Patent Description:
Sole structures generally include a layered arrangement extending between a ground surface and the upper. One layer of the sole structure includes an outsole that provides abrasion-resistance and traction with the ground surface. The outsole may be formed from rubber or other materials that impart durability and wear-resistance, as well as enhance traction with the ground surface. Another layer of the sole structure includes a midsole disposed between the outsole and the upper. The midsole provides cushioning for the foot and is generally at least partially formed from a polymer foam material that compresses resiliently under an applied load to cushion the foot by attenuating ground-reaction forces. The midsole may define a bottom surface on one side that opposes the outsole and a footbed on the opposite side that may be contoured to conform to a profile of the bottom surface of the foot. Sole structures may also include a comfort-enhancing insole and/or a sockliner located within a void proximate to the bottom portion of the upper.

High-intensity interval training (HIIT) workouts alternate bouts of going all-out with periods of rest to recover. The movements are diverse - burpees, kettlebell swings, lunges, mountain climbers, push-ups, squats and many more - and are sequenced to get maximum impact from maximum effort. In HIIT workout classes, athletes typically wear footwear that is optimized for cushioning or footwear that is optimized for support. Unfortunately, such footwear, while adequate for its intended purpose (i.e., cushioning or support), isn't designed to concurrently provide both benefits and, as a result, do not perform optimally during HIIT movements.

<CIT> describes a sole structure with plates and an intervening fluid-filled bladder and a method of manufacturing.

The subject matter of the claimed invention is defined in the independent claim. Specific embodiments are defined in the dependent claims.

One aspect of the disclosure includes an article of footwear. The article of footwear includes an upper. The article of footwear also includes a plate having a top surface facing the upper and a bottom surface formed on an opposite side than the top surface, the plate extending from a first end in a forefoot region to a second end in a heel region. The article of footwear also includes a first cushioning element having an upper surface attached to the bottom surface of the plate in the forefoot region and including a first side shield extending from the upper surface and along a medial side of the upper and a second side shield extending from the upper surface and along a lateral side of the upper. The article of footwear also includes one or more fluid-filled bladders each at least partially surrounded by the first cushioning element in the forefoot region and having a top surface attached to the bottom surface of the plate.

This aspect of the disclosure may include one or more of the following optional features. In some examples, the one or more fluid-filled bladders includes a first fluid-filled bladder disposed on a medial side and a second fluid-filled bladder disposed on a lateral side. In some implementations, the first end of the plate includes a lateral portion and a medial portion separated from the lateral portion by a gap. According to the claimed invention, the first cushioning element includes one or more apertures each configured to receive a corresponding one of the one or more fluid-filled bladders.

In some examples, each of the plate and the upper are received between the first side shield and the second side shield. In some configurations, one or more fluid-filled bladders is disposed between the first side shield and the second side shield. In some implementations, the first side shield and the second side shield include an arch extending from a first end to a second end along the respective side of the article of footwear.

Optionally, the article of footwear may include a second cushioning element disposed in the heel region and spaced apart from the first cushioning element by a gap in a mid-foot region of the article of footwear. Here, the article of footwear may include an outsole having a first fragment attached to the first cushioning element, a second fragment attached to the second cushioning element, and a third fragment attached to the one or more fluid-filled bladders. In some examples, the plate includes one or more upper sockets each receiving a first end of one of the one or more bladders and the outsole includes one or more lower sockets each receiving a second end of one of the one or more bladders.

Referring to <FIG>, an article of footwear <NUM> includes an upper <NUM> and sole structure <NUM>. The footwear <NUM> may further include an anterior end <NUM> associated with a forward-most point of the footwear <NUM>, and a posterior end <NUM> corresponding to a rearward-most point of the footwear <NUM>. As shown in <FIG>, a longitudinal axis A<NUM> of the footwear <NUM> extends along a length of the footwear <NUM> from the anterior end <NUM> to the posterior end <NUM> parallel to a ground surface, and generally divides the footwear <NUM> into a medial side <NUM> and a lateral side <NUM>. Accordingly, the medial side <NUM> and the lateral 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 medial side <NUM> to the lateral 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> may be subdivided into a toe portion <NUM>T corresponding with phalanges and a ball portion <NUM>B associated with metatarsal bones of a foot. The mid-foot region <NUM> may correspond with an arch area of the foot, and the heel region <NUM> may correspond with rear portions of the foot, including a calcaneus bone.

The upper <NUM> includes interior surfaces that define an interior void <NUM> configured 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 form the interior void <NUM>. Suitable materials of the upper <NUM> 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 reference to <FIG>, in some examples, the upper <NUM> includes a strobel having a bottom surface opposing the sole structure <NUM> and an opposing top surface defining a footbed of the interior void <NUM>. Stitching or adhesives may secure the strobel to the upper <NUM>. The footbed may be contoured to conform to a profile of the bottom surface (e.g., plantar) of the foot. Optionally, the upper <NUM> may also incorporate additional layers such as an insole or sockliner that may be disposed upon the strobel and reside within the interior void <NUM> of the upper <NUM> to receive a plantar surface of the foot to enhance the comfort of the article of footwear <NUM>. An ankle opening <NUM> in the heel region <NUM> may provide access to the interior void <NUM>. For example, the ankle opening <NUM> may receive a foot to secure the foot within the void <NUM> and to facilitate entry and removal of the foot from and to the interior void <NUM>. In some examples, one or more fasteners <NUM> extend along the upper <NUM> to adjust a fit of the interior void <NUM> around the foot and to accommodate entry and removal of the foot therefrom.

Referring to <FIG>, the sole structure <NUM> includes a midsole <NUM> configured to provide characteristics of cushioning and responsiveness, and an outsole <NUM> configured to provide a ground-engaging surface to the article of footwear <NUM>. Unlike conventional midsoles formed of a single slab material, the midsole <NUM> of the present example is formed as a composite structure and includes various subcomponents configured to impart desired characteristics to the article of footwear <NUM>. For example, the midsole <NUM> includes a rigid or semi-rigid plate <NUM>, a forefoot cushioning element <NUM>, a heel cushioning element <NUM>, and a fluid cushioning arrangement <NUM> having one or more fluid-filled bladders <NUM>. Likewise, the outsole <NUM> includes a composite structure and includes a toe fragment <NUM> attached to the forefoot cushioning element <NUM> at the anterior end <NUM>, a forefoot fragment <NUM> disposed in the forefoot region <NUM> and attached to the fluid cushioning arrangement <NUM>, and a heel fragment <NUM> attached to the heel cushioning element <NUM> at the posterior end <NUM>.

With continued reference to <FIG>, the plate <NUM> includes an elastomeric material, such as a polyether block amide (PEBA) (e.g., Pebax® brand elastomers manufactured by Arkema S. The plate <NUM> extends from a first end <NUM> disposed in the forefoot region <NUM> to a second end <NUM> disposed at the posterior end <NUM>. The plate <NUM> includes a top surface 225a attached to the strobel of the upper <NUM> and bottom surface 225b formed on an opposite side of the plate <NUM> from the top surface 225a. A distance from the top surface 225a to the bottom surface 225b defines a thickness of the plate <NUM>. As shown, the first end <NUM> of the plate <NUM> may include a forked configuration where a gap or split <NUM> extends through the thickness of the plate <NUM> and partially along a length of the plate <NUM> from the first end <NUM>. Thus, the gap <NUM> separates the first end <NUM> into medial and lateral tabs 228a, 228b that can flex independently from each other. As shown in <FIG>, the medial and lateral tabs 228a, 228b may include sockets 229a, 229b on the bottom surface 225b for engaging and securing the bladders <NUM> of the fluid cushioning arrangement <NUM>.

The forefoot cushioning element <NUM> and the heel cushioning element <NUM> each 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. The forefoot cushioning element <NUM> and the heel cushioning element <NUM> may include the same or different materials to impart desired performance characteristics to the respective regions of the sole structure <NUM>. Example resilient polymeric materials for the cushioning elements <NUM>, <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 above for barrier layers. 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 adodicarbonamide, sodium bicarbonate, and/or an isocyanate.

With continued reference to <FIG>, the forefoot cushioning element <NUM> extends from a first end <NUM> at the anterior end <NUM> to a second end <NUM> disposed in the mid-foot region <NUM>. The forefoot cushioning element <NUM> includes a top surface 233a attached to the bottom surface 225b of the plate <NUM> and a bottom surface 233b disposed on the opposite side. A distance from the top surface 233a to the bottom surface 233b defines a thickness of the forefoot cushioning element <NUM>. The forefoot cushioning element <NUM> includes one or more apertures 234a, 234b formed through the entire thickness (i.e., from the top surface 233a to the bottom surface 233b), which are configured to receive each of the bladders <NUM> therein. Accordingly, when the sole structure <NUM> is assembled, the bladders <NUM> of the fluid cushioning arrangement <NUM> will be surrounded by the forefoot cushioning element <NUM>.

The forefoot cushioning element <NUM> further includes a pair of shields 235a, 235b extending upwardly from opposite sides of the forefoot cushioning element <NUM> between the first end <NUM> and the second end <NUM>. Here, each of the shields 235a, 235b is configured to extend upwardly along one of the medial and lateral sides <NUM>, <NUM> of the upper <NUM> in a portion of the forefoot region <NUM> associated with the ball of the foot, thereby providing lateral reinforcement and stability to the sides of the upper <NUM> in that region. In the illustrated example, each of the shields 235a, 235b is formed as an arched structure extending from a first end 236a, 236b to a second end 237a, 237b along the side of the forefoot cushioning element <NUM>. Here, the arched structure provides the desired lateral stability, while still allowing the sole structure <NUM> to flex suitably across the ball portion <NUM>B of the forefoot region <NUM>. As best shown in <FIG> and <FIG>, the shields 235a-235b define lateral openings 238a, 238b extending from an outer periphery of the forefoot cushioning element <NUM> and intersecting with the apertures <NUM> formed through the thickness of the forefoot cushioning element <NUM>. Thus, when the sole structure <NUM> is assembled, the bladders <NUM> may be exposed through the openings 238a, 238b formed through the forefoot cushioning element <NUM>.

Referring still to <FIG>, the heel cushioning element <NUM> is attached to a bottom surface of the plate <NUM> and extends from a first end <NUM> in the mid-foot region <NUM> to a second end <NUM> at the posterior end <NUM> of the sole structure <NUM>. As best shown in <FIG>, the first end <NUM> of the heel cushioning element <NUM> faces or opposes the second end <NUM> of the forefoot cushioning element <NUM>. However, the first end <NUM> of the heel cushioning element <NUM> is separated from the second end <NUM> of the forefoot cushioning element <NUM> by a gap <NUM> in the mid-foot region <NUM>. Here, a bottom surface of the plate <NUM> is exposed along the gap <NUM>. The gap provides stability in movements commonly associated with HIIT training exercises, such as plank positions, and allows the foot to bend naturally when driving into mountain climbers. The first end <NUM> of the heel cushioning element <NUM> may include a notch <NUM> extending along a longitudinal direction of the article of footwear <NUM>, such that the first end <NUM> is separated into medial and lateral fingers 246a, 246b that can move independently of each other.

The fluid cushioning arrangement <NUM> of the illustrated example includes a pair of bladders <NUM> each defining a respective chamber for including a pressurized fluid. A first one of the bladders <NUM> is disposed on the medial side <NUM> of the sole structure <NUM> in the forefoot region <NUM>, and a second one of the bladders <NUM> is disposed on the lateral side <NUM> of the sole structure <NUM> in the forefoot region <NUM>. As discussed above, each of the bladders <NUM> extends through one of the apertures <NUM> formed through the forefoot cushioning element <NUM> such that a top surface of each bladder <NUM> is received within one of the sockets 229a, 229b and attached to the bottom surface 225b of the plate <NUM>, and a bottom surface of each bladder <NUM> is received by a socket the forefoot fragment <NUM> of the outsole <NUM>.

Each of the bladders <NUM> may include a first barrier element 248a and a second barrier element 248b formed of an elastomeric material. The chamber of each of the bladders <NUM> may receive a tensile element <NUM> (<FIG>) therein. Each tensile element <NUM> may include a series of tensile strands <NUM> extending between an upper tensile sheet <NUM> and a lower tensile sheet <NUM>. The upper tensile sheet <NUM> may be attached to the first barrier element 248a while the lower tensile sheet <NUM> may be attached to the second barrier element 248b. In this manner, when the bladder <NUM> receives the pressurized fluid, the tensile strands <NUM> of the tensile element <NUM> are placed in tension. Because the upper tensile sheet <NUM> is attached to the first barrier element 248a and the lower tensile sheet <NUM> is attached to the second barrier element 248b, the tensile strands <NUM> retain a desired shape of the bladder <NUM> when the pressurized fluid is injected into the chamber.

With continued reference to <FIG>, the toe fragment <NUM> of the outsole <NUM> is formed of a resilient elastomeric material, and is disposed at the anterior end <NUM> of the sole structure <NUM>. The forefoot fragment <NUM> is disposed in the forefoot region <NUM> and is formed independently of each of the toe fragment <NUM> and the heel fragment <NUM>. As shown, the forefoot fragment <NUM> includes one or more sockets 256a, 256b formed in a top surface, which are configured to receive and secure a lower portion of corresponding ones of the bladders <NUM>. Thus the forefoot fragment <NUM> provides a bottom structure for securing the bladders <NUM>. In some instances, the forefoot fragment <NUM> may be formed of a material having a greater rigidity than the other fragments <NUM>, <NUM> to impart stability between the independent bladders <NUM>.

The heel fragment <NUM> extends around the heel region <NUM> and includes a first segment 258a extending along the medial side <NUM>, a second segment 258b extending along the lateral side <NUM>, and an arcuate third segment 258c extending around the posterior end <NUM>. As shown, the second segment 258b may be longer than the first segment 258a.

With particular reference to <FIG>, an article of footwear 10a is provided and includes an upper 100a and a sole structure 200a attached to the upper 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 article of footwear of <FIG>, the sole structure 200a includes a unitary midsole 202a including a single cushioning element including a foam material extending from the anterior end <NUM> to the posterior end <NUM>. Here, sole structure 200a does not include independent cushioning elements or bladders. The midsole 202a includes medial and lateral side shields 235c, 235d having a narrower profile than the side shields 235a, 235b of the previous example. In this example, the side shields 235c, 235d are formed as solid (i.e., not including openings) elements along the sides of the midsole 202a. Optionally, the midsole 202a may include arcuate relief channels 270a-270d formed in the peripheral surface of the midsole 202a on opposite ends of the side shields 235c, 235d to allow the midsole 202a to bend about the side shields 235c, 235d. Thus, the sole structure 200a is configured as a simplified, lightweight alternative to the sole structure <NUM>. The minimalistic sole structure 200a may be desirable for travel (i.e., packing in luggage) and for use in confined areas.

The upper 100a of the article of footwear 10a may include arcuate flex zones 130a, 130b partially surrounding the side shields 235c, 235d. As shown, the flex zones 130a, 130b each extend from a first one of the relief channels 130a, 130c at an anterior end of one of the side shields 235c, 235d to a second one of the relief channels 130b, 130d formed at an anterior end of the respective side shield 235c, 235d. Thus, the upper 100a cooperates with the relief channels 170a-170d to provide flexibility along the metatarsophalangeal (MTP) joint.

With particular reference to <FIG>, an article of footwear 10b is provided and includes an upper 100b and a sole structure 200b attached to the upper 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.

Referring to <FIG>, another example of an article of footwear 10b according to the principles of the present disclosure is configured for use with a bicycle. The upper 100b includes a translucent mesh material extending over the forefoot region <NUM> and along the lateral side <NUM> along the mid-foot region <NUM>. The upper 100b further includes a forefoot strap <NUM> and a mid-foot strap <NUM> each extending over the upper 100b from the medial side <NUM> to the lateral side <NUM>.

The forefoot strap <NUM> includes a medial forefoot band <NUM> attached at a biteline formed between the upper 100b and the sole structure 200b on the medial side <NUM> and a lateral forefoot band <NUM> attached at the biteline on the lateral side <NUM>. Each of the forefoot bands <NUM>, <NUM> includes a fixed end <NUM>, <NUM> attached at the biteline and a free end operable to adjustably attach to the free end of the other forefoot band <NUM>, <NUM>. As shown, the fixed ends <NUM>, <NUM> of the forefoot bands <NUM>, <NUM> are flared (i.e., increase in width along a direction towards the biteline) and include an arcuate reinforcement strip <NUM> attached to or embedded within the fixed end <NUM>, <NUM>. Thus, the fixed ends <NUM>, <NUM> of the forefoot strap <NUM> may function similar to the shields 235a, 235b discussed above to provide lateral stability along the ball region of the foot while also allowing the upper to flex or bend along the metatarsophalangeal (MTP) joint.

The mid-foot strap <NUM> includes a medial mid-foot band <NUM> and a lateral mid-foot band <NUM> cooperating to extend over the upper 100b adjacent to the ankle opening <NUM>. The medial mid-foot band <NUM> is integrally formed with the upper 100b, as shown in <FIG> and <FIG>. Thus, medial mid-foot band <NUM> extends along the medial side of the footwear and defines a medial quarter panel and a medial heel panel. When the medial mid-foot band <NUM> is attached to the lateral mid-foot band <NUM>, the medial mid-foot band <NUM> can be drawn over an instep region of the foot to adjust a size of the upper 100b and the ankle opening <NUM>. Here, the lateral mid-foot band <NUM> includes a fixed end <NUM> attached to the upper 100b on a lateral side <NUM> of the ankle opening <NUM> and a second end configured to adjustably attach to the medial mid-foot band <NUM>.

The sole structure 200b includes a forefoot plate <NUM> and a heel plate <NUM> attached to the upper 100b. The forefoot plate <NUM> includes a coupler <NUM> with SPD and Delta cleats. The forefoot plate <NUM> also includes a plurality of vents <NUM> formed through a thickness of the forefoot plate <NUM> and in communication with the interior void <NUM> of the upper <NUM> to provide ventilation to the plantar surface of the foot within the upper 100b. Each of the forefoot plate <NUM> and the heel plate <NUM> includes resilient studs <NUM> to provide traction during walking.

Claim 1:
An article of footwear (<NUM>) comprising:
an upper (<NUM>);
a plate (<NUM>) having a top surface (225a) facing the upper (<NUM>) and a bottom surface (225b) formed on an opposite side than the top surface (225a), the plate (<NUM>) extending from a first end (<NUM>) in a forefoot region (<NUM>) to a second end (<NUM>) in a heel region (<NUM>);
a first cushioning element (<NUM>) having an upper surface (233a) attached to the bottom surface (225b) of the plate (<NUM>) in the forefoot region (<NUM>) and including a first side shield (235a) extending from the upper surface (233a) and along a medial side (<NUM>) of the upper (<NUM>) and a second side shield (235b) extending from the upper surface (233a) and along a lateral side (<NUM>) of the upper (<NUM>); and
one or more fluid-filled bladders (<NUM>) each at least partially surrounded by the first cushioning element (<NUM>) in the forefoot region (<NUM>) and having a top surface attached to the bottom surface (225b) of the plate (<NUM>),
wherein the first cushioning element (<NUM>) includes one or more apertures (234a, 234b) each configured to receive a corresponding one of the one or more fluid-filled bladders (<NUM>), the one or more apertures (234a, 234b) being formed through the entire thickness, i.e., from the top surface (233a) to the bottom surface (233b).