Patent Description:
An article of footwear typically includes a sole structure configured to be located under a wearer's foot to space the foot away from the ground. Sole structures in athletic footwear are typically configured to provide cushioning, motion control, and/or resilience.

<CIT> describes a customized shoe sole having a multi-level cushion column, which can improve impact absorption and dispersion while walking. The customized shoe sole comprises at least one multi-level cushion column including a plurality of cushion layers piled vertically, wherein at least one of the cushion layers has an elastic hardness different from those of the other layers, so as to start to be elastically deformed under a specific load condition.

<CIT> describes athletic shoes, including mid-soles. The mid-soles include independent and selectively shaped cells in cushioning units. Said cells containing unpressurized air. The cells not only act to stabilize the foot, but also to provide cushioning to protect the runner.

<CIT> describes that a Reactive Energy Fluid Filled Toroid Apparatus includes concentric fluid filled toroids that are contained in the midsole of a shoe. The toroid apparatus provides cushioning for the foot and dynamically reacts to off-center impacts from footsteps to redistribute impact forces and to stabilize and support the foot by cradling a portion of the foot in the shoe.

<CIT> describes that a bladder which is particularly useful for a sole assembly of a shoe is formed of multiple layers of barrier film to provide multiple pressurized layers of cushioning fluid or gas when the bladder is filled.

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

Various footwear sole structures with midsole systems are disclosed, each with multiple cushioning layers configured to work together as a system to absorb a compressive load, such as a dynamic compressive load due to impact with the ground, in stages of progressive cushioning (referred to as staged or graded cushioning) according to the relative stiffness values of the layers. Underfoot loads are "dosed" or "staged" to the wearer, with each stage having a different effective stiffness. The progressive cushioning may be correlated with different regions of the sole structure, such as by providing an initial stiffness response in the heel region at heel impact, with a stiffness that increases as the foot moves forward to toe-off at the forefoot region. For example, the sole structure may provide first, second and third stages of compression, in order, each providing a different stiffness, with the third stage being the stiffest. Because the third stage of compression occurs after the first and second stages, it may coincide with movement of the article of footwear to a dorsiflexed position in which the wearer is near a final toe-off.

The cushioning response is therefore staged not only in relation to absorption of the initial impact force, but also in relation to the forward roll of the foot from heel to toe. In one example, the midsole system initially provides a low, linear rate of change of load to displacement (i.e., compressive stiffness), followed by a higher, possibly nonlinear rate, and then a more rapid, exponentially increasing rate. The sole structure provides the graded cushioning while being lightweight and flexible. Moreover, various embodiments may exhibit an unloading behavior (i.e., behavior when the dynamic compressive force is removed) that provides significant energy return.

Referring to the drawings wherein like reference numbers refer to like components throughout the views, <FIG> shows an article of footwear <NUM>. The article of footwear <NUM> includes a sole structure <NUM> and an upper <NUM> secured to the sole structure <NUM>. The upper <NUM> is configured to receive and retain a foot <NUM> so that the foot <NUM> is supported on the sole structure <NUM> with the sole structure <NUM> positioned below the foot <NUM>, and between the foot <NUM> and the ground, which is represented by a ground surface G. As discussed herein, the sole structure <NUM> includes a midsole system <NUM> that has multiple cushioning units <NUM>, each cushioning unit having multiple cushioning layers disposed relative to one another such that the midsole system <NUM> absorbs a dynamic compressive load (such as due to impact with the ground) in stages of progressive cushioning in a sequence according to the relative stiffness of the cushioning layers. As used herein, "stiffness" of a cushioning layer is the ratio of change in compressive load (e.g., force in Newtons) to displacement of the cushioning layer (e.g., displacement in millimeters along the axis of the compressive load). An outsole <NUM> is secured to the midsole system <NUM> as described herein. <FIG> is a bottom view of the midsole system <NUM>, with the outsole <NUM> removed. <FIG> shows that the midsole system <NUM> has eight cushioning units 19A, 19B, 19C, 19D, 19E, 19F, <NUM>, <NUM>. The cushioning units 19A-<NUM> are referred to with reference numeral <NUM> when discussing features common to each of the cushioning units 19A-<NUM>. In the embodiment of <FIG>, each of the cushioning units 19A-<NUM> is in fluid communication with each of the other cushioning units via channels <NUM> that interconnect the respective second cushioning layer <NUM> of adj acent ones of the cushioning units. As further discussed herein, the fluid interconnection allows gas within the second sealed chambers <NUM> of the fluidly-interconnected cushioning units <NUM> in the heel region to be displaced to the cushioning units in the midfoot region and, if interconnected, to the forefoot region following, for example, a heel strike, increasing stiffness of the midfoot and forefoot cushioning units as the foot rolls forward to toe-off. In other embodiments shown and discussed herein, some or all of the cushioning units <NUM> may instead be fluidly-isolated from some or all of the other cushioning units.

With reference to <FIG> and <FIG>, a single one of the cushioning units <NUM> of the midsole system <NUM> is shown. The cushioning unit <NUM> includes a first cushioning layer <NUM>, a second cushioning layer <NUM>, and a third cushioning layer <NUM>. As is evident in <FIG> and <FIG>, the third cushioning layer <NUM> extends in a forefoot region <NUM>, a midfoot region <NUM>, and a heel region <NUM> of the midsole system <NUM>. The midfoot region <NUM> is between the heel region <NUM> and the forefoot region <NUM>. As is understood by those skilled in the art, the forefoot region <NUM> generally underlies the toes and metatarsal-phalangeal joints of an overlying foot <NUM>. The midfoot region <NUM> generally underlies the arch region of the foot <NUM>. The heel region <NUM> generally underlies the calcaneus bone. The first cushioning layer <NUM>, the second cushioning layer <NUM>, and the third cushioning layer <NUM> are stacked with the second cushioning layer <NUM> partially overlying the first cushioning layer <NUM>, and the third cushioning layer <NUM> overlying the second cushioning layer <NUM> when the article of footwear <NUM> is worn on a foot <NUM> so that the sole structure <NUM> is disposed with the third cushioning layer <NUM> nearest the foot <NUM> and the first cushioning layer <NUM> nearest the ground surface G, such as when the outsole <NUM> is in contact with the ground surface G. The first cushioning layer <NUM> includes a ground-facing outer surface <NUM> of the midsole system <NUM>, and the third cushioning layer <NUM> includes a foot-facing outer surface <NUM> of the midsole system <NUM>. The ground-facing outer surface <NUM> is a domed lower surface of the cushioning unit <NUM>. As is apparent in <FIG>, the first cushioning layer <NUM> underlies the second cushioning layer <NUM>, and the domed lower surface <NUM> extends away from the second cushioning layer <NUM>. The second cushioning layer <NUM> is annular and borders a central portion of the first cushioning layer <NUM> (i.e., the portion between the phantom lines <NUM> of <FIG>, as discussed herein.

The midsole system <NUM> includes a first polymeric sheet <NUM>, a second polymeric sheet <NUM>, and a third polymeric sheet <NUM>. The first cushioning layer <NUM> is formed by the first and second polymeric sheets <NUM>, <NUM>, which form and define a first sealed chamber <NUM> bounded by the first polymeric sheet <NUM> and the second polymeric sheet <NUM>. The second cushioning layer <NUM> is formed by the second polymeric sheet <NUM> and the third polymeric sheet <NUM>, which form and define a second sealed chamber <NUM> bounded by the second polymeric sheet <NUM> and the third polymeric sheet <NUM>.

The first, second, and third polymeric sheets <NUM>, <NUM>, <NUM> are a material that is impervious to gas, such as air, nitrogen, or another gas. This enables the first sealed chamber <NUM> to retain a gas at a first predetermined pressure, and the second sealed chamber <NUM> to retain a gas at a second predetermined pressure. A third cushioning layer <NUM> of the midsole system <NUM> is removed in <FIG>. <FIG> shows the same portion of the sole structure <NUM> as <FIG>, but with the third cushioning layer <NUM> included. Having the first sealed chamber <NUM> of the cushioning unit <NUM> shown not in fluid communication with the first sealed chamber <NUM> of any of the other cushioning units <NUM> or with the second sealed chamber <NUM> or chambers of the same or other cushioning units <NUM> allows separate, discrete, first sealed chambers <NUM> to be optimized in geometry and pressure for various areas of the foot. For example, the cushioning units <NUM> can be customized in number, size, location, and fluid pressure for a foot map of pressure loads of a specific wearer, or for a population average of wearers of the particular size of footwear. Separate cushioning units <NUM> also enhance flexibility of the midsole system <NUM> as areas between the cushioning units <NUM> are of reduced thickness, as is apparent in the side view of <FIG>, and thus reduce bending stiffness of the midsole system <NUM>. For example, areas of webbing (also referred to herein as bonds), best shown in <FIG>, where the first and second polymeric sheets <NUM>, <NUM> are bonded to one another between the domed first chambers <NUM> of adjacent cushioning units <NUM>, are of reduced thickness. The areas between cushioning units <NUM> function as flex grooves and can be disposed at desired flex regions of the midsole system <NUM>. In <FIG>, channels <NUM> are shown that connect the second chambers <NUM> of each cushioning units <NUM> for fluid communication with one another.

The polymeric sheets <NUM>, <NUM>, <NUM> can be formed from a variety of materials including various polymers that can resiliently retain a fluid such as air or another gas. Examples of polymer materials for polymeric sheets <NUM>, <NUM>, <NUM> include thermoplastic urethane, polyurethane, polyester, polyester polyurethane, and polyether polyurethane. Moreover, the polymeric sheets <NUM>, <NUM>, <NUM> can each be formed of layers of different materials. In one embodiment, each polymeric sheet <NUM>, <NUM>, <NUM> is formed from thin films having one or more thermoplastic polyurethane layers with one or more barrier layers of a copolymer of ethylene and vinyl alcohol (EVOH) that is impermeable to the pressurized fluid contained therein as disclosed in <CIT>. Each polymeric sheet <NUM>, <NUM>, <NUM> may also be formed from a material that includes alternating layers of thermoplastic polyurethane and ethylene-vinyl alcohol copolymer, as disclosed in <CIT> and <CIT>. Alternatively, the layers may include ethylene-vinyl alcohol copolymer, thermoplastic polyurethane, and a regrind material of the ethylene-vinyl alcohol copolymer and thermoplastic polyurethane. The polymeric sheets <NUM>, <NUM>, <NUM> may also each be a flexible microlayer membrane that includes alternating layers of a gas barrier material and an elastomeric material, as disclosed in <CIT> and <CIT> Additional suitable materials for the polymeric sheets <NUM>, <NUM>, <NUM> are disclosed in <CIT> and <CIT>. Further suitable materials for the polymeric sheets <NUM>, <NUM>, <NUM> include thermoplastic films containing a crystalline material, as disclosed in <CIT> and <CIT>, and polyurethane including a polyester polyol, as disclosed in <CIT>, <CIT>, and <CIT>. In selecting materials for the polymeric sheets <NUM>, <NUM>, <NUM>, engineering properties such as tensile strength, stretch properties, fatigue characteristics, dynamic modulus, and loss tangent can be considered. The thicknesses of polymeric sheets <NUM>, <NUM>, <NUM> can be selected to provide these characteristics.

The first and second sealed chambers <NUM>, <NUM> are not in fluid communication with one another. Stated differently, the first and second sealed chambers <NUM>, <NUM> are sealed from one another by the second polymeric sheet <NUM>. This allows the first and second sealed chambers <NUM>, <NUM> to retain gas at different pressures. The first sealed chamber <NUM> retains gas at a first predetermined pressure when the midsole system <NUM> in an unloaded state, and the second sealed chamber <NUM> retains gas at a second predetermined pressure in the unloaded state. The unloaded state is the state of the midsole system <NUM> when it is not under either steady state or dynamic loading. For example, the unloaded state is the state of the midsole system <NUM> when it is not bearing any loads, such as when it is not on the foot <NUM>. The second predetermined pressure can be different than the first predetermined pressure. In the embodiment shown, the second predetermined pressure is higher than the first predetermined pressure. In one non-limiting example, the first predetermined pressure is <NUM> Pa (<NUM> pounds per square inch (psi)), and the second predetermined pressure is <NUM> Pa (<NUM> psi). The predetermined pressures may be inflation pressures of the gas to which the respective sealed chambers <NUM>, <NUM> are inflated just prior to finally sealing the chambers <NUM>, <NUM>. The lowest one of the predetermined pressures, such as the first predetermined pressure, may be ambient pressure rather than an inflated pressure. The different cushioning units <NUM> can have different pressures in their respective first sealed chambers <NUM>, as the first sealed chambers <NUM> are not in fluid communication with one another. For example, pressures of the first sealed chambers <NUM> of cushioning units <NUM> in the heel region <NUM> can be lower than pressures in the midfoot region <NUM> and/or the forefoot region <NUM>.

In the embodiment shown, the third cushioning layer <NUM> is foam. By way of non-limiting example, the foam of the third cushioning layer <NUM> may be at least partially a polyurethane foam, a polyurethane ethylene-vinyl acetate (EVA) foam, and may include heat-expanded and molded EVA foam pellets.

The first cushioning layer <NUM> has a first stiffness K1 that is determined by the properties of the first and second polymeric sheets <NUM>, <NUM>, such as their thicknesses and material, and by the first predetermined pressure in the first sealed chamber <NUM>. The second cushioning layer <NUM> has a second stiffness K2 that is determined by the properties of the second and third polymeric sheets <NUM>, <NUM>, such as their thicknesses and material, and by the second predetermined pressure in the second sealed chamber <NUM>. The third cushioning layer <NUM> has a third stiffness K3 that is dependent on the properties of the foam material, such as the foam density. The stiffness K1, K2, and/or K3 need not be linear throughout a stage of compression. For example, the stiffness K3 of the third cushioning layer may increase exponentially with displacement.

A dynamic compressive load on the sole structure <NUM> is due to an impact of the article of footwear <NUM> with the ground, as indicated by a footbed load FL of a person wearing the article of footwear <NUM> and an opposite ground load GL. The footbed load FL is shown in <FIG> as a series of arrows acting on the foot-facing outer surface <NUM>, and the ground load GL is shown as a series of arrows acting on a ground contact surface <NUM> of the outsole <NUM>. The footbed load FL is represented by all of the downward arrows on the foot-facing outer surface <NUM>. The ground load GL is represented by all of the upward arrows on the ground contact surface <NUM>. The dynamic compressive load is absorbed by the first cushioning layer <NUM>, the second cushioning layer <NUM>, and the third cushioning layer <NUM> of a particular cushioning unit <NUM> in a sequence according to increasing magnitudes of the first stiffness K1, the second stiffness K2, and the third stiffness K3 from least stiff to most stiff. In the embodiment shown, the stiffness of the cushioning layers <NUM>, <NUM>, <NUM> increase in the following order: first stiffness K1, third stiffness K3, and second stiffness K2, and the dynamic compressive load is thus absorbed by the cushioning layers in the following order: first cushioning layer, <NUM>, third cushioning layer <NUM>, and second cushioning layer <NUM> but any combination of relative pressures is possible.

The second polymeric sheet <NUM> and the third polymeric sheet <NUM> are bonded to one another between the first sealed chamber <NUM> and the third cushioning layer <NUM> at a bond <NUM> (also referred to herein as webbing) having an outer periphery <NUM> with a closed shape. In the embodiment shown, the closed shape is substantially circular, as best shown in the bottom view of <FIG>, where the bond <NUM> is visible through the first polymeric sheet <NUM>. The polymeric sheets are indicated as substantially transparent. Alternatively, any or all of the polymeric sheets could instead be opaque. The second sealed chamber <NUM> borders the outer periphery <NUM> of the bond <NUM>. All three of the first polymeric sheet <NUM>, the second polymeric sheet <NUM>, and the third polymeric sheet <NUM> are bonded to one another at a peripheral flange <NUM> at an outer periphery of the midsole system <NUM> as shown in <FIG>. The bond <NUM> is disposed substantially level with an uppermost extent <NUM> of the second sealed chamber <NUM> when the sole structure <NUM> is unloaded, as indicated in <FIG> and <FIG>. At the time of bonding the second and third polymeric sheets <NUM>, <NUM> at the bond <NUM>, all of the polymeric sheets <NUM>, <NUM>, <NUM>, are in the initial, flat stacked state. The bond <NUM> can be positioned at the uppermost extent <NUM> of the second sealed chamber <NUM> by inflating the second sealed chamber <NUM> prior to inflation of the first sealed chamber <NUM>, and at a higher inflation pressure than the first sealed chamber <NUM>. When inflation occurs in this order with these relative inflation pressures, the bond <NUM> will roll upward from a position substantially level with the flange <NUM> to the position shown in <FIG> and <FIG> as the first sealed chamber <NUM> is inflated and sealed. The third cushioning layer <NUM> is thereafter bonded to the upper surface <NUM> of the third polymeric sheet <NUM>.

With the bond <NUM> disposed substantially level with an uppermost extent <NUM> of the second sealed chamber <NUM>, a relatively flat upper surface <NUM> is presented to the third cushioning layer <NUM> at the uppermost extent <NUM> of the second cushioning layer <NUM>. This helps to enable a relatively flat foot-facing outer surface <NUM> of the midsole system <NUM> if such is desired. For example, the cushioning unit <NUM> illustrated in <FIG> and <FIG> extends generally the width of the footbed at a heel portion <NUM> of the sole structure <NUM>, as is evident in <FIG>. Because the bond <NUM> is higher than the flange <NUM>, there is no depression or central cavity between the uppermost extent <NUM> and a top surface of the bond <NUM>. In other embodiments, the bond <NUM> need not be level with the uppermost extent <NUM>, in which case a cavity between the bond and the uppermost extent <NUM> can be left as a void at ambient pressure under the third cushioning layer <NUM>, or can be filled by the third cushioning layer <NUM>.

Although the bond <NUM> is shown as substantially circular, in other embodiments, the closed shape may be substantially oval, or may be an equilateral polygon, such as a substantially triangular bond or a substantially rectangular. It should be appreciated that each of the closed shapes may have rounded corners. Equilateral closed shapes are relatively easy to dispose closely adjacent to one another in various orientations to cover select portions of a midsole. Each bond is surrounded at an outer periphery by an annular second cushioning layer having substantially the same shape as the bond which it surrounds. A bond that has any of these closed shapes also enables the first polymeric sheet <NUM> to have a ground-facing outer surface <NUM> that is a domed lower surface such as shown in <FIG>. The unrestrained portion of the first sealed chamber <NUM> tends to adopt the domed shape due to the force of the internal gas pressure on the inner surfaces of the polymeric sheets <NUM>, <NUM> bounding the first sealed chamber <NUM>.

Selection of the shape, size, and location of various bond portions of a midsole, such as the midsole system <NUM>, enables a desired contoured outer surface of the finished midsole system. Prior to bonding at the bond <NUM>, at the flange <NUM>, and at the bond <NUM> discussed below, the polymeric sheets <NUM>, <NUM>, <NUM> are stacked, flat sheets. Anti-weld material may be ink-jet printed at all selected locations on the sheets where bonds are not desired. For example, the anti-weld material may be printed on both sides of the second polymeric sheet <NUM> and/or on the upper surface of the first polymeric sheet <NUM>, and the upper surface of the second polymeric sheet <NUM>. The stacked, flat polymeric sheets are then heat pressed to create bonds between adjacent sheets on all adjacent sheet surfaces except for where anti-weld material was applied. No radio frequency welding is necessary.

Once bonded, the polymeric sheets <NUM>, <NUM>, <NUM> remain flat, and take on the contoured shape only when the chambers <NUM>, <NUM> are inflated and then sealed. The polymeric sheets <NUM>, <NUM>, <NUM> are not thermoformed. Accordingly, if the inflation gas is removed, and assuming other components are not disposed in any of the sealed chambers, and the polymeric sheets are not yet bonded to other components such as the outsole <NUM> or the cushioning layer <NUM>, the polymeric sheets <NUM>, <NUM>, <NUM> will return to their initial, flat state. The outsole <NUM> is bonded to the ground-facing outer surface <NUM> by adhesive or otherwise only after inflation and sealing of the first sealed chamber <NUM>.

In the embodiment shown in <FIG>, the second sealed chamber <NUM> is an annulus (i.e., is substantially annular) that has the equilateral shape of the bond <NUM> that it borders. In the embodiment of <FIG>, the second chamber <NUM> is a ring-shaped annulus (i.e., generally toroidal). A bond that has one of the closed shapes discussed herein enables the ground-facing outer surface <NUM> of the underlying first polymeric sheet <NUM> to adopt a domed shape that is substantially centered under the bond, as shown by the domed ground-facing outer surface <NUM> (also referred to as a domed lower surface <NUM> or domed portion <NUM>) centered under bond <NUM> and extending away from the second and third cushioning layers <NUM>, <NUM>. The domed lower surface <NUM> is thus also centered under and stabilized by the higher pressure second sealed chamber <NUM> of the second cushioning layer <NUM>, which borders and surrounds the outer periphery <NUM> of the bond <NUM>. A domed ground-facing outer surface provides a relatively large amount of vertical displacement of the first cushioning layer <NUM> under dynamic compression in comparison to a flat lower surface, prolonging the stage of load absorption by the first cushioning layer <NUM>. The first stage of compression is represented by portion <NUM> of the load versus displacement curve <NUM> of <FIG> that represents the absorption of the dynamic compressive load by the first cushioning layer <NUM> with the first stiffness K1, which, in the embodiment of <FIG> and <FIG> is the least stiff cushioning layer.

With reference to <FIG>, a central portion of the first sealed chamber <NUM> directly underlies the third cushioning layer <NUM> as a bond <NUM> and a peripheral portion of the first sealed chamber <NUM> directly underlies a portion of the second sealed chamber <NUM>. The central portion is between lines <NUM> and the peripheral portion is outward of lines <NUM>. The first polymeric sheet <NUM> and the second polymeric sheet <NUM> are bonded to one another at a bond <NUM> along an outer peripheral portion <NUM> of an underside <NUM> of the second sealed chamber <NUM>. Accordingly, the first sealed chamber <NUM> underlies the second sealed chamber <NUM> only inward of the outer peripheral portion <NUM> (i.e., only inward of the phantom lines <NUM>). The portion of the second sealed chamber <NUM> overlying the first sealed chamber <NUM> is the annular portion between the phantom lines <NUM> and <NUM>. The bond <NUM> reduces the height of the first sealed chamber <NUM> under the bond <NUM> to height H1, which is lower in comparison to a height that would exist if the first and second polymeric sheets <NUM>, <NUM> were bonded to one another only at the flange <NUM>. A reduced height of the first sealed chamber <NUM> may enhance the stability of the first cushioning layer <NUM> in that it may minimize tilting or tipping of the domed ground-facing outer surface <NUM> during compression. By varying the size of the bond <NUM>, the height H1 and thus the amount of displacement available in compression of the first cushioning layer <NUM> can be tuned, affecting the domain of the low rate portion <NUM> of the load versus displacement curve <NUM> (i.e., the displacement over which the low rate portion <NUM> extends).

As discussed, the second sealed chamber <NUM> directly overlies only the peripheral portion of the first sealed chamber <NUM>. The peripheral portion is the ring-shaped portion between the phantom lines <NUM> and <NUM>. The third cushioning component <NUM> directly overlies only a remaining central portion of the first sealed chamber <NUM>, i.e., that portion between (inward of) the phantom lines <NUM>. With this relative disposition of the cushioning layers <NUM>, <NUM>, <NUM>, the first cushioning layer <NUM> absorbs the dynamic compressive load in series with the second cushioning layer <NUM> and the third cushioning layer <NUM> at the peripheral portion of the first sealed chamber <NUM> (the portion between phantom lines <NUM> and <NUM>), and the first cushioning layer <NUM> absorbs the dynamic compressive load in parallel with the second cushioning layer <NUM> and in series with the third cushioning layer <NUM> at the central portion of the first sealed chamber <NUM> (the portion between the phantom lines <NUM>). As used herein, a cushioning layer directly overlies another cushioning layer when it is not separated from the cushioning layer by a cushioning portion of an intervening cushioning layer (i.e., a foam portion or a gas-filled sealed chamber). A bond that separates cushioning layers, such as bond <NUM>, is not considered a cushioning portion of a cushioning layer. Accordingly, cushioning layers are considered to directly overlie one another when separated only by a bond. The first sealed chamber <NUM> directly underlies the bond <NUM> and the third cushioning layer <NUM> directly overlies the bond <NUM>. The third cushioning layer <NUM> directly overlies the remaining portion of the first sealed chamber <NUM> as it is separated from the remaining portion of the first sealed chamber <NUM> only by bond <NUM> and not by the second sealed chamber <NUM>.

As described, the second cushioning layer <NUM> is disposed at least partially in series with the first cushioning layer <NUM> relative to a dynamic compressive load FL, GL applied on the midsole system <NUM>. More specifically, the first cushioning layer <NUM> and the second cushioning layer <NUM> are in series relative to the load FL, GL between the phantom lines <NUM> and <NUM>. The third cushioning layer <NUM> is disposed at least partially in series with the first cushioning layer <NUM> and at least partially in series with the second cushioning layer <NUM> relative to the dynamic compressive load FL, GL. More specifically, the third cushioning layer <NUM> is directly in series with the first cushioning layer <NUM> inward of the phantom lines <NUM>. The first cushioning layer <NUM>, the second cushioning layer <NUM>, and the third cushioning layer <NUM> are in series relative to the dynamic compressive load FL, GL between the phantom lines <NUM> and <NUM>. The third cushioning layer <NUM> is in series with the first cushioning layer <NUM> but not the second cushioning layer <NUM> between the phantom lines <NUM>. The third cushioning layer <NUM> is in series with the second cushioning layer <NUM> but not the first cushioning layer <NUM> outward of the phantom lines <NUM>.

The outsole <NUM> is secured to the domed lower surface <NUM> of the first polymeric sheet <NUM>. The outsole <NUM> includes a central lug <NUM> substantially centered under the domed lower surface <NUM> of the first polymeric sheet <NUM> and serving as ground contact surface <NUM>. The outsole <NUM> also includes one or more side lugs <NUM> disposed adjacent the central lug <NUM>, i.e., surrounding the central lug <NUM> and further up the sides of the domed ground-facing outer surface <NUM>. The side lugs <NUM> are shorter than the central lug <NUM>, and are configured such that they are not in contact with (i.e., are displaced from) the ground surface G when the sole structure <NUM> is unloaded, or is under only a steady state load or a dynamic compressive load not sufficiently large to cause compression of the first sealed chamber <NUM> to the state of <FIG>. The lugs <NUM>, <NUM> may be an integral portion of the outsole <NUM> as shown in <FIG> and <FIG>. In an alternative embodiment of a sole structure 12A shown in <FIG>, an outsole 20A has a central lug 60A and side lugs 62A not integrally formed with but secured to the outsole 20A so that the outsole 20A with the lugs 60A, 62A functions as a unitary component and in a manner substantially the same as outsole <NUM> and lugs <NUM>, <NUM>.

The width W1 of the central lug <NUM> at the ground contact surface G is less than a width W2 of the domed lower surface <NUM> of the first polymeric sheet <NUM>. Because the central lug <NUM> rests on the ground surface G, the reaction load (ground load GL) of the dynamic compressive load on the midsole system <NUM> is initially applied through the central lug <NUM> toward a center of the domed lower surface <NUM> of the first polymeric sheet <NUM> where the maximum available displacement of the first sealed chamber <NUM> exists (i.e., at the greatest height H1 of the first sealed chamber <NUM>). Because the central lug <NUM> is not as wide as the first sealed chamber <NUM>, the first sealed chamber <NUM> may compress around the central lug <NUM>.

The material of the outsole <NUM> in the embodiment shown has a fourth stiffness K4 (i.e., compressive stiffness) that is greater than the first stiffness K1 of the first cushioning layer <NUM>, and may be more or less stiff than either or both of the second stiffness K2 of the second cushioning layer <NUM> and the third stiffness K3 of the third cushioning layer <NUM>. For example, the outsole <NUM> could be polymeric foam, such as injected foam. In the embodiment shown, the fourth stiffness K4 is greater than the first stiffness K1, the second stiffness K2, and the third stiffness K3.

With reference to <FIG>, the stages of absorption of the dynamic compressive load FL, GL, represented by the footbed load FL and the ground load GL, are schematically depicted assuming that the first stiffness K1 of the first cushioning layer <NUM> is less than the second stiffness K2 of the second cushioning layer <NUM>, and the third stiffness K3 of the third cushioning layer <NUM> is greater than the first stiffness K1 and less than the second stiffness K2. When the sole structure <NUM> initially receives the dynamic compressive load FL, GL, a first stage of compression I occurs, in which the least stiff first cushioning layer <NUM> is the first to compress, and compresses around the lug <NUM>, changing the shape of the first sealed chamber <NUM> and compressing the gas in the first sealed chamber <NUM> such that the overall volume of the first sealed chamber <NUM> reduces relative to the state shown in <FIG> and <FIG>. The first stage of compression I is represented in <FIG>. Compression of the second sealed chamber <NUM>, the third cushioning layer <NUM>, and the outsole <NUM> in the first stage of compression I, either does not occur or is only minimal. In the first stage of compression I shown in <FIG>, the compression of the first sealed chamber <NUM> moves the side lugs <NUM> level with the central lug <NUM>, causing the side lugs <NUM> to now form part of the ground contact surface <NUM> over which the ground load GL is spread, such that the ground contact surface <NUM> is larger in area compared to the steady-state loading of <FIG> and <FIG>. The midsole system <NUM> has an effectively linear stiffness during the first stage of compression I, as represented by the portion <NUM> of the stiffness curve <NUM>, with a numerical value substantially equal to the first stiffness K1.

In the second stage of compression II, shown in <FIG>, the third cushioning layer <NUM> begins compressing, as indicated by the decreased thickness of the third cushioning layer <NUM> in comparison to <FIG>. Compression of the first sealed chamber <NUM> of the first cushioning layer <NUM> may continue in series with compression of the third cushioning layer <NUM> in the second stage of compression II, assuming that the first cushioning layer <NUM> has not reached its maximum compression under the dynamic compressive load. The midsole system <NUM> has an effective stiffness during the second stage of compression II that is a dependent upon the third stiffness K3, and may be partially dependent on the first stiffness K1. The effective stiffness of the midsole system <NUM> during the second stage of compression II is represented by the portion <NUM> of the stiffness curve <NUM> in <FIG>.

In the third stage of compression III, shown in <FIG>, the second cushioning layer <NUM> begins compressing by compression of the gas in the second sealed chamber <NUM>. If compression of the first sealed chamber <NUM> has not yet reached its maximum compression under the dynamic compressive load, then compression of the first sealed chamber <NUM> will continue in series with the second cushioning layer <NUM>, such as in the volume between phantom lines <NUM> and <NUM>, and in parallel with the second cushioning layer <NUM> in the volume between lines <NUM>. If compression of the third cushioning layer <NUM> has not already reached its maximum under the dynamic compressive load in the second stage II, then compression of the third cushioning layer <NUM> will continue during the third stage III in series with compression of the second cushioning layer <NUM> and in series with compression of the first cushioning layer <NUM>, assuming compression of the first cushioning layer <NUM> has not already reached its maximum under the dynamic compressive load. The stiffness K4 of the outsole <NUM> can be selected such that compression of the outsole <NUM> will not begin until after the third stage of compression III.

The midsole system <NUM> has an effective stiffness in the third stage of compression III that corresponds mainly with the relatively stiff second cushioning layer <NUM>. Sealed chambers of compressible gas tend to quickly ramp in compression in a non-linear manner after an initial compression. The effective stiffness of the midsole system <NUM> during the third stage of compression III is dependent upon the second stiffness K2, potentially to a lesser extent in part on the first stiffness K1 (if the first sealed chamber <NUM> continues compressing in series and/or parallel with the second sealed chamber <NUM>), and potentially to a lesser extent in part on the third stiffness K3 (if the foam of the cushioning layer <NUM> continues compressing in series and/or parallel with the second sealed chamber <NUM>). The effective stiffness of the midsole system <NUM> during the third stage of compression III is represented by the portion <NUM> of the stiffness curve <NUM> in <FIG>. Because the third stage of compression III occurs after the first and second stages, it may coincide with movement of the article of footwear <NUM> to a dorsiflexed position in which an athlete is nearing a final toe-off position (i.e., when completing a forward step or stride just prior to the article of footwear being lifted out of contact with the ground). Greater compressive stiffness may be desirable at toe off to provide the athlete with a sensation of connection to the ground, in comparison to at the initial impact when energy absorption and isolation from the ground is most desirable.

Additionally, because in the embodiment shown, the second sealed chambers <NUM> of each of the cushioning units 19A-<NUM> are in fluid communication with one another, compression of the second sealed chamber <NUM> of the rearmost cushioning unit 19A in the heel region <NUM> can displace gas forward to the second sealed chamber <NUM> of the adjacent cushioning unit 19B, then to cushioning unit 19C, and so on forward to cushioning unit <NUM>. The advancement of the displaced gas is encouraged by the natural rolling of the foot <NUM> forward from heel to toe. Accordingly, by the time of toe-off, the pressures in the second sealed chambers <NUM> of the forward-most cushioning units, such as <NUM>, 19E, and <NUM>, are greater than the initial pressure of the second sealed chamber <NUM> of the rearmost cushioning unit 19A, supporting the foot during toe-off, and effectively returning energy from the heel strike at the forefoot.

As best shown in <FIG> and <FIG>, the third cushioning layer <NUM> overlays all of the various cushioning units. The cushioning layer <NUM> acts as a carrier that effectively holds the cushioning units relative to one another. More specifically, the cushioning layer <NUM> has a lower surface <NUM> that has a plurality of recesses <NUM> shaped such that the cushioning units 19A-<NUM> are nested in the third cushioning layer <NUM>, each at a respective recess <NUM>. The cushioning units 19A-<NUM> are only partially nested in the cushioning layer <NUM>, with the portion above the flange <NUM> in the respective recess <NUM>. The cushioning units 19A-<NUM> can be secured to the cushioning layer <NUM> in the recesses <NUM> such as with adhesive or by thermal bonding. The third cushioning layer <NUM> may also have small channel recesses interconnecting the recesses <NUM> and receiving the channels <NUM> of <FIG>, or the channels <NUM> may be un-nested, just below the lower surface <NUM> of the third cushioning layer <NUM>.

<FIG> shows an example of a third cushioning layer 26A for use with a midsole system <NUM> including multiple cushioning units <NUM>, not being part of the claimed invention but useful for the understanding of the claimed invention. The third cushioning layer 26A includes a plurality of recesses 27A, 27B at a lower surface <NUM> for receiving and partially nesting the cushioning units <NUM>. The recess 27A are peripheral recesses, located adjacent a periphery <NUM> of the third cushioning layer 26A, which is also the periphery of the sole structure <NUM>. The periphery <NUM> has a medial periphery 29A, and a lateral periphery 29B. The recesses 27B are central recesses, disposed inward relative to the peripheral recesses 27A so that the peripheral recesses 27A are between the periphery <NUM> and the central recesses 27B. In an embodiment, cushioning units <NUM> disposed in the peripheral recesses 27A are each fluidly isolated from each other one of the cushioning units <NUM>. In contrast the cushioning units <NUM> disposed in the central recesses 27B may be in fluid communication with one another via channels <NUM>, and are referred to as interconnected cushioning units. Such an arrangement enables each peripheral cushioning unit (i.e., the isolated cushioning units <NUM> disposed at the peripheral recesses 27A) to maintain a stiffness response independent of the progression of foot loading. For example, each peripheral cushioning unit may be configured and pressurized to provide a relatively stiff response, providing stability to discourage overpronation and/or underpronation (supination). The interconnected, central cushioning units <NUM> disposed at the central recesses 27B would allow gas to be displaced amongst the second sealed chambers <NUM> of the respective central cushioning units, which may provide energy return by utilizing the pressure at more rearward units, which may be subjected to loading prior to the more forward central units, to add stiffness to the more forward units via the added pressure of the transferred gas.

<FIG> show one example of a midsole system 18A with a group of interconnected cushioning units <NUM>, referred to with reference numbers 19A1, 19B1, and 19C1. Each of the cushioning units is identical to cushioning unit <NUM> shown and described with respect to <FIG>. The second sealed chambers <NUM> of the respective cushioning units are fluidly connected with one another by fluid channels <NUM> formed by and between the second and third polymeric sheets <NUM>, <NUM>. In the embodiments shown, dual channels <NUM> are shown between the cushioning units 19A1, 19B1, 19C1. As is evident in <FIG> not being part of the claimed invention but useful for the understanding of the claimed invention, the domed lower surfaces <NUM> of the respective cushioning units 19A1, 19B1, 19C1 protrude and extend away from the second sealed chambers <NUM>. Additional channels 43A, 43B in communication with the second sealed chamber <NUM> of the cushioning unit 19A1 are shown with a seal <NUM>, closing off the interconnected cushioning units 19A1, 19B1, 19C1, so that no other cushioning units can communicate with those of the interconnected cushioning units 19A1, 19B1, 19C1.

<FIG> show another example of a midsole system <NUM> for a sole structure of an article of footwear. The midsole system <NUM> comprises a plurality of cushioning units <NUM> as described with respect to <FIG>. The cushioning units <NUM> are all interconnected cushioning units as they are effectively interconnected with one another via the channels <NUM> shown between various adjacent cushioning units <NUM>. Only some of the cushioning units <NUM> and channels <NUM> are labelled for clarity in the drawings.

The midsole system <NUM> also comprises two sets of linking chambers 51A, 51B. The linking chambers 51A link (i.e., fluidly-connect) the second sealed chambers <NUM> of at least some of the laterally-surrounding cushioning units <NUM>. Stated differently, for each linking chamber 51A, at least some of the interconnected cushioning units <NUM> laterally surround the linking chamber 51A. The respective second sealed chamber <NUM> of each of these laterally-surrounding interconnected cushioning units <NUM> is in fluid communication with the linking chamber 51A via a respective channel <NUM>. The linking chambers 51A do not have the bond <NUM> between the second polymeric sheet <NUM> and the third polymeric sheet <NUM>, so they create upward-extending domes <NUM> at the upper surface <NUM> of the third polymeric sheet <NUM>, as best seen in the perspective view of <FIG> not being part of the claimed invention but useful for the understanding of the claimed invention. The domes <NUM> extend above the remainder of the upper surface <NUM>.

The linking chambers 51B link (i.e., fluidly-connect) the first sealed chambers <NUM> of at least some of the laterally-surrounding cushioning units <NUM>. Stated differently, for each linking chamber 51B, at least some of the interconnected cushioning units <NUM> laterally surround the linking chamber 51B. The respective first sealed chamber <NUM> of each of these laterally-surrounding, interconnected cushioning units <NUM> is in fluid communication with the linking chamber 51B via a respective channel 43B. The linking chambers 51B create downward-extending domes <NUM> at the lower surface <NUM> of the first polymeric sheet <NUM>, as best seen in the <FIG> not being part of the claimed invention but useful for the understanding of the claimed invention. The domes <NUM> extend generally in a similar manner as the domed lower surfaces <NUM> of the linked, laterally surrounding cushioning units <NUM>.

The linking chambers 51A permit the second chambers <NUM> of the laterally surrounding cushioning units <NUM> to more quickly and evenly distribute and react to a compressive load on any one or more of the linked, laterally surrounding chambers <NUM>. Similarly, the linking chambers 51B permit the first chambers <NUM> of the laterally surrounding cushioning units <NUM> to more quickly and evenly distribute and react to a compressive load on any one or more of the linked, laterally surrounding chambers <NUM>.

<FIG> shows another example of a sole structure <NUM> for an article of footwear not being part of the claimed invention but useful for the understanding of the claimed invention. The sole structure <NUM> includes a midsole system <NUM> that comprises a plurality of cushioning units <NUM> as described with respect to <FIG>. The plurality of cushioning units <NUM> include both fluidly isolated cushioning units 19P, and different groups of interconnected cushioning units 19Q and 19R. The cushioning units 19P, 19Q, and 19R are referred to with reference numeral <NUM> when discussing features common to each of the cushioning units 19A-<NUM>. Each of the cushioning units <NUM> is partially nested in a respective recess of an overlaying third cushioning layer 26B, as discussed with respect to cushioning layers <NUM> and 26A. More specifically, the plurality of cushioning units include multiple isolated cushioning units 19P each disposed adjacent a periphery <NUM> of the sole structure <NUM>, and each fluidly-isolated from all other ones of the plurality of cushioning units <NUM>. A first group of interconnected cushioning units 19R and a second group of interconnected cushioning units 19Q are disposed inward of the isolated cushioning units 19P relative to the periphery <NUM>. Stated differently, the multiple isolated cushioning units 19P are disposed between the periphery <NUM> and the interconnected sets of cushioning units 19Q, 19R. By isolating each peripheral cushioning unit 19P, each peripheral cushioning unit 19P can maintain a stiffness response independent of the progression of foot loading. For example, each peripheral cushioning unit 19P may be configured and pressurized to provide a relatively stiff response, providing stability to discourage overpronation and/or underpronation (supination).

The first group of interconnected cushioning units 19R is in the forefoot region <NUM>, and each are interconnected via channels <NUM> and linking chambers 51A, 51B as described with respect to <FIG>, so that all of the first chambers <NUM> are fluidly connected, and all of the second chambers <NUM> are fluidly connected. The first group of interconnected cushioning units 19R extend only in the forefoot region <NUM>, and can be tuned with inflation pressures in the linked first chambers <NUM>, and the linked second chambers <NUM> suitable for toe-off.

The second group of interconnected cushioning units 19Q is disposed in the heel region <NUM> and the midfoot region <NUM> and each is fluidly-isolated from the first group 19R and from the peripheral cushioning units 19P. The cushioning units 19Q are interconnected via channels <NUM> and linking chambers 51A, 51B as described with respect to <FIG>, so that all of the first chambers <NUM> are fluidly connected, and all of the second chambers <NUM> are fluidly connected. The interconnected cushioning units 19Q of the second group are arranged in a serpentine shape. The serpentine shape may also be referred to as an "S" shape. The serpentine shape winds from the rearmost unit 19Q1 forward toward the lateral side at unit 19Q2, then forward toward the medial side at unit 19Q3, then finally back toward the center at unit 19Q4 in progressing forward from the heel region, tracking the loading pattern of a typical foot strike and forward roll. The loading pattern of the foot roll can push some of the gas in the respective sealed chambers <NUM>, <NUM> of the second group of cushioning units 19Q from the heel toward the midfoot, allowing the pressure at the heel <NUM> at impact to be lower than the loaded pressure of the midfoot <NUM> in the same interconnected chambers <NUM>, <NUM>.

<FIG> show another embodiment of a sole structure <NUM> that includes a midsole system <NUM> comprising a plurality of cushioning units <NUM> each described as described with respect to <FIG>. As shown in <FIG>, each cushioning unit <NUM> is partially nested in a recess <NUM> in the bottom surface of the cushioning layer <NUM> as described herein. As shown in the bottom view of the midsole system <NUM> in <FIG> (with the layer <NUM> removed), each cushioning unit <NUM> is shown fluidly isolated from each other cushioning unit. However, some or all of the cushioning units may be interconnected by channels <NUM> and/or linking chambers, as described herein.

The sole structure <NUM> includes an additional cushioning layer <NUM> underlying the plurality of cushioning units <NUM>. The additional cushioning layer <NUM> may be another layer of the midsole system, or may be an outsole, or a combination of a midsole layer and an outsole. As shown, the cushioning layer <NUM> serves as an outsole, and forms the ground contact surface <NUM>. The additional cushioning layer <NUM> includes a plurality of stanchions <NUM> extending generally upward from a base <NUM> of the cushioning layer <NUM>. The stanchions <NUM> are spaced apart from one another in correspondence with relative spacing of the cushioning units <NUM> such that the stanchions <NUM> can interface with the cushioning units <NUM> in a one-to-one ratio. Stated differently, the stanchions <NUM> are paired with the cushioning units <NUM>. Each stanchion <NUM> may be generally round in cross-section perpendicular to its length. The center 72C of each stanchion may be hollowed out, as shown in <FIG> in order to reduce weight.

Each stanchion <NUM> interfaces with the domed lower surface <NUM> of a respective one of the plurality of cushioning units <NUM>. Each stanchion <NUM> has a concave upper surface <NUM> (also referred to herein as the stanchion interface area) that cups at least a portion of the domed lower surface <NUM> of the respective one of the plurality of cushioning units <NUM>. Under compressive loading of a cushioning unit <NUM>, the domed lower surface <NUM> of the first cushioning layer <NUM> is compressed against the stanchion <NUM>.

The stanchions <NUM> are configured to affect the cushioning response of the sole structure <NUM> as the foot strikes with an impact in the heel region <NUM>, and the wearer's weight moves forward from heel to toe. For example, the stanchions <NUM> decrease in height from the heel region to the forefoot region, as shown in <FIG>. In other words, the stanchions <NUM> in the heel region <NUM> extend further from the base <NUM> than those in the midfoot region <NUM> and the forefoot region <NUM>. The stanchions <NUM> also increase in width, at least in width relative to the width of the overlying cushioning unit <NUM> or both, from the heel region <NUM> to the forefoot region <NUM>. Generally, a narrower stanchion <NUM> relative to a domed lower surface <NUM> of a cushioning unit <NUM> will allow more of the first cushioning layer <NUM> to collapse over the stanchion <NUM> under compressive loading, isolating loading to the first cushioning layer for a greater range of displacement (compression) than a wider stanchion. Assuming the first cushioning layer <NUM> is less stiff than the second cushioning layer <NUM>, a narrower stanchion relative to the domed lower surface may provide a softer (less stiff) initial loading response. Similarly, a shorter stanchion <NUM>, such as in the forefoot region <NUM>, allows less displacement of the cushioning unit <NUM> prior to the domed lower surface <NUM> of the cushioning unit bottoming out relative to the stanchion, providing a stiffer initial loading response relative to a taller stanchion.

The interface area of the stanchion <NUM> (i.e., the surface <NUM> where it contacts and cups the domed lower surface <NUM>) to the total area of the domed lower surface <NUM> governs how the first cushioning layer <NUM> can deform (compress). Generally, a larger ratio of the area of surface <NUM> to the total area of the domed lower surface <NUM> (i.e., a larger ratio of the interface area to total area) results in a stiffer response of the cushioning unit <NUM> by minimizing the ability of the first cushioning layer <NUM> to deform over the stanchion <NUM>. In one or more embodiments, a ratio of stanchion interface area <NUM> to total area of the domed lower surface <NUM> for each of the plurality of cushioning units <NUM> may be greater on average for the forefoot cushioning units (i.e., the four cushioning units <NUM> furthest to the right in <FIG>) interfacing with the forefoot stanchions <NUM> than for the heel cushioning units interfacing with the heel stanchions <NUM>. Accordingly, the less stiff first cushioning layer <NUM> affects cushioning over a greater range of displacement in the heel region <NUM> than in the forefoot region <NUM>, providing a relatively stiffer response in the forefoot region, as is appropriate for supporting toe-off.

The increase in compressive force with vertical displacement of the sealed chambers <NUM> by the corresponding stanchions <NUM> (i.e., stiffness) in the heel region <NUM> is illustrated in <FIG>, in the midfoot region in <FIG>, and in the forefoot region in <FIG> illustrates that the relatively tall stanchions and low ratio of interface area <NUM> to total area of the cushioning unit <NUM> results in a relatively low, linear stiffness for a relatively large amount of vertical displacement in the heel region. The nonlinear portion of the curve in <FIG> begins when the cushioning units <NUM> bottom out against the base <NUM>. <FIG> illustrates that the somewhat shorter and wider stanchions <NUM> in the midfoot region <NUM> result in a quicker transition to a higher, nonlinear stiffness in the midfoot region <NUM> than in the heel region <NUM>. <FIG> illustrates that the nearly one-to-one ratio of the interface area <NUM> and domed surface <NUM> results in a fast-loading, energy efficient linear stiffness greater than the stiffness of the linear portion of the stiffness in the heel region and midfoot region, as is appropriate for toe-off. In a nonlimiting example, the stanchions <NUM> can be <NUM> diameter at the rear of the heel region <NUM>, while the cushioning units <NUM> are <NUM> in diameter. The width of the stanchions gradually progress to <NUM> in the midfoot region <NUM>, and then to <NUM> in the forefoot region <NUM>. The cushioning units <NUM> may be smaller in diameter in the forefoot region <NUM>, such as <NUM> to match the diameter of the overlying cushioning unit <NUM> supported thereon.

<FIG> shows a sole layer <NUM> included in the sole structure <NUM> of the article of footwear <NUM> of <FIG> not being part of the claimed invention but useful for the understanding of the claimed invention. The sole structure <NUM> comprises a midsole system <NUM> having a bladder <NUM> comprising four stacked polymeric sheets <NUM>, <NUM>, <NUM>, <NUM> bonded to one another and defining a first cushioning layer <NUM>, a second cushioning layer <NUM>, and a third cushioning layer (i.e., the sole layer <NUM>), each cushioning layer comprising a sealed chamber retaining gas in isolation from each other sealed chamber. The four stacked polymeric sheets include a first polymeric sheet <NUM>, a second polymeric sheet <NUM>, a third polymeric sheet <NUM>, and a fourth polymeric sheet <NUM>. The first cushioning layer <NUM> is formed by the first and second polymeric sheets <NUM>, <NUM>, which form and define a first sealed chamber <NUM> bounded by the first polymeric <NUM> and the second polymeric sheet <NUM>. The second polymeric sheet <NUM> and the third polymeric sheet <NUM> form and define a second sealed chamber <NUM> bounded by the second polymeric sheet <NUM> and the third polymeric sheet <NUM>. The third cushioning layer <NUM> includes a third sealed chamber <NUM> that is formed, defined, and bounded by the third polymeric sheet <NUM> and the fourth polymeric sheet <NUM>. The first, second, third, and fourth polymeric sheets <NUM>, <NUM>, <NUM>, and <NUM> are a material that is impervious to gas, such as air, nitrogen, or another gas. This enables the first sealed chamber <NUM> to retain a gas at a first predetermined pressure, the second sealed chamber <NUM> to retain a gas at a second predetermined pressure, and the third sealed chamber <NUM> to retain a gas at a third predetermined pressure.

The sole layer <NUM> overlies the bladder <NUM> and is configured with a bottom surface <NUM> having an outer peripheral portion <NUM> and a central portion <NUM> surrounded by the outer peripheral portion <NUM>. As shown in <FIG>, the outer peripheral portion <NUM> extends around the front, the rear, the medial side, and the lateral side of the sole layer <NUM>, and completely surrounds the central portion <NUM>. The central portion <NUM> is recessed in the bottom surface <NUM> further than the outer peripheral portion <NUM>, such that a ridge <NUM> generally defines a boundary between the portions <NUM>, <NUM>. An insole <NUM> overlies the sole layer <NUM>, and a footwear upper <NUM> is secured to the sole structure <NUM>.

As shown in <FIG>, the outer peripheral portion <NUM> is mated with an upper surface <NUM> of bladder <NUM> in an unloaded state of the sole structure <NUM>, and the central portion <NUM> is at least partially spaced apart from the upper surface <NUM> of the bladder <NUM> in the unloaded state of the sole structure <NUM>. Stated differently, the outer peripheral portion <NUM> of the surface <NUM> has a complete and constant interface with the entire area of the outer peripheral portion of the bladder <NUM> (i.e., is geometrically "keyed" to the corresponding outer peripheral portion of the bladder <NUM>), while the central portion <NUM> is not keyed to the bladder. This configuration allows greater displacement of the bladder <NUM> relative to the central portion <NUM> than the outer peripheral portion <NUM> prior to compression of the bladder <NUM> under a compressive load on the sole structure <NUM>. Compression of the outer peripheral portion <NUM>, by contrast, begins immediately under a compressive load due to the keyed outer peripheral portion <NUM>. An immediate, relatively high stiffness may thus be achieved at the outer peripheral portion <NUM>, in order to provide stability to counteract foot tendencies for overpronation and supination.

Because the central portion <NUM> is not keyed to the bladder <NUM>, one or more gaps <NUM> exist between the top surface <NUM> of the bladder <NUM> and the central portion <NUM> of the surface <NUM> of the sole layer <NUM>. This allows some vertical displacement of the sole layer <NUM> and the bladder <NUM> relative to one another under a compressive load, as shown in <FIG>. The central portion <NUM> may achieve a softer (less stiff) initial cushioning response as the sole structure <NUM> initially compresses until the top surface <NUM> of the bladder <NUM> conforms to the central portion <NUM> of the bottom surface <NUM> of the sole layer <NUM> after the initial stage of compressive loading, presenting an initially soft ride (low stiffness) to the overlying central portion of the foot.

The sole structure <NUM> also includes an underlying sole layer <NUM>, such as an outsole or an additional midsole layer, which underlies the bladder <NUM>. In the embodiment shown, the sole layer <NUM> is an outsole. An upper surface <NUM> of the underlying sole layer is mated with a bottom surface <NUM> of the bladder <NUM> in both the unloaded state and under compressive loading of the sole structure <NUM>.

<FIG> shows a midsole system <NUM> for an exemplary sole structure for an article of footwear not being part of the claimed invention but useful for the understanding of the claimed invention. The midsole system <NUM> has a first cushioning unit 519A and a second cushioning unit 519B. Each of the cushioning units 519A, 519B is identical to the cushioning unit <NUM> shown and described with respect to <FIG>, with the outsole <NUM> being optional. Moreover, each of the cushioning units is connected to other cushioning units. For example, the first cushioning unit 519A is connected to cushioning units 519C and 519D, and may be in fluid communication with either of both of cushioning units 519C, 519D. <FIG> is a fragmentary view of the midsole system <NUM>, and other cushioning units may also be connected to cushioning unit 519A. The second cushioning unit 519B is connected to cushioning units 519E and 519F, and may be in fluid communication with either of both of cushioning units 519E, 519F. <FIG> is a fragmentary view of the midsole system <NUM>, and other cushioning units may also be connected to cushioning unit 519B.

As described with respect to cushioning unit <NUM>, each cushioning unit 519A, 519B includes a first, a second, and a third polymeric sheet, indicated as sheets 32A, 34A, and 36A for the first cushioning unit 519A, and sheets 32B, 34B, and 36B for the second cushioning unit 519B. The first cushioning unit 519A comprises a first cushioning layer 22A that includes a first sealed chamber 38A, and a second cushioning layer 24A that includes a second sealed chamber 40A. The first sealed chamber 38A and the second sealed chamber 40A each retain gas in isolation from one another. The second cushioning unit 519B comprises a first cushioning layer 22B that includes a first sealed chamber 38B, and a second cushioning layer 24B that includes a second sealed chamber 40B. The first sealed chamber 38B and the second sealed chamber 40B each retain gas in isolation from one another. As described herein with respect to cushioning unit <NUM>, the first cushioning layer 22A, 22B of each cushioning unit 519A, 519B has a domed surface 28A, 28B extending away from the respective second cushioning layer 24A, 24B, and the second cushioning layer 24A, 24B is annular and borders a central portion of the first cushioning layer 22A, 22B.

The first cushioning unit 519A is inverted and the second cushioning unit 519B is stacked on the inverted first cushioning unit 519A such that the first cushioning layer 22A of the first cushioning unit 519A interfaces with and underlies the first cushioning layer 22B of the second cushioning unit 519B. More specifically, the domed surface 28A of the first cushioning unit 519A (now an upper surface, as the first cushioning unit 519A is inverted) interfaces with the domed lower surface 28B of the second cushioning unit 519B. The cushioning units 519A, 519B are thus disposed in an inverted relationship to one another. The cushioning units 519C, 519E, and the cushioning units 519D and 519F interface in a like manner. In embodiments in which the first cushioning layers 22A, 22B are less stiff than the second cushioning layers 24A, 24B, such as when the pressure of the gas in the first sealed chambers 38A, 38B of the respective first cushioning layers 22A, 22B are less than the pressure of the gas in the second sealed chambers 40A, 40B of the respective second cushioning layers 24A, 24B in an unloaded state of the midsole system <NUM>, stacking the cushioning units 519A, 519B so that the least stiff first cushioning layers 22A, 22B interface with one another will effectively allow a greater range of displacement of the sole structure in an initial (first) stage of compression that is affected only by the least stiff first cushioning layers 22A, 22B than if a stiffer layer were disposed vertically between the first cushioning layers 22A, 22B.

<FIG> shows another example of a midsole system <NUM> for a sole structure for an article of footwear with vertically stacked cushioning units not being part of the claimed invention but useful for the understanding of the claimed invention. The midsole system <NUM> has a first cushioning unit 619A and a second cushioning unit 619B. Each of the cushioning units 619A, 619B has four polymeric sheets, three cushioning layers, and three sealed chambers, constructed identically to those of the bladder <NUM> shown and described with respect to <FIG>. More specifically, each cushioning layer 619A and 619B includes the four stacked polymeric sheets. The four stacked polymeric sheets 432A, 434A, 436A, 437A of the first cushioning unit 619A are bonded to one another and defining a first cushioning layer 422A, a second cushioning layer 424A, and a third cushioning layer 426A, each cushioning layer comprising a sealed chamber 438A, 440A, 441A, respectively, retaining gas in isolation from each other sealed chamber. The four stacked polymeric sheets 432B, 434B, 436B, 437B of the second cushioning unit 619B are bonded to one another and defining a first cushioning layer 422B, a second cushioning layer 424B, and a third cushioning layer 426B, each cushioning layer comprising a sealed chamber 438B, 440B, 441B, respectively, retaining gas in isolation from each other sealed chamber. <FIG> is a fragmentary view of the midsole system <NUM>.

The first cushioning unit 619A is inverted and the second cushioning unit 619B is stacked on the inverted first cushioning unit 619A such that the first cushioning layer 422A of the first cushioning unit 619A interfaces with and underlies the first cushioning layer 422B of the second cushioning unit 619B. More specifically, the surface 428A of the first cushioning unit 619A interfaces with the surface 428B of the second cushioning unit 619B. The cushioning units 619A, 619B are thus disposed in an inverted relationship to one another. In embodiments in which the first cushioning layers 422A, 422B are less stiff than the second cushioning layers 424A, 424B, such as when the pressure of the gas in the first sealed chamber 438A, 438B of the respective first cushioning layer 422A, 422B is less than the pressure of the gas in the respective second sealed chamber 440A, 440B of the second cushioning layers 424A, 424B in an unloaded state of the midsole system <NUM>, stacking the cushioning units 519A, 519B so that the least stiff first cushioning layers 422A, 422B interface with one another will effectively allow a greater range of displacement of the midsole system <NUM> in an initial (first) stage of compression that is affected only by the least stiff first cushioning layers 422A, 422B than if a stiffer layer were disposed vertically between the first cushioning layers 422A, 422B.

<FIG> show polymeric sheets <NUM>, <NUM>, <NUM> with patterns of anti-weld material <NUM> disposed on the sheets. The pattern 711A is disposed on the top surface of the first sheet <NUM>. The pattern 711B is disposed on both upper and lower surfaces of the second sheet <NUM>. The pattern 711C is disposed on the lower surface of the third sheet <NUM>. If the sheets are then stacked in order of sheets <NUM>, <NUM>, <NUM>, with sheet <NUM> at the bottom, the sheets <NUM>, <NUM>, <NUM> will bond to one another in all adjacent surfaces not covered with the anti-weld material <NUM>. The patterns 711A, 711B, 711C will result in a series of the cushioning units <NUM> with the domed lower surfaces <NUM>. The channels <NUM> on the lower sheet <NUM> indicate that the first chambers <NUM> of the resulting cushioning units <NUM> will be in fluid communication. The channels <NUM> on the third sheet <NUM> indicate that the second chambers <NUM> of the resulting cushioning units will be in fluid communication. Only some of the channels <NUM> are labeled in the drawings.

In one non-limiting example, the various embodiments of midsoles disclosed herein may provide energy return from about <NUM>% to about <NUM>%, when energy return is measured as the percent restoration of initial drop height of an impact tester, or is measured with a mechanical tester such as an INSTRON® tester available from Instron Corporation, Norwood Massachusetts.

Assembled, ready to wear footwear articles (e.g., shoes, sandals, boots, etc.), as well as discrete components of footwear articles (such as a midsole, an outsole, an upper component, etc.) prior to final assembly into ready to wear footwear articles, are considered and alternatively referred to herein in either the singular or plural as "article(s) of footwear" or "footwear".

As used in the description and the accompanying claims, unless stated otherwise, a value is considered to be "approximately" equal to a stated value if it is neither more than <NUM> percent greater than nor more than <NUM> percent less than the stated value.

Those having ordinary skill in the art will recognize that terms such as "above", "below", "upward", "downward", "top", "bottom", etc., may be used descriptively relative to the figures.

The term "longitudinal" refers to a direction extending a length of a component. For example, a longitudinal direction of an article of footwear extends between a forefoot region and a heel region of the article of footwear. The term "forward" or "anterior" is used to refer to the general direction from a heel region toward a forefoot region, and the term "rearward" or "posterior" is used to refer to the opposite direction, i.e., the direction from the forefoot region toward the heel region. In some cases, a component may be identified with a longitudinal axis as well as a forward and rearward longitudinal direction along that axis. The longitudinal direction or axis may also be referred to as an anterior-posterior direction or axis.

The term "transverse" refers to a direction extending a width of a component. For example, a transverse direction of an article of footwear extends between a lateral side and a medial side of the article of footwear. The transverse direction or axis may also be referred to as a lateral direction or axis or a mediolateral direction or axis.

The term "vertical" refers to a direction generally perpendicular to both the lateral and longitudinal directions. For example, in cases where a sole structure is planted flat on a ground surface, the vertical direction may extend from the ground surface upward. It will be understood that each of these directional adjectives may be applied to individual components of a sole structure. The term "upward" or "upwards" refers to the vertical direction pointing towards a top of the component, which may include an instep, a fastening region and/or a throat of an upper. The term "downward" or "downwards" refers to the vertical direction pointing opposite the upwards direction, toward the bottom of a component and may generally point towards the bottom of a sole structure of an article of footwear.

Claim 1:
A sole structure (<NUM>) for an article of footwear comprising:
a midsole system (<NUM>) including a plurality of cushioning units (<NUM>), each cushioning unit (<NUM>) including:
a first cushioning layer (<NUM>) comprising a first sealed chamber (<NUM>); and
a second cushioning layer (<NUM>) comprising a second sealed chamber (<NUM>), the first sealed chamber (<NUM>) and the second sealed chamber (<NUM>) each retaining gas in isolation from one another;
wherein the first cushioning layer (<NUM>) underlies the second cushioning layer (<NUM>) and has a domed lower surface (<NUM>) extending away from the second cushioning layer (<NUM>);
wherein the sole structure (<NUM>) further comprises an additional cushioning layer (<NUM>) underlying the plurality of cushioning units (<NUM>);
wherein the additional cushioning layer (<NUM>) includes a plurality of stanchions (<NUM>);
wherein each stanchion (<NUM>) interfaces with the domed lower surface (<NUM>) of a respective one of the plurality of cushioning units (<NUM>); and
wherein at least some of the plurality of stanchions (<NUM>) have concave upper surfaces (<NUM>) each of which cups at least a portion of the domed lower surface (<NUM>) of the respective one of the plurality of cushioning units (<NUM>).