HK1214096B - Article of footwear - Google Patents

Description

Footwear

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of priority to U.S. patent application Ser. No. 13/693,596, entitled “Article of Footwear,” filed on Dec. 4, 2012. Application No. 13/693,596 is incorporated herein by reference in its entirety.

background

Conventional footwear typically includes two main components: an upper and a sole structure. The upper provides a covering for the foot and securely positions the foot relative to the sole structure. The sole structure is secured to the lower surface of the upper and is configured to be positioned between the foot and the ground when the wearer is standing, walking, or running. The sole structure is often designed to cushion, protect, and support the foot. The sole structure may also be designed to increase traction and to help control potentially harmful foot motions, such as excessive pronation.

Many types of athletic footwear have sole structures that include a deformable midsole. The primary component of many conventional midsoles is a resilient polymer foam material that extends throughout the length of the footwear. The physical properties of the midsole often depend on the density and other properties of the polymer foam material, as well as on the spatial configuration of the midsole. By varying these factors throughout the midsole, the relative hardness, attenuation of ground reaction forces, and energy absorption properties can be modified to meet the specific requirements of the activity for which the footwear is intended to be used.

Cushioning and shock attenuation are valuable properties of sole structures. However, the components that provide these properties also tend to reduce the degree to which the shoe wearer can feel the contours and other features of the ground. This loss of sensation regarding ground features can be disadvantageous. The feel of the ground surface as perceived by the underside of a person's foot can provide useful clues about the conditions of the ground over which a person may move. For example, a runner may adjust his or her movements when sensing rough, uneven, and/or loose terrain.

Commonly owned U.S. Patent No. 6,990,755 describes an article of footwear having an articulated sole structure in which a plurality of grooves separate discrete sole elements of the midsole. The resulting sole structure helps mimic the feel of barefoot running while providing a degree of cushioning and protection to the wearer's foot. However, there remains an ongoing need for improved footwear that protects the wearer's foot while also providing a natural feel of motion and tactile feedback regarding ground conditions.

Summary of the Invention

This summary is provided to introduce selected concepts in a simplified form that are further described below in the detailed description. This summary is not intended to identify key features or essential features of the invention.

In some embodiments, an article of footwear may include an upper, an outsole, and a compressible foam midsole. The outsole may be directly bonded to an exterior surface of a lasting element of the upper. The midsole may be contained within the upper and non-destructively removable from the upper.

In some embodiments, an article of footwear may include an upper and an outsole. The outsole may include a plurality of discrete lugs distributed across a bottom outer surface of the outsole. A compressible foam midsole may be included within the upper. The midsole may be non-destructively removable from the upper and may include a plurality of raised areas on an upper surface configured to accommodate a plantar surface of a wearer's foot.

In some embodiments, an article of footwear may include an upper and an outsole bonded to the upper. The outsole may include a plurality of discrete raised portions distributed across a bottom outer surface of the outsole. Each raised portion may be separated from an adjacent raised portion by a gap region. The outsole may have a thickness in the gap region between approximately 0.5 mm and approximately 0.8 mm. The article may also include a compressible foam midsole contained within the upper.

Additional embodiments are described herein.

BRIEF DESCRIPTION OF THE DRAWINGS

In the figures of the drawings, in which like reference numerals refer to similar elements, some embodiments are illustrated by way of example and not by way of limitation.

1A and 1B are respective lateral and medial side views of an article of footwear according to some embodiments.

1C is a bottom view of the article of footwear of FIGS. 1A and 1B .

2A-2D are lateral side, medial side, front, and rear views, respectively, of the midsole of the article of footwear from Figs. 1A and IB.

2E is a bottom view of the midsole of the article of footwear from FIGS. 1A and 1B .

2F is an upper lateral front perspective view of the midsole of the article of footwear from FIGS. 1A and 1B .

3A and 3B are regional cross-sectional views taken from the positions indicated in FIG. 1A .

3C is a regional cross-sectional view similar to FIG. 3A but illustrating the shift in localized pressure.

4A and 4B are respective lateral and medial side views of an article of footwear according to some additional embodiments.

4C is a bottom view of the article of footwear of FIGS. 4A and 4B .

5A-5D are lateral side, medial side, front, and rear views, respectively, of the midsole of the article of footwear from Figs. 4A and 4B.

5E is a bottom view of the midsole of the article of footwear from FIGS. 4A and 4B .

5F is an upper lateral front perspective view of the midsole of the article of footwear from FIGS. 4A and 4B .

6A and 6B are respective lateral and medial side views of an article of footwear according to some additional embodiments.

6C is a bottom view of the article of footwear of FIGS. 6A and 6B .

7A-7D are lateral side, medial side, front, and rear views, respectively, of the midsole of the article of footwear from Figs. 6A and 6B.

7E is a bottom view of the midsole of the article of footwear from FIGS. 6A and 6B .

7F is an upper lateral front perspective view of the midsole of the article of footwear from FIGS. 6A and 6B .

DETAILED DESCRIPTION

In at least some embodiments, an article of footwear includes a thin, highly flexible outsole. The outsole can be directly bonded to the upper of the article. In certain embodiments, the outsole can be directly bonded to the underside of the upper's upper. The outsole can also include a plurality of discrete raised portions. The article can also include an inner foam midsole resting directly on the upper. In response to ground forces applied by the wearer of the article through walking, running, or other movements, each raised portion can vertically displace to apply localized pressure to the midsole. The midsole can then transfer some of this localized pressure to a localized area of the wearer's foot. Thus, the wearer can receive tactile feedback that provides information about the conditions of the ground surface on which the wearer may move. Articles of footwear according to at least some embodiments can provide the wearer with a highly specific sense of ground surface characteristics while still providing impact attenuation and other protection. As further described herein, additional features of one or more embodiments can also enhance the wearer's ability to sense the physical details of the ground surface.

The following discussion and accompanying figures describe articles of footwear according to several embodiments. Shoes according to various embodiments have configurations suitable for athletic activities such as running and cross-training. Other embodiments include footwear suitable for basketball, golf, walking, hiking, and other athletic and non-athletic activities. Therefore, those skilled in the relevant art will recognize that the concepts disclosed herein can be applied to a variety of shoe types and are not limited to the specific embodiments discussed below and depicted in the accompanying figures.

To assist and clarify the subsequent description of each embodiment, various terms are defined herein. Unless the context indicates otherwise, the following definitions apply throughout the entire specification (including the claims). "Shoe" and "article of footwear" are used interchangeably to refer to articles used to be worn on a person's foot. "Shoe" may or may not enclose the entire foot of the wearer. For example, "shoe" may include sandals or other articles that expose a large portion of the foot being worn. The "interior" of a shoe refers to the space occupied by the wearer's foot when the shoe is worn. The inside, inner surface, interior face, or other aspect of a shoe component refers to the side, surface, face, or other aspect of the component that is (or will be) oriented toward the inside of the shoe in a complete shoe. The outside, outer surface, exterior face, or other aspect of a component refers to the side, surface, face, or other aspect of the component that is (or will be) oriented away from the inside of the shoe in a complete shoe. In some cases, the inside, inner surface, interior face, or other aspect of a component may have other elements between the inside, inner surface, interior face, or other aspect and the inside of the complete shoe. Similarly, the outside, surface, exterior face, or other aspect of a component may have other elements between the outside, surface, exterior face, or other aspect of the component and the space surrounding the completed shoe exterior.

Unless the context indicates otherwise, "upper," "bottom," "above," "below," "above," "below," and similar positional terms assume that the shoe or shoe structure of interest is in the orientation that would result when the shoe (or shoe incorporating the shoe structure of interest) is in an undeformed condition with its outsole (and/or other ground-contacting sole structure elements) resting on a flat, horizontal surface. Notably, however, the term "upper" is reserved for describing the component of a shoe that at least partially covers the wearer's foot and helps secure the wearer's foot to the shoe's sole structure.

The elements of a shoe can be described based on the region and/or anatomical structure of the foot of the person wearing the shoe and by assuming that the shoe is appropriately made in a certain size for the foot to be worn. As an example, the forefoot area of the foot includes the metatarsal bones and the phalanges. The forefoot element of a shoe is an element having one or more parts positioned on, below, on the lateral side and/or medial side, and/or in the front of the wearer's forefoot (or its part) when the shoe is worn. As another example, the midfoot area of the foot includes the cuboid bone, the navicular bone, the medial cuneiform bone, the intermediate cuneiform bone and the lateral cuneiform bone and the head of the metatarsal bones. The midfoot element of a shoe is an element having one or more parts positioned on, below and/or on the lateral side and/or medial side of the wearer's midfoot (or its part) when the shoe is worn. As another example, the heel area of the foot includes the talus and the calcaneus. The heel element of a shoe is an element having one or more parts positioned on, below, on the lateral side and/or medial side and/or in the back of the wearer's heel (or its part) when the shoe is worn. The forefoot region may overlap the midfoot region, just as the midfoot region may overlap the heel region.

Unless otherwise specified, the longitudinal axis refers to the horizontal heel-toe axis along the center of the shoe and is generally parallel to a line that would follow the second metatarsal bone and the second phalange of the wearer's foot. The transverse axis refers to a horizontal axis through the shoe that is generally perpendicular to the longitudinal axis. The longitudinal direction is parallel (or generally parallel) to the longitudinal axis. The transverse direction is parallel (or generally parallel) to the transverse axis.

FIG1A and FIG1B are lateral and medial side views, respectively, of a shoe 100 according to some embodiments. Shoe 100 is a left shoe and is part of a pair of shoes that includes a right shoe (not shown) that is a mirror image of shoe 100. Shoe 100 includes an upper 101 configured to enclose and retain the foot of the wearer of shoe 100. Upper 101 and the uppers shown in the other figures are merely exemplary. Numerous additional embodiments exist in which the upper may be functionally similar to upper 101 and/or the uppers shown in the other figures, but may have a different visual appearance.

In an embodiment of the shoe 100, the upper 101 may include a lightweight mesh panel 102 and a partial liner 103. The partial liner 103 may be formed from a woven fabric material including elastic fibers. The partial liner 103 includes an ankle collar 105 that completely surrounds the wearer's foot at or above the ankle level. An opening 106 in the ankle collar 105 allows the wearer to insert the foot into the interior of the shoe 100. The ankle collar 105 and/or the partial liner 103 may provide a tight fit to the wearer's foot. In some embodiments, the ankle collar 105 and/or the partial liner 103 may include features (e.g., raised ribs, nodules, etc.) that apply localized pressure to the wearer's foot, for example, to enhance proprioception.

Mesh plate 102 covers the sides and top of the wearer's foot in the forefoot area in front of lacing gap 104. Lacing gap 104 is similar to the tongue opening in some conventional footwear designs. However, in the embodiment of shoe 100, a conventional tongue is not included. Instead, the edge of partial liner 103 is connected to mesh plate 102 at or near the edge of lacing gap 104. The other edge of the lower portion of partial liner 103, surrounding ankle collar 105, is connected to the upper edge of mesh plate 102 in the heel area of upper 101. Lace 107 is passed through a plurality of loops 108 and can be used to fasten upper 101 to the wearer's foot.

Although not visible in Figures 1A and 1B, upper 101 includes an upper element (e.g., a Strobel) that is stitched, bonded, or otherwise attached to the lower edge of mesh panel 102 and generally extends the full length and width of upper 101. The upper element forms the bottom portion of upper 101. The outer face of the upper element is directly bonded to outsole 110. As described in more detail below, outsole 110 is highly flexible and includes a plurality of raised portions 112 distributed across the bottom outer surface. As also described below, shoe 100 also includes a compressible foam midsole located within the interior of upper 101. The midsole rests directly on the inner face of the upper 101 upper element, with the upper surface of the midsole forming a footbed for the wearer of shoe 100. Outsole 110 and midsole form part of the sole structure of shoe 100. The sole structure is secured to the underside (plantar surface) of the wearer's foot when the wearer tightens the lace 107. The lower ends of the lace loops 108 may be attached to the edges of the lasting elements (and thereby extend around at least some portion under the plantar surface of the wearer's foot) so that the lace loops extend and wrap around a portion of the side and bottom of the wearer's foot.

Mesh panel 102 of upper 101 also includes a skin portion 114 bonded to the exterior of the mesh. Skin portion 114 can be formed from thermoplastic polyurethane (TPU), TPU with a polyurethane (PU) exterior, or other polymeric materials. In some embodiments, mesh panel 102 can be formed using materials and techniques such as those described in commonly-owned U.S. patent application Ser. No. 12/603,498, filed Oct. 21, 2009, and entitled “Composite Shoe Upper and Method of Making Same,” which is incorporated herein by reference in its entirety.

FIG1C is a bottom view of shoe 100 and shows additional details of the bottom exterior surface of outsole 110. Outsole 110 and the outsoles shown in the other figures are merely exemplary. There are numerous other embodiments in which the outsole may be functionally similar to outsole 110 and/or the outsoles shown in the other figures, but may have a different visual appearance.

As previously indicated, and as further illustrated in FIG1C , outsole 110 includes a plurality of raised portions 112 distributed over the outer ground-contacting area of outsole 110. In some embodiments, the raised portions are distributed over at least the forefoot area. In some embodiments, and as seen in FIG1C , the raised portions may be distributed over the forefoot area and over a substantial portion of the midfoot and heel areas. Raised portions 112 are discrete. In particular, each raised portion 112 is separated from an adjacent raised portion by a gap 116. To avoid confusion between FIG1C and text, only some of the raised portions 112 and gaps 116 are labeled in FIG1C to indicate the relative arrangement of the raised portions and gaps.

The size of the raised portion 112 can vary based on location. In addition, the height of the raised portion 112 can also vary based on location. As used herein, the "height" of a raised portion refers to the amount that the raised portion extends beyond the outer surface of the outsole 110, which forms a gap 116 around the raised portion. In some embodiments, raised portions located in areas expected to experience greater foot pressure can have a greater height than raised portions in other areas. The areas expected to experience greater pressure can vary based on the activities for which a particular shoe is intended. In at least some embodiments, such areas can include the heel area, the area of the metatarsal-phalangeal joint, and the big toe (i.e., the big toe).

In at least some embodiments, the raised portion 112 has a small cross-sectional area size relative to the area of the outsole 110 contacting the ground surface. For example, and as seen in Figure 1C, the widest part of the outsole 110 is marked "W". Approximately eight raised portions 112 fit in this widest part 112. In some embodiments, and for some or all of the raised portions 112, the maximum width of a single raised portion is approximately 0.4 inches (10.2 mm) or less. For example, in the embodiment of the shoe 100, the raised portion 112 has a square cross-section. Therefore, the maximum width of such a square raised portion is the diagonal dimension from one corner to another. In some embodiments, the maximum width of some or all of the raised portions can be smaller (e.g., approximately 0.3 inches (7.6 mm) or less, approximately 0.25 inches (6.4 mm) or less, approximately 0.15 inches (3.8 mm) or less). In other embodiments, the raised portion can also have other shapes. Some embodiments may also include an outsole comprising raised portions of varying cross-sectional shapes.

In some embodiments, and as also seen in FIG. 1C , the spacing between raised portions 112 may vary based on location. For example, the gaps 116 between the raised portions in the heel region are relatively narrow. In some embodiments, an example of such a gap width in the heel region is between approximately 0.015 inches and approximately 0.025 inches (e.g., approximately 0.02 inches). Conversely, the gaps 116 between the raised portions in each forefoot region are relatively wide. In some embodiments, an example of such a gap width in the forefoot region is between approximately 0.1 inches and approximately 0.16 inches (e.g., approximately 0.13 inches). However, these gap widths are merely examples, and in some embodiments, the gaps in these and/or other regions may have widths outside of these ranges.

Outsole 110 can be formed by synthetic rubber with hardness and other properties, and this hardness and other properties are similar to the hardness and other properties of synthetic rubber compounds conventionally used for footwear outsoles. However, as previously pointed out, outsole 110 is highly flexible. Therefore, in at least some embodiments, outsole 110 has a thickness between about 0.5 millimeters and about 0.8 millimeters in the region of gap 116. This allows outsole 110 to be significantly bent between adjacent raised portions 112. And then, this allows each raised portion 112 to transfer ground pressure to the wearer's foot (for example, by displacing in the vertical direction relative to adjacent raised portions) with higher clarity. This allows the wearer of shoe 100 to better feel the various features of the ground or other surfaces on which the wearer is standing, walking, running, etc. In some embodiments, a part of outsole 110 can be formed by a rubber compound that is harder and more durable than other parts of the outsole. For example, a rubber with higher durability can be used on the bottom of the raised portions in the crash pad located in the heel area and/or located in some other high-pressure areas that usually wear faster.

Figures 2A and 2B are respective lateral and medial side views of a midsole 200 of shoe 100. Figures 2C and 2D are respective front and rear views of midsole 200. Midsole 200 and the midsoles shown in the other figures are merely exemplary. Numerous other embodiments exist in which a midsole may be functionally similar to midsole 200 and/or the midsoles shown in the other figures, but may have a different visual appearance.

To generally illustrate the position of the midsole 200 within the shoe 100, the upper 101 and the outsole 110 are approximately represented by dashed lines in Figures 2A and 2B. When the wearer of the shoe 100 walks, runs, jumps, etc., the midsole 200 reduces ground reaction forces and absorbs energy. The midsole 200 is not permanently attached to the upper 101 or to the outsole 110. Instead, the midsole 200 is simply placed within the shoe 100. The midsole 200 can be non-destructively removed from the shoe 100 through the opening 106 (see Figures 1A and 1B) in the ankle upper 105 and then replaced through the opening 106.

The midsole 200 may also include a heel reinforcement 202. The heel reinforcement 202 may be formed from a denser and less compressible foam than the rest of the midsole 200 and may be formed as a separate component that is bonded to the foam material of the midsole 200. The heel reinforcement 202 helps provide stability to the wearer's foot by centering the wearer's heel. In some embodiments, the shape and/or position of the heel reinforcement may vary. The heel reinforcement configuration may vary based on the shoe's intended use and/or the wearer's gait characteristics. For example, the midsole of a shoe intended for basketball may have a larger and/or denser heel reinforcement than the midsole of a shoe intended for straight-line running. As another example, the heel reinforcement for an "over-pronator" may be sized and/or shaped differently than the heel reinforcement for a wearer with a more neutral gait. In some embodiments, the heel reinforcement may be omitted.The midsole 200 also includes a plurality of transverse grooves 201, as discussed in greater detail below in conjunction with FIG. 2E.

Midsole 200 is formed from a viscoelastic foam material. In at least some embodiments, midsole 200 is formed from compressed ethylene vinyl acetate (EVA) foam. EVA foam is also known as phylon. In at least some such embodiments, and for portions of midsole 200 other than heel cup 202, the EVA foam may have properties within the ranges listed, for example, in Table 1.

Table 1

Other materials may also be used for the midsole 200. However, as an example, in some embodiments, the midsole may be formed from a foam material, such as those used in the LUNAR family of footwear products available from NIKE, Inc. of Beaverton, Oregon. Additional examples of foam materials that may be used for the midsole 200 include those described in U.S. Patent No. 7,941,938, which is hereby incorporated by reference herein. Other materials that may be used for the midsole 200 include TPU foam and PU foam.

FIG2E is an upward view of midsole 200. Midsole 200 includes a transverse groove 201 extending at least partially between the lateral side and the medial side. Longitudinal grooves 203 extend lengthwise along midsole 200. Grooves 201 and 203 create an articulated structure that imparts relatively high flexibility and articulation. In particular, grooves 201 and 203 define a plurality of elements (such as element 204) by exposing the sides of those elements. By flexing along grooves 201 and 203, element 204 can separate and move away from each other when the wearer walks, runs, etc. In some embodiments, the midsole 200 may have a groove pattern such as that described for exterior midsoles in U.S. Provisional Patent Application Serial No. 61/632,837, filed on December 15, 2011, and entitled "Articulated Sole Structure with Rearwardly Angled Mediolateral Midfoot Sipes," which is incorporated herein by reference. Other groove patterns may also be used. Grooves 201 and 203 also allow for vertical displacement of elements 204 relative to adjacent elements 204, for example, to transmit vertical displacement of each outsole projection 112 through the midsole 200 to the plantar surface of the wearer's foot.

FIG2F is a front perspective view of the upper, outer side of the midsole 200. Upper surface 205 is contoured to conform to the underside of the foot of the wearer of shoe 100. Surface 205 is configured to act as a footbed and accommodate the plantar surface of the wearer's foot. A raised edge 206 surrounds upper surface 205. Edge 206 helps stabilize midsole 200 within upper 101 and provides support to the sides of the wearer's foot. Edge 206 is higher in the midsole and heel portions of midsole 200 compared to the forefoot portion.

The upper surface 205 and the inner side of the edge 206 may have a pattern formed thereon to increase traction against the sock-wearing foot of the wearer of the shoe 100. The pattern may include raised portions 207 separated by shallow channels 208. In some embodiments, the raised portions 207 have a height of approximately 1 mm (relative to the surrounding channels 208). The raised portions 207 cooperate with the raised portions 112 and help transmit the feel of the ground characteristics to the underside of the wearer's foot. The channels 208 may also help increase air flow to the underside of the wearer's foot and allow for greater moisture evaporation than would occur if the upper surface 205 were smooth.

Although in the embodiment of midsole 200, raised portion 207 comprises a triangle, other shapes may be employed. In at least some embodiments, outsole raised portion 112 and raised portion 207 are sized so that they are approximately the same size. In some embodiments, for example, the average cross-sectional area of the outsole raised portion is within a range of about 50% to about 200% of the average cross-sectional area of the raised portion. In some embodiments, the average cross-sectional area of the outsole raised portion is within a range of about 20% to about 500% of the average cross-sectional area of the raised portion. In certain embodiments, the outsole raised portion and midsole raised portion are sized so that the number of raised portions along a first transverse path through the outsole in a transverse direction is within a range of about 50% to about 200% of the number of raised portions located along a second transverse path through the midsole and directly above the first transverse path. In some embodiments, the number of raised portions along a first path across the outsole in a lateral direction is in a range from about 20% to about 500% of the number of raised portions located along a second lateral path directly above the first lateral path. In some embodiments, the pattern of raised portions on the upper surface of the midsole may correspond to or otherwise correlate with a pattern of raised portions on the outsole of a shoe incorporating the midsole.

FIG3A is a regional cross-sectional view of the shoe 100 from the position indicated in FIG1A . As can be seen in FIG3A , the bottom (and outer) surface of the midsole 200 rests directly on the upper (and inner) surface of the lasting element 301. The cross-section of FIG3A is parallel to one of the transverse grooves 201 in the midsole 200 and shows the intersection of four longitudinal grooves 203 with the transverse groove 201. FIG3B is similar to FIG3A , but shows only a regional cross-sectional view of the midsole 200. As shown in FIG3B , the midsole 200 includes a span portion 302 and an articulated portion 303. The boundaries of the span portion 302 and the articulated portion 303 are only approximately indicated in FIG3B . The articulated portion 303 includes a plurality of elements 204 formed by the grooves 201 and 203. The span portion 302 includes the portion of the midsole 200 above the grooves 201 and 203. The element 204 is connected to (eg, integrally formed with) the span portion 302 and extends downwardly from the span portion 302 .

The grooves in the midsole 200 can be formed by cutting those grooves after the midsole 200 has been formed. Such cutting can be performed using a hot knife tool, a laser or other cutting device. In some embodiments, the grooves can be formed during the molding of the midsole, for example, by including blades corresponding to the desired groove positions in the midsole mold. In some embodiments, the grooves are formed so that the span portion 302 has a thickness t above the grooves of approximately 3 millimeters. In some embodiments, the portion of the midsole configured to be under the wearer's forefoot has a total thickness between approximately 3 millimeters and approximately 6 millimeters. In some such embodiments with thinner midsoles, the grooves can have a reduced depth or there are no grooves.

In at least some embodiments, midsole 200 lacks a cloth or other upper linear element applied to the upper portion of surface 205. In this way, the wearer (perhaps covered by socks) rests directly on the exposed surface of the foam forming midsole 200. The absence of an upper cloth also helps increase the degree to which details about the ground surface are transmitted vertically through the sole structure and felt by the underside of the wearer's foot. If the upper cloth were adhered to surface 205, it would exert a tensile force that would tend to resist deformation of midsole 200 as the wearer moves. This tensile force would reduce the degree to which midsole 200 can transmit pressure from each raised portion 112 to the wearer's foot, thereby reducing the clarity with which the user can feel the characteristics of the ground.

In some embodiments, the midsole may have additional elements added to an upper surface, such as surface 205. However, in at least some such embodiments, those additional elements span only a limited portion of the midsole's upper surface. For example, individual features, such as triangles 207, may have coverings, but such coverings may not span the gaps (such as channels 208) between such features. Additionally or alternatively, if desired, portions of the upper fabric or linear elements may be positioned (i.e., one spanning some gaps or channels 208) in areas of the foot where pressure transmission through the sole structure is less useful or less desirable.

FIG3C is a regional cross-sectional view of shoe 100 taken from the same location as the view of FIG3A . However, FIG3C illustrates the result of a localized upward pressure P. For example, upward pressure P may be caused by the wearer of shoe 100 stepping on a rock, a tree root, or some other object while running. Pressure P pushes one or more protrusions 112 upward. For convenience, this protrusion is labeled 112-1, and two adjacent protrusions are labeled 112-2 and 112-3. Due to the flexibility of outsole 110 provided by the thin area of gap 116, protrusion 112-1 is able to move upward with only minimal impact on adjacent protrusions 112-2 and 112-3.

The upward pressure on the protrusion 112-1 is transmitted to the underside of the midsole 200. Although the foam of the midsole 200 compresses slightly (thereby absorbing some of the energy from the pressure P), the local area LR of the midsole 200 above the protrusion 112-1 also moves upward. The underside of the wearer's foot feels this pressure in the area LR. Therefore, the wearer of the shoe 100 can be aware that he or she has stepped on an object in this area. The combination of discrete protrusions 112, highly flexible gaps 116 and the midsole 200 allows the wearer of the shoe 100 to sense the presence of ground objects with more clarity than is possible with many conventional footwear designs. These features also allow the wearer to feel and sense the contours or slope of the ground surface, even without stepping on foreign objects.

3C also illustrates how the raised area 207 of the midsole 200 can help improve the clarity with which the wearer of the shoe 100 feels the contours of objects and/or the ground. As the midsole 200 moves upward, the portion of the surface 205 in the region LR curves. This can cause the edge 321 of the raised area 207 to become more prominent and produce more localized pressure on portions of the wearer's foot.

Figures 4A and 4B are lateral and medial side views of a shoe 400 according to some other embodiments. Shoe 400 includes an upper 401, which is similar to upper 101 of shoe 100 and can be formed in a manner similar to that of upper 101. Like upper 101, upper 401 also includes a mesh panel 402 and a partial liner 403. Partial liner 403 is also formed from a partially elastic fabric material and includes an ankle collar 405 similar to ankle collar 105. Partial liner 403 is connected to mesh panel 402 in a manner similar to that in which partial liner 103 is connected to mesh panel 102 (e.g., by stitching, fusing, etc.). However, upper 401 differs from upper 101 in several respects. For example, the portion of mesh panel 402 surrounding the heel area does not extend upward as far as the similar heel area of mesh panel 102. Skin panel 414 of this example structure also has a different configuration than skin panel 114 of mesh panel 102. Notably, skin panel 414 includes panels 499 and 498 that extend upwardly to lace opening 404. In some embodiments, mesh panel 402 may include a counter or other support element in the heel area (e.g., as a separate component on the medial side, lateral side, and/or engaged with mesh panel 402).

Shoe 400 also includes an outsole 410 similar to outsole 110 of shoe 100. Specifically, outsole 410 is thin, highly flexible, and is directly bonded to the lasting element (not shown) of upper 401. Outsole 410 also includes a plurality of discrete raised portions 412. However, unlike outsole 110, outsole 410 includes a more raised lateral edge 497 and a more raised medial edge 496. Edge 496 and edge 497 provide increased lateral support and arch support, respectively.

4C is a bottom view of shoe 100 and illustrates additional details of the bottom exterior surface of outsole 410. Similar to outsole 110, outsole 410 includes a plurality of discrete raised portions 412. Raised portions 412 are small relative to the area of outsole 410 that contacts the ground surface and are separated from each other by gaps 416. Like raised portions 112 of outsole 110, the height and cross-sectional area of raised portions 412 can vary based on location, and the spacing between raised portions 412 can also vary based on location.

5A and 5B are respective lateral and medial side views of the midsole 500 of the shoe 400. FIG. 5C and 5D are respective front and rear views of the midsole 500. In order to generally illustrate the position of the midsole 500 in the shoe 400, the upper 401 and the outsole 410 are approximately represented by dotted lines in FIG. 5A and 5B. The midsole 500 can be formed of materials such as those described in conjunction with the midsole 200. Like the midsole 200, the midsole 500 weakens ground reaction forces and absorbs energy. The midsole 500 is not permanently attached to the upper 401 or to the outsole 410 and can be removed non-destructively from the shoe 400 through the opening of the ankle collar 405.

The midsole 500 includes a forefoot lateral reinforcement 510 and a forefoot medial reinforcement 511. Reinforcements 510 and 511, which may be formed of a higher density and less compressed foam similar to the heel reinforcement 202 of the midsole 200, help stabilize the forefoot of the wearer. In the embodiment of the shoe 500, the midsole 400 does not have a heel reinforcement (although one may be provided if desired). Reinforcements 510 and 511 (as well as reinforcement 202) may also be formed separately as components that are joined to the foam of the midsole component (e.g., via a cement or adhesive, a mechanical connector, etc.).

5E is a bottom view of midsole 500. Midsole 500 also includes a plurality of transverse grooves 501 and longitudinal grooves 503, and also includes diagonal grooves 513. However, in the embodiment of shoe 500, grooves 501, 503, and 513 are relatively shallow compared to the grooves of midsole 200.

FIG5F is a front perspective view of the upper lateral portion of the midsole 500. The upper surface 505 of the midsole 500 includes a plurality of raised areas 507 separated by channels 508. The raised areas 507, which may have a height of approximately 1 mm, provide benefits similar to those provided by the raised areas 207 of the midsole 200. As with the midsole 200, the raised areas 507 of the midsole 500 and the raised portions 412 of the outsole 410 are sized so that they are approximately the same size. The upper surface 505 of the midsole 500 may also be free of upper fabric or other linear elements.

Figures 6A and 6B are lateral and medial side views of a shoe 600 according to some further embodiments. Shoe 600 includes an upper 601, which is similar to upper 101 of shoe 100 and may be formed in a manner similar to that of upper 101. Like upper 101, upper 601 includes a mesh panel 602 and a partial liner 603. Partial liner 603 is also formed from a partially elastic fabric material and includes an ankle collar 605 similar to ankle collar 105. Partial liner 603 is connected to mesh panel 602 in a manner similar to that in which partial liner 103 is connected to mesh panel 102. Upper 601 differs from upper 101 in several respects. For example, and similar to upper 401 of shoe 100, the skin panel 614 of mesh panel 602 includes panels 699 and 698 that extend upward toward lace opening 604. In some embodiments, plate 699 and/or plate 698 may extend all the way to opening 604 and/or may include a portion (eg, formed of a thinner and/or different color material) that extends all the way to opening 604 .

Shoe 600 includes an outsole 610. Like outsole 110 of shoe 100, outsole 610 is a thin, highly flexible lasting element (not shown) that is directly bonded to upper 601. Outsole 610 also includes a plurality of discrete projections 612.

6C is a bottom view of shoe 600 and illustrates additional details of the bottom exterior surface of outsole 610. Similar to outsole 110, outsole 610 includes a plurality of discrete raised portions 612. Raised portions 612 are small relative to the area of outsole 610 that contacts the ground surface and are separated from each other by gaps 616. As with raised portions 112 of outsole 110, the height and cross-sectional area of raised portions 612 can vary based on location, and the spacing between raised portions 612 can also vary based on location.

7A and 7B are each lateral side view and medial side view of the midsole 700 of the shoe 600. FIG. 7C and 7D are each front view and rear view of the midsole 700. In order to generally illustrate the position of the midsole 700 in the shoe 600, the upper 601 and the outsole 610 are approximately represented by dotted lines in FIG. 7A and 7B. The midsole 700 can be formed of materials such as those described in conjunction with the midsole 200. Like the midsole 200, the midsole 700 weakens ground reaction forces and absorbs energy. The midsole 700 is not permanently attached to the upper 601 or to the outsole 610 and can be removed non-destructively from the shoe 600 through the opening of the ankle collar 605.

Midsole 700 includes lateral forefoot reinforcement 710 and heel reinforcement 702. Reinforcements 702 and 710, which may be formed of a higher density and less compressible foam similar to heel reinforcement 202 of midsole 200, help stabilize the wearer's forefoot and heel.

FIG7E is a bottom view of midsole 500. Instead of grooves, the bottom surface of midsole 700 includes a pattern of grooves that are similar to the channels between the raised portions on the upper surface of midsole 700. Those channels can be seen in the upper, outer front perspective view of midsole 700 in FIG7F. Upper surface 705 of midsole 700 includes a plurality of raised areas 707 separated by channels 708. Raised areas 707, which may have a height of approximately 1 mm, provide benefits similar to those provided by raised areas 207 of midsole 200. As with midsole 200, raised areas 707 of midsole 700 and raised portions 612 of outsole 610 are sized so that they are approximately the same size. Upper surface 705 of midsole 700 may also be devoid of top cloth or other linear elements.

In some embodiments, shoes having outsoles and/or midsoles (such as those of shoes 100, 400, and 600) and shoes having outsoles and/or midsoles according to other embodiments may have uppers such as those described in co-owned U.S. patent application serial number 13/681,842 (filed on November 20, 2012 and entitled "Footwear Upper Incorporating A Knitted Component With Collar And Throat Portions"), which is incorporated herein by reference in its entirety.

In some embodiments, only portions of the outsole may include discrete raised portions separated by gaps, where the outsole thickness in those gaps is relatively thin. For example, some embodiments may include an outsole in which some or all of the forefoot area is similar to the forefoot area of outsole 110, outsole 410, or outsole 610, but in which the heel area is substantially thicker and/or lacks discrete raised portions.

In some embodiments, the shoe may include an outsole that is slightly thicker and/or may include additional midsole elements. For example, a rubber outsole may be bonded to a relatively thin outer midsole formed of EVA or other compressible material, wherein the outer midsole is in turn bonded to the upper elements of the upper. The outsole and outer midsole may still be relatively thin, for example, to allow each raised portion on the outsole to apply upward pressure independently of adjacent raised portions. In some such embodiments, a removable inner midsole similar to the midsole described above (e.g., midsole 200, 500, and/or 700) may also be included.

As previously noted, upper 101 and the uppers shown in other figures, outsole 110 and the outsole shown in other figures, and midsole 200 and the midsole shown in other figures are merely exemplary. There are countless other embodiments in which the upper, outsole, and/or midsole may function similarly to the upper, outsole, or midsole described herein, but which may have a different visual appearance.

The description of the foregoing embodiments has been provided for purposes of illustration and description. The foregoing description is not intended to be exhaustive or to limit the embodiments of the invention to the precise form disclosed, and modifications and variations are possible in light of the above teachings or may be acquired from the practice of the various embodiments. The embodiments discussed herein are selected and described in order to illustrate the principles and properties of the various embodiments and their practical applications to enable those skilled in the art to utilize the invention in various embodiments and to utilize the invention with various modifications suitable for the specific use contemplated. Any and all combinations, subcombinations, and permutations of features from the embodiments described above are within the scope of the invention. With respect to claims relating to a device, an article of manufacture, or some other physical component or combination of components, reference in the claims to a potential or intended wearer or user of the component does not require the actual wearing or use of the component or the presence of a wearer or user as part of the claimed component or combination of components.

Claims (10)

1. A type of footwear, comprising: The upper includes a backing element; The outsole, formed of a synthetic rubber material directly bonded to the outer surface of the upper element, includes a plurality of discrete protrusions distributed across the bottom outer surface of the outsole in the forefoot, midfoot, and heel regions. Each of the discrete protrusions has a maximum width of 0.4 inches or less. Each of the discrete protrusions is spaced apart from adjacent protrusions by gap regions, and the outsole has a thickness between 0.5 mm and 0.8 mm in the gap regions. A compressible foam midsole is contained within the upper, the midsole being non-destructively removable from the upper and resting on the gusset element, wherein the bottom of the midsole includes a plurality of longitudinal grooves and a plurality of transverse grooves formed therein, wherein at least one of the longitudinal grooves is included in a portion of the forefoot area, midfoot area, and heel area of the midsole, wherein the transverse grooves include a plurality of transverse grooves in the heel area of the midsole and a plurality of transverse grooves in the midfoot area of the midsole, and wherein the upper surface of the midsole has a contoured profile conforming to the underside of the wearer's foot, the upper surface of the contoured profile also including a plurality of raised areas distributed on the upper surface of the contoured profile and separated by grooves, the plurality of raised areas having a height of about 1 mm relative to the surrounding grooves; The sole interlayer includes a raised edge surrounding the upper surface of the band and includes a heel raised edge portion, a midfoot raised edge portion, and a forefoot raised edge portion, wherein the heel raised edge portion and the midfoot raised edge portion are higher than the forefoot raised edge portion; and The outsole, the gusset element, and the midsole are configured such that, in response to a local upward pressure on one of the plurality of discrete protrusions, the protrusion is able to move upward while adjacent protrusions are minimally affected, the gusset element is upwardly deformable in a local area above the protrusion, and a portion of the contoured upper surface of the midsole is able to be pushed upward in that local area. 2. The footwear article of claim 1, wherein the average cross-sectional area of the plurality of discrete protrusions is in the range of 20% to 500% of the average cross-sectional area of the plurality of protrusion regions; wherein the compressible foam of the sole interlayer comprises compressed ethylene vinyl acetate foam; and wherein the compressed ethylene vinyl acetate foam has an expansion ratio of at least 189% and not more than 191%, an Asker C hardness value of at least 36 and not more than 40, a specific gravity of at least 0.1 gr/cc and not more than 0.12 gr/cc, a plyometric tear strength of at least 1.2 kg/cm, a compression set of not more than 60%, a tensile strength of at least 14 kg/ ^cm³ , an elongation of at least 250%, a tear strength of at least 7 kg/cm, a shrinkage rate of not more than 2%, and a resilience of at least 45%. 3. The footwear article of claim 1, wherein the upper surface of the contoured part of the sole interlayer lacks an upper fabric portion. 4. The footwear article of claim 1, wherein the contoured upper surface of the sole interlayer lacks padding. 5. The footwear article of claim 1, wherein the contoured upper surface of the sole interlayer is substantially composed of the exposed foam material forming the sole interlayer. 6. The footwear article of claim 1, wherein the sole interlayer includes a hinged portion, the hinged portion including the groove and a span over the groove, and wherein the span has a thickness of about 3 mm in the footbed area. 7. The footwear article of claim 1, wherein the thickness of the sole interlayer in the region configured to accommodate the forefoot portion of the shoe is between 3 mm and 6 mm. 8. The footwear article of claim 1, wherein the plurality of discrete protrusions and the plurality of protruding areas are sized such that the number of protrusions along a first lateral path through the outsole in the lateral direction is in the range of 50% to 200% of the number of protruding areas along a second lateral path through the sole interlayer and directly above the first lateral path. 9. The footwear article of claim 1, wherein the average cross-sectional area of the plurality of discrete protrusions is in the range of 20% to 500% of the average cross-sectional area of the plurality of protrusion regions; wherein the compressible foam of the sole interlayer comprises compressed ethylene vinyl acetate foam; wherein the sole interlayer comprises a U-shaped heel reinforcement positioned on the lower outer portion of the heel region of the sole interlayer; and wherein the heel reinforcement is formed of a denser and less compressible foam than the compressible foam forming other portions of the sole interlayer. 10. The footwear article of claim 1, wherein the plurality of discrete protrusions and the plurality of protruding areas are made to be approximately the same size.