from any suitable combination of one or more barrier layers, as described in greater detail below.

In some implementations, the upper barrier layer <NUM> and the lower barrier layer <NUM> cooperate to define a geometry (e.g., thickness, width, and length) 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 <NUM>, <NUM> are not joined together and, thus, are separated from one another.

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

As best shown in <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> on opposite sides of the bladder <NUM>, which are connected (i.e., in fluid communication) with each other by one or more conduits <NUM>. When assembled to in the sole structure <NUM>, the cushions <NUM> of the chamber <NUM> are configured to be at least partially exposed along a peripheral edge of the sole structure <NUM>.

Referring still to <FIG> and now to <FIG>, each of the cushions <NUM> includes a tubular body <NUM> extending between a first terminal end <NUM> and a second terminal end <NUM>. The tubular body <NUM> defines a substantially circular cross section that extends along a longitudinal axis A<NUM> of the cushion <NUM>. As shown, the thickness T<NUM> of the tubular body <NUM> is substantially constant along the longitudinal axis A<NUM> from the first terminal end <NUM> to the second terminal end <NUM>. Here, the thickness T<NUM> of the tubular body <NUM> defines a first thickness T<NUM>-<NUM> of the chamber <NUM>.

As shown in <FIG>, the first terminal end <NUM> and the second terminal end <NUM> of each cushion <NUM> are tapered in opposite directions extending away from the tubular body <NUM> along the longitudinal axis A<NUM> of each cushion <NUM>. For example, the first terminal end <NUM> of each cushion <NUM> is formed where an end portion of the lower barrier layer <NUM> converges with and is joined to the upper barrier layer <NUM> at the peripheral seam <NUM> to enclose an anterior end of the tubular body <NUM>. As shown, a portion of the first terminal end <NUM> formed by the upper barrier layer <NUM> is substantially flat (i.e., continuous with the tubular body <NUM>), while a portion of the first terminal end <NUM> formed by the lower barrier layer <NUM> tapers or converges towards the upper barrier layer <NUM>. Referring still to <FIG>, the second terminal end <NUM> of each cushion <NUM> is formed where another end portion of the lower barrier layer <NUM> converges with and is joined to the upper barrier layer <NUM> at the peripheral seam <NUM> to enclose the opposite end of the tubular body <NUM>. As shown, a portion of the second terminal end <NUM> formed by the upper barrier layer <NUM> is substantially flat (i.e., continuous with the tubular body <NUM>), while a portion of the second terminal end <NUM> formed by the lower barrier layer <NUM> tapers or converges towards the upper barrier layer <NUM>.

As provided above, each of the cushions <NUM> defines a respective longitudinal axis A<NUM> that extends from the first terminal end <NUM> to the second terminal end <NUM>. 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 the bladder <NUM>. Accordingly, 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> such that a first one of the cushions <NUM> extends along the lateral side <NUM> and a second one of the cushions <NUM> extends along the medial side <NUM>. Furthermore, the longitudinal axes A<NUM> of the cushions <NUM> are parallel 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>.

With 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 tubular bodies <NUM> of 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>, the conduits <NUM> include a first conduit <NUM> extending between the tubular bodies <NUM> of the cushions <NUM> adjacent to the first terminal ends <NUM>, a second conduit <NUM> extending between the tubular bodies <NUM> of the cushions <NUM> adjacent to the second terminal ends <NUM>, and a third conduit <NUM> disposed between the first conduit <NUM> and the second conduit <NUM> and connecting intermediate portions of the tubular bodies <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> and <FIG>, the conduits <NUM> are defined by the cooperation of the upper barrier layer <NUM> and the lower barrier layer <NUM>. As shown in <FIG>, the upper barrier layer <NUM> and the lower barrier layer <NUM> are formed to provide a plurality of cylindrically-shaped conduits <NUM>, each having a substantially similar second thickness T<NUM>-<NUM> that is less than the thickness T<NUM>-<NUM> of the cushions <NUM>. A profile of each of the conduits <NUM> is substantially defined by the upper barrier layer <NUM> and the lower barrier layer <NUM>, whereby the upper barrier layer <NUM> and the lower barrier layer <NUM> are molded to define arcuate upper and lower portions of each conduit <NUM>. Although the lower barrier layer <NUM> is initially provided in a substantially flat state, the lower barrier layer <NUM> may bulge from the web area <NUM> when the chamber <NUM> is pressurized and the lower barrier layer <NUM> is biased apart from the upper barrier layer <NUM>, as illustrated in <FIG>.

With reference to <FIG> and <FIG>, the web area <NUM> is formed at a bonded region of the upper barrier layer <NUM> and the lower barrier layer <NUM>, and extends between and connects each of the segments <NUM>, <NUM> of the chamber <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 overall thickness T<NUM> of the fluid-filled chamber <NUM>. Optionally, the upper and lower barrier layers <NUM>, <NUM> may be joined together to form a plurality of flanges <NUM> protruding from the peripheral seams <NUM> at the terminal ends <NUM>, <NUM> of the cushions <NUM> and the conduits <NUM>. The flanges <NUM> may be used as attachment points for further securing the bladder <NUM> to the chassis <NUM>.

In the illustrated example, the web area <NUM> and the cushions <NUM> of the chamber <NUM> cooperate to define an upper pocket <NUM> on a first side of the bladder <NUM> associated with the upper barrier layer <NUM>. Here, the conduits <NUM> may be disposed within the upper pocket <NUM> to form an alternating series of bulges and recesses along a length of the upper pocket <NUM>. As described in greater detail below, the chassis <NUM> may include one or more features configured to mate with the upper pocket <NUM> when the sole structure <NUM> is assembled. For instance, the chassis <NUM> may include indentations and protrusions 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 <NUM>, <NUM>) encompasses both monolayer and multilayer films. In some embodiments, one or both of 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 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 barrier layers <NUM>, <NUM> can independently be transparent, translucent, and/or opaque. For example, the upper barrier layer <NUM> may be transparent, while the lower barrier layer <NUM> 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 <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>' - dimethyldiphenyl-<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 Mitchell et al. , <CIT>, <CIT>, the disclosures of which are incorporated by reference in their entirety. 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>, which is incorporated by reference in its entirety. In further embodiments, 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 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 chamber <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, barrier layers <NUM>, <NUM> 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. In some examples, the 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. 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 <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.

In some implementations, the upper and lower barrier layers <NUM>, <NUM> 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 <NUM> and the lower barrier layer <NUM> are joined and bonded together. In some implementations, adhesive bonding joins the upper barrier layer <NUM> and the lower barrier layer <NUM> to form the web area <NUM> and the peripheral seam <NUM>. In other implementations, the upper barrier layer <NUM> and the lower barrier layer <NUM> 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 <NUM>, <NUM> are heated to a temperature that facilitates shaping and melding. In some examples, the barrier layers <NUM>, <NUM> 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 <NUM>, <NUM>. 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 <NUM>, <NUM> 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 <NUM>, <NUM> such that pressure increases cause the barrier layers <NUM>, <NUM> 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>. As discussed below, the cradle <NUM> is configured to receive and support the bladder <NUM> within the heel region <NUM> of the cushioning element <NUM>.

The cushioning element <NUM> includes a first material, and extends continuously from a first end <NUM> at the anterior end <NUM> of the sole structure <NUM> to a second end <NUM> at the posterior end <NUM> of the sole structure <NUM>. The cushioning element <NUM> includes a top surface <NUM> extending continuously from the first end <NUM> to the second end <NUM>, which defines a footbed of the chassis <NUM>. The cushioning element <NUM> further includes a bottom surface <NUM> formed on an opposite side of the cushioning element <NUM> from the top surface <NUM>. A distance from the top surface <NUM> to the bottom surface <NUM> defines an overall thickness T<NUM> (<FIG>) of the cushioning element <NUM>. As best shown in <FIG>, <FIG> and <FIG>, the cushioning element <NUM> further includes a recessed surface <NUM> offset from the bottom surface <NUM> towards the top surface <NUM>.

As shown, the aforementioned surfaces <NUM>, <NUM>, <NUM> of the cushioning element <NUM> cooperate to define a support member <NUM> in the forefoot region <NUM> and a recess <NUM> in the heel region <NUM>. The support member <NUM> of the cushioning element <NUM> is formed between the top surface <NUM> and the bottom surface <NUM>, and extends continuously from the first end <NUM> of the cushioning element <NUM> to an end wall <NUM> in the mid-foot region <NUM>. Accordingly, the support member <NUM> provides cushioning and support characteristics of the chassis <NUM> in the forefoot region, beneath the phalanges and the ball of the foot. The end wall <NUM> extends continuously across the entire width of the cushioning element <NUM> from a first end 158a on the lateral side <NUM> to a second end 158b on the medial side <NUM>. As shown, the end wall <NUM> extends along an arcuate path from the first end 158a to the second end 158b to define a convex curvature relative to a vertical axis (i.e., perpendicular to the longitudinal and lateral axes) of the sole structure <NUM>.

A cross-sectional profile of the end wall <NUM> varies along the width of the sole structure <NUM> to provide different compression characteristics at the ends 158a, 158b of the end wall <NUM> than in an intermediate portion of the end wall <NUM>. For example, the end wall <NUM> may be substantially straight at each of the first end 158a and the second end <NUM>, whereby each end 158a, 158b is formed at an oblique angle Θ<NUM> relative to the bottom surface <NUM>. For example, each end 158a, 158b extends in a direction oriented from the top surface <NUM> to the bottom surface <NUM> and from the first end <NUM> to the second end <NUM> of the cushioning element <NUM>. The cross-sectional shape of the end wall <NUM> gradually transitions from each of the straight ends 158a, 158b to a concave intermediate portion 158c (<FIG>). The concave intermediate portion 158c may be tuned to alter cushioning properties of the support member <NUM>. Additionally, the concave intermediate portion 158c may function as a socket to receive and secure a portion of the cradle <NUM> at the end wall <NUM>.

With continued reference to <FIG>, <FIG> and <FIG>, the recess <NUM> is defined, in part, by the recessed surface <NUM>. In the illustrated example, the recess <NUM> is defined at the anterior end by the end wall <NUM> in the mid-foot region <NUM>. Accordingly, the recess <NUM> extends from the mid-foot region <NUM> through the posterior end <NUM>. A depth of the recess <NUM>, defined by the offset distance from the bottom surface <NUM> to the recessed surface <NUM>, corresponds to a height of the cradle <NUM>. When the cradle <NUM> is received within the recess <NUM>, the bottom portion of the cradle <NUM> is flush with the bottom surface <NUM> of the cushioning element <NUM> to provide a continuous support surface along the bottom of the chassis <NUM>.

The cushioning element <NUM> further includes an upper dock <NUM> disposed on the recessed surface <NUM>. Generally, the upper dock <NUM> is configured to at least partially mate with the upper pocket <NUM> formed by the upper barrier layer <NUM> of the bladder <NUM>. As shown, the upper dock <NUM> includes a plurality of upper ribs <NUM>, extending from the lateral side <NUM> to the medial side <NUM> of the cushioning element <NUM> and arranged in series along a direction from the first end <NUM> to the second end <NUM> of the cushioning element <NUM>. Each of the upper ribs <NUM> extends from the upper dock <NUM> to a distal end <NUM> facing away from the recessed surface <NUM>. Here, the upper ribs <NUM> are configured to be received in the upper pockets <NUM> and between adjacent ones of the conduits <NUM> of the bladder <NUM>. Accordingly, sides of the upper 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 upper ribs <NUM> may extend fully between the conduits <NUM>, such that the distal ends <NUM> are in contact with the top side of the web area <NUM> when the sole structure <NUM> is assembled.

As described above, the cushioning element <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 cushioning element <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 continued reference to <FIG>, the cradle <NUM> is received within the recess <NUM> of the cushioning element <NUM>, and cooperates with the cushioning element <NUM> and the outsole <NUM> to support the bladder <NUM>. In the illustrated example, the cradle <NUM> includes a top plate <NUM>, a first end support <NUM>, and a second end support <NUM> that cooperate to define a receptacle <NUM> disposed beneath the top plate <NUM>. The receptacle <NUM> is configured to receive the bladder <NUM> therein. When the sole structure <NUM> is assembled, the top plate <NUM> is received against the recessed surface <NUM> of the cushioning element <NUM>. Like the cushioning element <NUM>, the cradle <NUM> may include a resilient polymeric material, such as foam or rubber, to impart properties of cushioning, responsiveness, and energy distribution to the foot of the wearer. However, the material of the cradle <NUM> has a greater hardness and/or stiffness than the materials of the cushioning element <NUM> to provide the heel region <NUM> with a relatively rigid interface between the cushioning element <NUM> and the bladder <NUM>. For example, the material of the cradle <NUM> may have a hardness of about <NUM> Shore A while the material of the cushioning element <NUM> includes a hardness ranging from <NUM> to <NUM> Shore C.

As shown, the top plate <NUM> extends from the first end support <NUM> to the second end support <NUM> and defines an upper portion of the receptacle <NUM>. The top plate <NUM> includes a top surface 168a facing the recessed surface <NUM> of the cushioning element <NUM> and a bottom surface 168b formed on an opposite side from the top surface 168a. A distance from the top surface 168a to the bottom surface 168b defines a thickness of the top plate <NUM>, which may be substantially constant along a direction from the first end support <NUM> to the second end support <NUM>.

The bladder <NUM> may be configured to contact the cushioning element <NUM>. In one aspect of such a configuration, the top plate <NUM> includes a pair of openings <NUM> formed through the thickness of the top plate <NUM>. Each opening is configured to matingly receive a corresponding one of the upper ribs <NUM> of the upper dock <NUM> of the cushioning element <NUM>, wherein the upper ribs <NUM> are placed into contact with the web area <NUM> of the bladder <NUM> disposed between the segments <NUM>. As shown, the openings <NUM> are formed as independent openings <NUM> separated by a portion of the cradle <NUM>. Thus, where the cradle <NUM> includes materials having a greater stiffness than the materials forming the cushioning element <NUM>, the relatively stiff material of the cradle <NUM> functions as a brace to minimize deflection associated with bending and torsional forces at the base of each rib <NUM> while still allowing the softer material of the upper ribs <NUM> to compress along the height of each rib <NUM> (i.e., from the distal end <NUM> to the recessed surface <NUM>).

The first end support <NUM> of the cradle <NUM> is disposed adjacent to and faces the end wall <NUM> of the recess <NUM>, while the second end support <NUM> is disposed between the cushioning element <NUM> and the outsole <NUM> at the posterior end <NUM> of the sole structure <NUM>. Each of the end supports <NUM>, <NUM> extends from the top plate <NUM> to a respective distal end <NUM>, <NUM> that faces and attaches to the outsole <NUM>. As shown in <FIG> and <FIG>, the first end support <NUM> has a shape and cross-sectional profile configured to engage the end wall <NUM> of the support member <NUM> such that the first end support <NUM> cooperates or interfaces with end wall <NUM> to secure a position of the first end support <NUM> relative to the cushioning element <NUM>. The distal end <NUM> of the first end support <NUM> includes a lip <NUM> extending outwardly therefrom. The lip <NUM> is substantially planar and extends between the outsole <NUM> and the support member <NUM> when the sole structure <NUM> is assembled - further securing the first end support <NUM> to the cushioning element <NUM>. Furthermore, the lip <NUM> may provide a spring element at the anterior end of the cradle <NUM> by providing a responsive biasing force at the distal end <NUM> when the first end support <NUM> is compressed.

Each end support <NUM>, <NUM> includes an inner surface 184a, 184b defining opposite ends of the receptacle <NUM>. Each inner surface 184a, 184b has a concave cross-sectional shape extending across a width of the receptacle <NUM> from the lateral side <NUM> to the medial side <NUM>. The arcuate shape of each end support <NUM>, <NUM> forms a resilient structure at each end of the cradle <NUM>, which allows the end supports <NUM>, <NUM> to compress. The end supports <NUM>, <NUM> may have different radii to provide different spring rates at each end of the cradle <NUM>.

As provided above, the top plate <NUM> and the end supports <NUM>, <NUM> cooperate to define the receptacle <NUM> of the cradle <NUM> for receiving the bladder <NUM> therein. As shown, the respective edges of the plate <NUM> and the supports <NUM>, <NUM> may cooperate to define a peripheral opening <NUM> into the receptacle <NUM> on opposite sides of the cradle <NUM>. In other words, the receptacle <NUM> extends continuously through the cradle <NUM> from the lateral side <NUM> to the medial side <NUM>. The receptacle <NUM> defines an active space within which the bladder <NUM> can compress and expand. As discussed in greater detail below, the bladder <NUM> provides the majority of the support and cushioning in the heel region.

With reference to <FIG> and <FIG>, the outsole <NUM> includes an inner surface 188a facing the midsole <NUM> and an exterior surface 188b defining a ground-engaging surface of the sole structure <NUM>. The outsole <NUM> may include a lower dock <NUM> formed on the inner surface 188a, which is configured to receive a lower portion (e.g., the lower barrier layer <NUM>) of the bladder <NUM> when the sole structure <NUM> is assembled. As shown in <FIG>, a distal end surface of the lower dock <NUM> defines a recess <NUM> having a profile corresponding to the profile of the lower barrier layer <NUM> of the bladder <NUM>. Accordingly, the recess <NUM> has a profile and arrangement corresponding to the shape (e.g., elongate with rounded ends) and arrangement (e.g., converging) of the conduits <NUM> and bodies <NUM> of the cushions <NUM>. The recess <NUM> may define a pair of lower ribs <NUM> configured to oppose the upper ribs <NUM> of the upper dock <NUM>. However, unlike the upper ribs <NUM>, which extend fully between the conduits <NUM> and contact the top side of the web area <NUM>, the lower ribs <NUM> may be spaced apart from the bottom side of the web area <NUM> formed by the lower barrier layer <NUM>.

With reference now to <FIG>, <FIG>, and <FIG>, the outsole <NUM> may include a depression <NUM> formed opposite the lower dock <NUM> in the exterior surface 188b of the outsole <NUM>. Thus, the lower dock <NUM> is spaced apart from the ground surface by the depression <NUM> when the sole structure <NUM> is in an uncompressed state. In use, the web area <NUM> and the lower dock <NUM> may cooperate to provide a trampoline-like response in the heel region <NUM>.

The outsole <NUM> further includes a lower support pad <NUM> configured to cooperate with the second end support <NUM> of the cradle <NUM> to support the posterior end <NUM> of the sole structure <NUM>. As best shown in the cross-sectional view of <FIG>, the lower support pad <NUM> extends from the inner surface 188a of the outsole <NUM> and defines a cavity configured to receive the distal end <NUM> of the second end support <NUM>.

The outsole <NUM> may further include a plurality of apertures <NUM> formed through a thickness of the outsole from the inner surface 188a to the exterior surface <NUM>. When included, the apertures <NUM> may expose corresponding reliefs <NUM> formed in the bottom surface <NUM> of the support member <NUM>. The reliefs <NUM> are depressions formed in the bottom surface <NUM>. In the illustrated example, the apertures <NUM> have an obround shape and the reliefs are generally ellipsoidal. The apertures <NUM> expose the ellipsoidal reliefs <NUM> in the bottom surface <NUM>. The apertures <NUM> and the reliefs <NUM> cooperate to provide flexions along the forefoot region <NUM> and the mid-foot region <NUM>.

As set forth above, the components of the sole structure <NUM> cooperate to form a pressure-responsive shock-absorber in the heel region <NUM> of the sole structure <NUM>. Here, the tubular bodies <NUM> of the cushions <NUM> of the bladder <NUM> are supported between the bottom surface 168b of the plate <NUM> and the interior surface 188a of the outsole <NUM>, while the distal ends <NUM>, <NUM> of the cushions <NUM> taper away from the interior surface 188a of the outsole <NUM>. As best shown in <FIG> and <FIG>, the terminal ends <NUM>, <NUM> of the cushions <NUM> are spaced apart from the end supports <NUM>, <NUM> of the cradle <NUM>. Thus, as the heel region <NUM> of the sole structure <NUM> is compressed, the tubular bodies <NUM> are compressed between the plate <NUM> and the outsole <NUM>. The localized contact between the bladder <NUM>, the plate <NUM>, and the outsole <NUM> allows increased displacement of the fluid within the chamber <NUM> when the bladder <NUM> is compressed, as the distal ends <NUM>, <NUM> of the cushions <NUM> are free to expand to accommodate the displaced fluid.

In addition to the relationship between the plate <NUM> and the cushions <NUM>, the upper ribs <NUM> of the cushioning element <NUM> provide a resilient interface between the web area <NUM> of the bladder <NUM> and the cushioning element <NUM>. By forming the upper ribs <NUM> using the softer material of the cushioning element <NUM>, the upper ribs <NUM> are configured to absorb compressive forces applied by the web area <NUM> when the bladder <NUM> is compressed while still functioning to secure a position of the bladder <NUM> within the receptacle <NUM>. As provided above, the end supports <NUM>, <NUM> of the cradle <NUM> are arcuate in shape and, as such, are configured to bend or flex when the top plate <NUM> is compressed towards the outsole <NUM>. Accordingly, the upper ribs <NUM> and the end supports <NUM>, <NUM> provide supplementary support and cushioning to the bladder <NUM> in the heel region <NUM>. In some examples, the end supports <NUM>, <NUM> may be resilient structures that provide a responsive reaction to the foot after compression, similar to a spring.

While the chassis <NUM> and bladder <NUM> provide cushioning properties in the heel region <NUM>, the support member <NUM> provides cushioning and support in the forefoot region <NUM>. In some instances, the material of the cushioning element <NUM> may provide different performance characteristics than the chassis <NUM> and the bladder <NUM>. For example, the support member <NUM> may provide localized, micro-level cushioning along the forefoot region <NUM> where the foot includes more joints, while the cradle <NUM> provides more general, macro-level cushioning at the heel region <NUM> where the calcaneus bone is located.

The upper <NUM> is attached to the sole structure <NUM> and forms an enclosure having 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>. 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 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, whereby a material panel extends 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> may be further described as including 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 counter <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 counter <NUM> cooperate to form a collar <NUM>, which defines the ankle opening <NUM> of the interior void <NUM>.

The illustrated upper <NUM> includes a plurality of mid-foot tessellation panels <NUM>. <FIG> illustrates a first one of the mid-foot tessellation panels <NUM> disposed on the lateral side <NUM> of the upper <NUM>. However, the upper <NUM> may also include a mid-foot tessellation panel (not shown) on the medial side <NUM> having a mirrored geometry from the mid-foot tessellation panel <NUM> shown in <FIG>. The mid-foot tessellation panel <NUM> has the shape of a parallelogram and includes a first end <NUM> facing the anterior end <NUM> and a parallel second end <NUM> facing the posterior end <NUM>. The mid-foot tessellation panel <NUM> extends from a bottom edge <NUM> adjacent to the sole structure <NUM> at a bite-line (i.e., where the upper <NUM> and the sole structure <NUM> meet) and a top edge <NUM> adjacent to the throat <NUM>. As shown, the second end <NUM> of the mid-foot tessellation panel <NUM> is parallel to the first end 158a of the end wall <NUM> such that the second end <NUM> and the first end 158a extend at the same oblique angle Θ<NUM> relative to the bottom surface <NUM>. Optionally, the second end <NUM> of the mid-foot tessellation panel <NUM> may be collinear with the first end 158a of the end wall <NUM>. Thus, the mid-foot tessellation panel <NUM> and the end wall <NUM> may cooperate to provide targeted flexibility in the article of footwear <NUM>.

Claim 1:
A sole structure (<NUM>) for an article of footwear (<NUM>), the sole structure (<NUM>) comprising:
a cushioning element (<NUM>) including a first material, and comprising a recess (<NUM>) in a heel region (<NUM>) of the sole structure (<NUM>);
a cradle (<NUM>) including a second material, attached to the cushioning element (<NUM>), and including a top plate (<NUM>) disposed against the cushioning element (<NUM>), a first end support (<NUM>), and a second end support (<NUM>) that cooperate to define a receptacle (<NUM>) disposed beneath the top plate (<NUM>), wherein the top plate (<NUM>) extends from the first end support (<NUM>) to the second end support (<NUM>) and defines an upper portion of the receptacle (<NUM>), the first end support (<NUM>) comprising a first distal end (<NUM>) and disposed adjacent to and facing an end wall (<NUM>) of the recess (<NUM>), the first distal end (<NUM>) of the first end support (<NUM>) including a lip (<NUM>) extending outwardly therefrom, the second end support (<NUM>) disposed at a posterior end (<NUM>) of the sole structure (<NUM>);
a bladder (<NUM>) disposed within the cradle (<NUM>) between the first end support (<NUM>) and the second end support (<NUM>), the cradle (<NUM>) configured to be received within the recess (<NUM>), the receptacle (<NUM>) configured to receive the bladder (<NUM>) therein, and an upper barrier layer (<NUM>) of the bladder (<NUM>) contacting the top plate (<NUM>); and
an outsole (<NUM>) disposed adjacent to the top plate (<NUM>) on an opposite side of the cradle (<NUM>) from the cushioning element (<NUM>), the first end support (<NUM>) and the second end support (<NUM>) each contacting the outsole (<NUM>).