HK1214482B

HK1214482B - Article of footwear comprising a sole structure including a billows structure

Info

Publication number: HK1214482B
Application number: HK16102099.8A
Authority: HK
Inventors: 弗雷德里克‧J‧杜简; 马修‧J‧霍姆斯; 特洛伊‧C‧林德纳; 本杰明‧奈斯昂科姆; 多洛莉丝‧S‧汤普森
Original assignee: 耐克创新有限合夥公司
Priority date: 2013-03-15
Filing date: 2014-03-13
Publication date: 2018-08-31

Description

Article of footwear including a sole structure incorporating a billows structure

Information on related applications

The present application claims the following priority: (a) U.S. patent application No. 13/835,715 entitled "Sole Structures and arms of Footweek sunlight with Protective Elements" and filed 3/15/2013; (b) U.S. patent application No. 13/838,051 entitled "Sole Structures and devices of Footwear Having a Lightweight Midsole members with protective elements" and filed 3/15/2013; and (c) U.S. patent application No. 13/837,967 entitled "SoleStructure and arms of Footwear Having a Lightweight Midsole members with protective Elements" filed 3/15 of 2013. Each of these priority applications is incorporated herein by reference in its entirety.

Technical Field

The present invention relates to the field of footwear. More particularly, aspects of this invention relate to sole structures and/or articles of footwear (e.g., athletic footwear) that include a relatively soft and/or lightweight foam midsole component partially covered by a protective component.

Background

Conventional articles of athletic footwear include two primary elements, an upper and a sole structure. The upper provides a covering for the foot that securely receives the foot and securely positions the foot with respect to the sole structure. In addition, the upper may have a configuration that protects the foot and provides ventilation, thereby cooling the foot and removing perspiration. The sole structure is secured to a lower surface of the upper and is positioned generally between the foot and any contact surfaces. In addition to attenuating ground reaction forces and absorbing energy, the sole structure may provide traction and control potentially harmful foot motions, such as over pronation. The general features and configurations of the upper and the sole structure are discussed in greater detail below.

The upper forms a void on an interior of the footwear for receiving a foot. The void has the general shape of a foot, and an entrance to the void is provided at the ankle opening. Accordingly, the upper extends over instep and toe areas of the foot, along medial and lateral sides of the foot, and around a heel area of the foot. A lacing system is often incorporated into the upper to selectively vary the size of the ankle opening and allow the wearer to modify certain dimensions of the upper, particularly girth, to accommodate feet with different proportions. In addition, the upper may include a tongue that extends under the lacing system to enhance the comfort of the footwear (e.g., to relieve pressure applied to the foot by the laces), and the upper may also include a heel counter to limit or control movement of the heel.

The sole structure generally incorporates multiple layers that are conventionally referred to as an "insole," a midsole, "and an" outsole. The insole, which may also constitute a sockliner, is a thin member positioned within the upper and adjacent to the plantar (lower) surface of the foot to enhance footwear comfort (e.g., to wick moisture away and provide a soft, comfortable feel). The midsole, which is traditionally attached to the upper along the entire length of the upper, forms the middle layer of the sole structure and serves a variety of purposes that include controlling foot motions and attenuating impact forces. The outsole forms the ground-contacting element of footwear and is often formed of a durable, wear-resistant material that includes texturing or other features to improve traction.

The primary element of a conventional midsole is a resilient, polymer foam material, such as a polyurethane foam or an ethylene vinyl acetate ("EVA") foam, that extends throughout the length of the footwear. The properties of the polymer foam material in the midsole are primarily dependent upon factors including the dimensional configuration of the midsole and the specific characteristics of the material selected for the polymer foam, including the density and/or hardness of the polymer foam material. By varying these factors throughout the midsole, the relative stiffness, degree of ground reaction force attenuation, and energy absorption properties may be varied to meet the specific requirements of the activity for which the footwear is intended to be used.

Despite the many available footwear models and characteristics, new footwear models and configurations continue to be developed and are a welcome advance in the art.

Summary of The Invention

This summary is provided to introduce a selection of general 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.

While potentially useful with any desired type or style of footwear, aspects of the present invention may be of particular interest with sole structures used in articles of athletic footwear, including basketball shoes, running shoes, cross-training shoes, spiking shoes, tennis shoes, golf shoes, and the like.

A more specific aspect of this invention relates to a sole structure for an article of footwear that includes a first polymeric foam member for supporting at least a heel region and a midfoot region of a wearer's foot. The exposed outer edge of the first polymeric foam member includes a billows structure (billows structure) that extends continuously from a midfoot or forefoot area on a medial side of the first polymeric foam member, around the rear heel area, and continuously to a midfoot or forefoot area on a lateral side of the first polymeric foam member, at least in some examples. In at least some examples of the invention, other billows structures may be provided, including, for example, interwoven billows, support ribs, and the like. These billows structures may include two to eight billow outer ridges connected by a billow void area located between adjacent billow outer ridges.

Sole structures according to other examples of this invention may include a polymer foam member (optionally, a lightweight, low-density polymer foam material, such as having less than 0.25 g/cm) for supporting at least a heel region and a midfoot region of a wearer's foot³A foam of density of). The exposed outer edge of the polymer foam member may include:

(a) a first billows structure comprising: a first outer billows ridge, a second outer billows ridge, a third outer billows ridge, a first interstitial area between the first outer billows ridge and the second outer billows ridge and a second interstitial area between the second outer billows ridge and the third outer billows ridge, and

(b) a second billows structure comprising: a fourth outer billows ridge, a fifth outer billows ridge and a third interstitial area between the fourth outer billows ridge and the fifth outer billows ridge,

wherein the fourth outer billows ridge originates in the first void area and the fifth outer billows ridge originates in the second void area. The exposed outer edge of the polymeric foam member may also include another billows structure, for example, wherein an outer billows ridge of the billows structure originates in the third void area. One billows structure may extend around a rear heel area of the sole structure, while another billows structure may be located at side midfoot areas of the sole structure. The outsole component may be engaged with the bottom surface of the polymer foam member.

Another sole structure according to some examples of this invention includes: a first polymeric foam member for supporting at least a heel region of a wearer's foot, wherein the first polymeric foam member forms an outer shell having: (a) a lateral side wall, (b) a medial side wall, (c) a rear heel wall connecting the medial side wall and the lateral side wall, (d) a bottom wall connecting the medial side wall, the lateral side wall, and the rear heel wall, and (e) an open end opposite the rear heel wall, and the first polymer foam member extends around a rear heel region of the sole structure. The second polymeric foam member has a heel portion at least partially received in a space defined by the shell of the first polymeric foam member, wherein a forefoot end of the second polymeric foam member extends beyond an open end of the first polymeric foam member. The second polymeric foam member has a density less than a density of the first polymeric foam member, and a portion of a bottom surface of the second polymeric foam member is exposed at a bottom forefoot region of the article of footwear. If desired, one or more protective elements may be engaged with the bottom surface of the second polymeric foam member in the bottom forefoot region.

Still further sole structures according to some examples of this invention would include: (a) a polymer foam member for supporting an entire plantar surface of a wearer's foot, wherein the polymer foam member comprises a material having a thickness of less than 0.25g/cm³And (b) a protective member engaged with the polymer foam member to cover at least 80% of a surface area of a bottom surface of the polymer foam member, wherein the protective member constitutes a web base surface (web surface) with a plurality of traction elements extending downward from the web base surface, and wherein a majority of the web base surface has a thickness of less than 2mm thick at locations between the plurality of traction elements.

At least some aspects of the invention provide the following:

1) an article of footwear comprising:

a shoe upper; and

a sole structure engaged with the upper, wherein the sole structure includes a first polymeric foam member for supporting at least a heel area and a midfoot area of a wearer's foot, wherein exposed outer edges of the first polymeric foam member include a billows structure extending continuously from a midfoot area or a forefoot area inboard of the first polymeric foam member, a midfoot area or a forefoot area proximate an outboard side of the first polymeric foam member, and wherein the billows structure includes five billows outer ridges connected by four billow void areas located between adjacent ones of the five billows outer ridges.

2) The article of footwear of item 1), wherein, at a rear heel area of the first polymeric foam member, a highest billows outer ridge is vertically separated from a lowest billows outer ridge by a vertical distance of at least 1.5 inches when the sole structure is oriented on a horizontal surface.

3) The article of footwear of item 1), wherein a central billows outer ridge extends rearwardly a maximum distance at a rear heel area of the first polymeric foam member when the sole structure is oriented on a horizontal surface.

4) The article of footwear of item 1), wherein the sole structure supports an entire plantar surface of a wearer's foot.

5) The article of footwear of item 1), wherein the first polymeric foam member constitutes an outer shell including the billows structure, wherein the outer shell includes:

the outer side of the wall is provided with a wall,

the inner side of the inner side wall is provided with a wall,

a rear heel wall connecting the medial and lateral side walls, an

A bottom wall connecting the medial side surface wall, the lateral side surface wall, and the rear heel wall,

wherein the billows structure extends continuously around the outer surfaces of the outer side wall, the rear heel wall and the inner side wall.

6) The article of footwear of item 5), wherein the sole structure further includes a second polymer foam member having a heel portion received in a space defined between the lateral side wall, the medial side wall, the rear heel wall, and the bottom wall of the first polymer foam member, and wherein a forefoot end of the second polymer foam member extends beyond a forward end of the lateral side wall and a forward end of the medial side wall.

7) An article of footwear according to item 6), wherein an exposed outer edge of the second polymeric foam member includes a billows structure extending around a forward toe area of the sole structure, wherein the billows structure of the second polymeric foam member includes three billows outer ridges connected by two billows void areas located between adjacent ones of the three billows outer ridges of the second polymeric foam member.

8) The article of footwear of item 7), wherein the billows structure of the second polymeric foam member is not continuous with the billows structure of the first polymeric foam member.

9) The article of footwear of item 7), wherein the billows structures of the second polymeric foam member are separated from the billows structures of the first polymeric foam member at a lateral forefoot area of the sole structure and at a medial forefoot area of the sole structure.

10) The article of footwear of item 6), wherein a bottom surface of the second polymer foam member is exposed at least at a forefoot portion of the bottom surface of the sole structure.

11) The article of footwear of item 10), wherein the sole structure further includes a first outsole member engaged with a bottom surface of the second polymeric foam member.

12) The article of footwear of item 11), wherein the sole structure further includes a second outsole member engaged with a bottom surface of the first polymeric foam member.

13) The article of footwear of item 6), wherein the bottom wall of the outer shell of the first polymeric foam member has an opening defined therethrough, and wherein a bottom surface of the second polymeric foam member is exposed through the opening.

14) The article of footwear of item 1), wherein the sole structure further includes an outsole member engaged with a bottom surface of the first polymeric foam member.

15) An article of footwear comprising:

a shoe upper; and

a sole structure engaged with the upper, wherein the sole structure includes a polymer foam member for supporting at least a heel region and a midfoot region of a wearer's foot, wherein an exposed outer edge of the polymer foam member includes:

a first billows structure comprising: a first outer billows ridge, a second outer billows ridge, a third outer billows ridge, a first interstitial area between the first outer billows ridge and the second outer billows ridge and a second interstitial area between the second outer billows ridge and the third outer billows ridge, and

a second billows structure comprising: a fourth outer billows ridge, a fifth outer billows ridge and a third interstitial area between said fourth outer billows ridge and said fifth outer billows ridge,

wherein the fourth outer billows ridge originates in the first void area and the fifth outer billows ridge originates in the second void area.

16) The article of footwear of item 15), wherein the first billows structure extends around a rear heel area of the sole structure, and wherein the second billows structure is located at side midfoot areas of the sole structure.

17) The article of footwear of item 15), wherein the sole structure further includes an outsole component engaged with a bottom surface of the polymer foam member.

18) The article of footwear of item 17), wherein the polymer foam member comprises a foam having a thickness of less than 0.25g/cm³The density of (a).

19) The article of footwear of item 15), wherein a window element extends through the polymeric foam member at a location between the first outer billows ridge and the second outer billows ridge.

20) The article of footwear of item 15), wherein the exposed outer edge of the polymeric foam member further includes a third billows structure having a sixth outer billows ridge, wherein the sixth outer billows ridge originates in the third void area.

Additional aspects of this invention relate to articles of footwear that include sole structures of the various types described above engaged with an upper. Additional aspects of this invention relate to methods for manufacturing sole structures and/or articles of footwear of the various types described above (and in more detail below). More specific aspects of the invention are described in more detail below.

Brief Description of Drawings

The foregoing summary of the invention, as well as the following detailed description of the invention, will be better understood when considered in conjunction with the accompanying drawings, in which like reference characters designate the same or similar elements throughout the various views, and in which reference characters appear.

1A-1F illustrate a sole structure according to one example of the invention;

2A-2F illustrate a sole structure according to another example of the invention;

figures 3A and 3B illustrate features of a sole structure according to another example of the invention;

FIG. 4 illustrates a heel region of a portion of a foam component that may be included in sole structures according to some examples of this invention;

FIG. 5 illustrates a basketball shoe in accordance with one example of this invention;

FIG. 6 illustrates a running shoe according to one example of the invention;

FIG. 7 illustrates a training shoe according to one example of the present invention;

8A-8F illustrate a sole structure according to another example of the invention;

FIG. 9 is an exploded view of a sole structure according to another example of the invention;

10A and 10B illustrate features of a sole structure according to another example of the invention;

11A-11C provide various views of an article of footwear according to another example of this invention; and is

12A-12C provide various views of an article of footwear according to another example of this invention.

Detailed description of the invention

In the following description of various examples of footwear structures and components according to the invention, reference is made to the accompanying drawings, which form a part hereof, and in which is shown by way of illustration various example structures and environments in which aspects of the invention may be practiced. It is to be understood that other configurations and environments may be used, and structural and functional modifications may be made from the specifically described configurations and functions without departing from the scope of the present invention.

I. General description of aspects of the invention

Aspects of this invention relate to sole structures and/or articles of footwear (e.g., athletic footwear) that include a relatively soft and lightweight foam midsole component partially covered by at least one more rigid and/or more dense cage (protective) component and/or other protective component. More specific features and aspects of the invention are described in more detail below.

A. Features of sole structures and articles of footwear according to examples of this invention

Aspects of this invention relate to sole structures for articles of footwear and articles of footwear (or other foot-receiving devices) including athletic footwear having such sole structures. Sole structures for articles of footwear according to at least some examples of this invention may include a first polymer foam member for supporting at least a heel region and a midfoot region of a wearer's foot. The exposed outer edge of the first polymeric foam member includes a billows structure that extends continuously from a midfoot or forefoot area on a medial side of the first polymeric foam member, around a rear heel area, to a midfoot or forefoot area on a lateral side of the first polymeric foam member. The billows structure may include two to eight billow outer ridges connected by a billow void area between adjacent billow outer ridges.

Sole structures according to at least some examples of this invention may include an outsole component (e.g., made of rubber, phylon, phylite, thermoplastic polyurethane, or the like) on a bottom surface (e.g., in one of the exposed spaces) of one or more of the foam protective component and/or the foam midsole component. The outsole elements may provide, for example, stiffness, strength, wear-resistance, and traction (e.g., by providing texturing, cleats, or other traction-enhancing structures on the bottom surface of the sole structure). In some example structures according to this invention, several separate outsole components would be positioned at various discrete locations around the bottom of the sole structure. The outsole component may also be considered a "protective" component for the lightweight midsole component.

If desired, at least some portions of the outer lateral edges of one or more of the lighter weight and/or less dense foam midsole material components and/or more dense protective components (optionally made of a heavier weight or more dense polymer foam material) may include billowed structures (described in more detail below), in accordance with at least some examples of this invention. Additionally or alternatively, if desired, at least some portions of the foam midsole component may include a billowed structure, such as a billowed structure optionally adjacent one or more protective components (if billowed). Although any number of separate billows structures on each component are possible without departing from this invention, in some examples, a separate sole structure may include 2 to 8 billows, and in some examples, may include 3-6 billows, in a top-to-bottom direction.

a second billows structure comprising: a fourth outer billows ridge, a fifth outer billows ridge and a third interstitial area between the fourth outer billows ridge and the fifth outer billows ridge,

Another example sole structure according to some examples of this invention includes: a first polymeric foam member for supporting at least a heel region of a wearer's foot, wherein the first polymeric foam member forms an outer shell having: (a) a lateral side wall, (b) a medial side wall, (c) a rear heel wall connecting the medial side wall and the lateral side wall, (d) a bottom wall connecting the medial side wall, the lateral side wall, and the rear heel wall, and (e) an open end opposite the rear heel wall, and the first polymer foam member extends around a rear heel region of the sole structure. The second polymeric foam member has a heel portion at least partially received in a space defined by the shell of the first polymeric foam member, wherein a forefoot end of the second polymeric foam member extends beyond an open end of the first polymeric foam member. The second polymeric foam member has a density less than a density of the first polymeric foam member, and a portion of a bottom surface of the second polymeric foam member is exposed at a bottom forefoot region of the article of footwear. If desired, a protective element may be engaged with the bottom surface of the second polymeric foam member in the bottom forefoot region.

Additional sole structures according to some examples of this invention will include: (a) a polymer foam member for supporting an entire plantar surface of a wearer's foot, wherein the polymer foam member comprises a material having a thickness of less than 0.25g/cm³And (b) a protective member engaged with the polymer foam member to cover at least 80% of a surface area of a bottom surface of the polymer foam member, wherein the protective member comprises a mesh base surface with a plurality of traction elements extending downwardly therefrom, wherein a majority of the mesh base surface is less than 2mm thick at locations between the plurality of traction elements.

Additional aspects of this invention relate to articles of footwear that include an upper (e.g., of any desired design, construction, or structure, including conventional designs, constructions, or structures) engaged with sole structures of the various types described above (and in greater detail below).

Additional aspects of this invention relate to methods of manufacturing articles of footwear or individual components thereof. Yet another particular aspect of the invention relates to methods of manufacturing sole structures for articles of footwear of the various types and configurations described above. While the various components and portions of the sole structure and article of footwear according to aspects of the present invention may be manufactured in manners conventionally known and used in the art, examples of method aspects of the present invention relate to combining sole structures and/or footwear portions and joining them together in manners that result in the various structures described above.

In view of the general description of features, aspects, structures, and arrangements according to the invention provided above, more detailed descriptions of specific example sole structures, articles of footwear, and methods according to the invention follow.

Detailed description of an exemplary sole structure and article of footwear according to the present invention

With reference to the figures and the following discussion, various sole structures, articles of footwear, and features thereof, in accordance with the present invention are disclosed. The sole structures and footwear depicted and discussed are athletic shoes, and the concepts disclosed with respect to various aspects of the footwear may be applied to a wide range of athletic footwear styles, including, but not limited to: walking shoes, tennis shoes, soccer shoes, football shoes, basketball shoes, running shoes, cross-training shoes, spiking shoes, golf shoes, and the like. In addition, at least some concepts and aspects of the invention may be applied to a wide range of non-athletic footwear, including work boots, sandals, loafers, and dress shoes. Accordingly, the present invention is not limited to the precise embodiments disclosed herein, but rather is generally applicable to footwear applications.

Fig. 1A-1F illustrate various views of an example sole structure 100 for an article of footwear that includes at least some aspects and features of the present invention. For purposes of this disclosure, and as shown in fig. 1A, when the footwear is worn on a suitably sized foot, portions of the article of footwear (and its various components) may be identified based on a foot region located at or near the portion of the article of footwear. For example, as shown in fig. 1A, the article of footwear and/or sole structure may be considered to have a "forefoot region" at the front of the foot, a "midfoot" region at the mid-portion or arch region of the foot, and a "heel region" at the rear of the foot. The footwear and/or sole structure also includes a "lateral side" (the "lateral" or "little toe side" of the foot) and a "medial side" (the "medial" or "big toe side" of the foot). The forefoot region generally includes portions of the footwear corresponding with the toes and the joints connecting the metatarsals with the phalanges. The midfoot region generally includes portions of the footwear corresponding with an arch area of the foot. The heel region generally corresponds with rear portions of the foot, including the calcaneus bone. The lateral side and the medial side of the footwear extend through the forefoot region, the midfoot region, and the heel region, and generally correspond with opposite sides of the footwear (and may be considered as being separated by a central longitudinal axis). These regions (although separated by demarcation lines in fig. 1A) and sides are not intended to demarcate precise areas of the footwear. Rather, the terms "forefoot region," "midfoot region," "heel region," "lateral side," and "medial side" are intended to represent general areas of an article of footwear and its various components to aid in the following discussion.

Fig. 1A shows a top view, fig. 1B shows a lateral side view, fig. 1C shows a medial side view, fig. 1D shows a bottom view, fig. 1E shows a heel or rear view, and fig. 1F shows a toe or front side view of the sole structure 100. As shown in fig. 1A-1F, this example sole structure 100 includes a single midsole component 102 that extends continuously in this particular structure 100 to support the full plantar surface of the wearer's foot, i.e., from the rear heel region of the sole 100 to the forward toe region of the sole 100 and from the lateral side edge to the medial side edge of the sole 100. The midsole component 102 may be constructed from a foam material, such as an ethylene vinyl acetate ("EVA") foam, a polyurethane foam, a phylon foam, and the like, although other midsole configurations are possible according to some examples of the invention. The top surface 102a of the midsole component 102 may be contoured, for example, to comfortably support and/or help position a plantar surface of a wearer's foot.

In some examples of the invention, the midsole component 102 will be at least partially formed from a material having a thickness of less than 0.25g/cm³(and in some examples, less than 0.2 g/cm)³At 0.075g/cm³To 0.2g/cm³And even in the range of 0.1g/cm³To 0.18g/cm³Density within the range of (a). If desired, the foam material of the midsole component 102 may include one or more openings defined therein and/or another impact-attenuating component, such as a fluid-filled bladder, a mechanical cushioning member, or the like, included therein. In certain embodiments of the invention, the entire midsole component 102 will be constructed of this lightweight foam material (e.g., having density characteristics as described above) and will extend to support the full foot (e.g., the full plantar surface) of the wearer. In the exemplary structure 100 as shown in fig. 1A-1F, the foam midsole component 102 is shown as a separate part from the protective component 104 (e.g., one or more of: another denser or harder midsole material (e.g., a polymer foam material); an outsole material; "cage" or "carrier" member, etc.) by a bond line 106 (the bond line 106 being provided in the figures as an illustrative aid to emphasize the change in position between the materials 102/104 in these figures). In this illustrated example, the midsole component 102 is located generally above the protective component 104 (and may be at least partially contained by the protective component 104). Alternatively, if desired, the midsole component 102 may be made of multiple component midsole (e.g., foam) portions, and/or the sole structure 100 may include multiple protective component portions 104.

As some evenAs a more specific example, at least some of the midsole component 102 may be made from a foam material such as described in U.S. Pat. No. 7,941,938, which is incorporated herein by reference in its entirety, in at least some example sole structures 100 according to this invention, all, substantially all, or at least some portions of the midsole component 102 may comprise a foam material comprising the reaction product of about 10% to about 100% hydrogenated or non-hydrogenated acrylonitrile butadiene copolymer, 0% to about 40% modified hydrogenated acrylonitrile butadiene copolymer, and 0% to about 90% α olefin copolymer, and at least one additive in an amount suitable to form a foam material³Less than 0.20g/cm³Less than 0.18g/cm³Less than 0.15g/cm³Less than 0.12g/cm³And, in some examples, about 0.10g/cm³. As an exemplary range, the light foam density may fall within, for example, 0.05g/cm³To 0.25g/cm³Or within each of the ranges indicated above.

Moreover, in accordance with at least some examples of this invention, the foam material used for the midsole component 102 may have a resiliency of greater than 40%, greater than 45%, at least 50%, and in one aspect, 50% -70%. The compression set may be 60% or less, 50% or less, 45% or less, and in some cases in the range of 20% to 60%. The hardness (durometer Asker C) of the foam material used for this example midsole component 102 may be, for example, 25 to 50, 25 to 45, 25 to 35, or 35 to 45, depending on the type of footwear, for example. The tensile strength of the foam material 102 may be at least 15kg/cm²And usually 15kg/cm²To 40kg/cm². The% elongation is from 150 to 500, usually above 250. The tear strength is from 6 to 15kg/cm, generally higher than 7. In at least some example configurations according to this invention, the foam material of at least some portions of midsole component 102 may have lower energy losses than conventional EVA foam, and may be lighter in weight than conventional EVA foam. Energy ofThe loss may be less than 30%, and optionally in the range of about 20% to about 30%. As a further example, if desired, at least some portions of the midsole component 102 may be made from a foam material used in the LUNAR family of footwear products available from NIKE corporation of greater than fordon, oregon.

While the above paragraphs describe potential properties and features of foam materials for the midsole component 102 according to some examples of this invention, those skilled in the art will recognize that the midsole component 102 may have other desirable properties, features, and/or combinations of features without departing from this invention. Other lightweight and/or low density foams may also be used. Due to the protective component 104 described in greater detail below, the lightweight foam midsole component 102 need not have sufficient hardness, durability, and/or abrasion resistance (at least at some higher impact ground contact locations) to directly contact the ground in use.

The protective component 104 in this example sole structure 100 may be made of any desired material without departing from this invention. For example, protective component 104 may be made from conventional outsole materials, such as rubber, Thermoplastic Polyurethane (TPU), or the like. As another example, the protective member 104 may be at least partially made of a polymer foam cage or carrier material, such as those described in the above-identified U.S. patent No. 7,941,938. Other conventional polymer foam materials may also be used for the protective member 104.

The foam midsole component 102 and the protective component 104 may be joined together in any desired manner, including in conventional manners as are known and used in the art (e.g., via cements or adhesives, via mechanical connectors, etc.), without departing from this invention. In this illustrated example, the protective component 104 fits within one or more recesses formed in the bottom and/or side surfaces of the polymer foam component 102. When present, the recesses may be formed during a molding process (or other forming process) that forms the lightweight foam component 102. Alternatively, the recesses may be created after the lightweight foam component 102 is formed, such as by a cutting or grinding action. The protective member 104 may include traction elements or other features for engaging the ground or other contact surface in use, such as chevron-like structures, raised ribs or ridges, recessed grooves, and the like, including conventional traction elements as are known and used in the art. As further examples, the bottom surface of the protective component 104 may be shaped to include a receptacle for receiving a removable cleat, and/or may be shaped to include the actual cleat element extending from its bottom surface.

As further shown in fig. 1D, the bottom surface of the protective component 104 need not completely cover the bottom surface of the midsole component 102. Instead, some spaces or holes may be provided in the protective member 104 through which the bottom surface of the lightweight foam material 102 is exposed. This feature may provide several potential advantages. For example, eliminating some of the protective components 104 may reduce the weight of the sole structure 100. Further, as shown in fig. 1D, breaks or gaps in the protective component 104 (e.g., elongated grooves or gaps in the forefoot region, as shown in fig. 1D) may be provided along a desired inflection line of the protective component 104, thereby helping to maintain the overall flexibility (and optionally, more natural flexibility) of the overall sole structure 100. The large opening in the protective component 104 at the heel region of this example sole structure 100 provides a relatively large and soft "crash pad" for the heel, for example, to provide better comfort and feel when the wearer's heel strikes the ground (e.g., when stepping down or landing a jump). It will be appreciated by those skilled in the art, given the benefit of this disclosure, that the openings in the protective member 104 are optional and, when present, may be provided in any desired size, shape and/or number without departing from the invention. Preferably, however, the areas of high wear resistance on the bottom surface of the sole structure 100 will include some layer of the protective component 104 overlying the lightweight (and more delicate) polymer midsole component 102 to help protect the structural integrity of the midsole component 102.

As best shown in fig. 1C and 1D, this example sole structure 100 includes an additional element, namely, a support panel 108 disposed in a central or midfoot region of the sole structure 100. The support panel 108 provides additional support to the arch region of the sole structure 100. In fig. 1C and 1D, the support panel 108 is shown separated from the midsole component 102 and/or the protective component 104 by a bond line 110. The bond line 110 is provided in the figures as an illustrative aid to emphasize the change in position between the support panel 108 and the material 102/104 in these figures. In this illustrated example, the support panel 108 may be at least partially sandwiched or layered between the midsole component 102 and the protective component 104 in at least the arch region of the sole structure 100. The support panel 108 may be engaged with one or more of the midsole component 102 and/or the protective component 104 by adhesives or cements, by mechanical connectors, and/or by any other desired means, including conventional means known or used in the art. Support panel 108 may be made from any desired number of pieces or portions and/or from any desired material (including conventional arch support materials and/or portions as are known and used in the art) without departing from this invention. Some more specific examples of materials include: thermoplastic polyurethane, nylon-based polymer materials (e.g., PEBAX), carbon fiber reinforced polymer materials, glass fiber reinforced polymer materials, other composite materials, and the like.

Fig. 1A-1F illustrate another feature that may be included in a sole structure 100 according to at least some examples of this invention. As shown in these figures, at least some portions of the outer edges or sides of midsole foam component 102 and/or protective component 104 may include a "billowed structure" 120. The term "billowed structure" or "billowed structure" as used herein means that the outer surface shape of the element has the outer surface shape of a billow (e.g., a wave-like structure having a series of wave crests (outermost portions or ridges) and troughs between the wave crests). In a sole structure, the "billowed structure" need not expand and compress in the same manner as a conventional bellows, but rather, the term more generally relates to the shape of the outer surface of the structure. In the illustrated example sole structure 100, the lightweight midsole foam component 102 has a series of 4 1/2 billows 122 (e.g., looking like four stacked disks around the heel area), and the protective component 104 includes 1/2 billows 124 (which connect with the bottom 1/2 billows 122 of the midsole foam component 102 to complete the bottommost billows in this sole structure 100). At least some portions of the billowed structure 120 may be disposed on a sidewall of the midsole component 102 (and its billowed structure 120) that protrudes upwardly from the top surface 102a of the midsole component 102, e.g., such that the midsole component 102 at least partially wraps around a wearer's foot (e.g., at least at the heel region). As some more specific examples, the outer shell of midsole component 102 (with billows structures 120 formed therein) may include a lateral side wall 130, a medial side wall 132, a rear heel wall 134 connecting medial side wall 132 and lateral side wall 130, and a top plantar surface support surface 102a connecting medial side wall 132, lateral side wall 130, and rear heel wall 134. The top plantar surface support surface 102a may be comprised of a layer of polymer foam (optionally with one or more fluid-filled bladders contained therein) that extends downward from the top surface 102a, for example, about 10-20mm (in the central heel region) and/or about 8-16mm (in the forefoot region (e.g., metatarsal head support region)). Walls 130, 132, and 134 may extend upward from top surface 102a and may be tapered or have different heights, for example, from 0-5mm at the forefoot region to 25-50mm (or even greater) at the rear heel region. At least some of the 4 1/2 billows of billows structure 120 may extend continuously around the outer surfaces of outer side wall 130, rear heel wall 134, and inner side wall 132.

The size, number, shape, and/or other characteristics of billowed structures 120 may be selected to control the feel of the article of footwear. Generally, a deeper billow (i.e., a larger dimension from a wave crest to the bottom of an adjacent wave trough) will provide a more responsive feel (e.g., faster return to original shape). The size, density, and/or stiffness of the midsole component 102 and/or the protective component 104 may also be controlled in order to achieve control over the feel of the sole structure 100 to the foot of the wearer. The billows structure 120 of this illustrated example sole structure 100 extends continuously and uninterrupted from a midfoot or forefoot region (see fig. 1B) of the medial side of the midsole component 102 to a midfoot or forefoot region (see fig. 1C) of the lateral side of the midsole component 102. The particular integral billows structure 120 includes five billow outer ridges connected by four billow void areas located between adjacent ones of the five billow outer ridges.

The billows structure may take many forms without departing from the invention. For example, FIGS. 1B, 1C, 1E, and 1F show the walls of the individual billows having a stepped configuration and the outermost ridges of each individual billows constituting relatively sharp corners. These are not essential conditions. As further examples, the billows sidewall may be smooth, straight, and/or curved, if desired. Furthermore, the outermost edge or ridge of each billows may be manufactured to be less sharp, smoothly curved, spaced, etc. without departing from this invention. Also, while the billows structures may appear similar on opposite interior sides of walls 130, 132, and 134 (e.g., with the billows peaks "cored out"; see, e.g., FIG. 9), in this illustrated example, the interior surfaces of walls 130, 132, and 134 are smooth (i.e., the billows are solid and not cored out).

Also, in this illustrated example sole structure 100, at a rear heel area of the midsole component 102, the highest billow outer ridge (the topmost billow ridge) is vertically separated from the lowest billow outer ridge (at the bottom) by a vertical distance of at least 1.5 inches when the sole structure 100 is oriented on a horizontal surface. Additionally or alternatively, in this sole structure 100, at a rear heel area of the midsole component 102, the central billow outer ridge (the third billow in this example) extends rearwardly a maximum distance when the sole structure 100 is oriented on a horizontal surface. These features can be best seen in fig. 1B and 1C, for example.

Moreover, as best shown in fig. 1B, 1C, and 1F, the exposed outer edge of the protective component 104 of this example sole structure 100 includes a billows structure 140 that extends around a forward toe area of the sole structure 100. The example billows structure 140 includes three billow outer ridges connected by two billow void areas between adjacent ones of the three billow outer ridges. As shown, the billows structure 140 of the protective component 104 of this example sole structure 100 is not continuous with the billows structure 120 of the midsole component 102. Rather, a billow structure 140 of the protective member 104 is separated from a billow structure 120 of the midsole member 102 by transition areas 142, 144, the transition areas 142, 144 being disposed at a lateral forefoot region and a medial forefoot region of the sole structure 100, respectively. Transition region 142 and/or transition region 144 may be made from midsole component 102, protective component 104, and/or another sole component. Moreover, transition region 142 and/or transition region 144 may have any desired structure, including another billows structure, one or more raised ribs or other support members, and so forth.

The sole structure 100 shown in fig. 1A-1F has a billows configuration 120 with at least some of the individual billows 122, 124 extending continuously and uninterrupted around the midsole component 102 and/or the protective component 104 from an outer side end thereof to an inner side end thereof. This is not a requirement. In contrast, fig. 2A-2F illustrate a similar sole structure 200 having similar portions and configurations as sole structure 100 of fig. 1A-1F, but with a different billows configuration.

For the sake of brevity, similar parts between the parts in fig. 1A-1F and fig. 2A-2F will not be described in detail in this specification. Rather, the following discussion will focus on the differences between the structures shown in FIGS. 2A-2F as compared to the structures shown in FIGS. 1A-1F. As will be appreciated by those skilled in the art, portions not described in detail below with respect to fig. 2A-2F may have the same or similar structures and/or the same or similar features and/or options as those similar portions and structures described above with respect to fig. 1A-1F.

Unlike the billows configuration 120 shown in fig. 1A-1F, in which at least some of the individual billows 122, 124 extend continuously and uninterrupted around the midsole component 102 and/or the protection component 104 from an outer side end thereof to an inner side end thereof, the billows configuration 220 of fig. 2A-2F includes mixed or interwoven billows. As best seen in fig. 2B, 2C, and 2E, the billows configuration 220a at the rear heel area of this sole structure 200 has a billow configuration (e.g., having five billow outer ridges and four billow void areas) similar to the billow configuration 120 at the rear heel area of the sole structure 100 of fig. 1A-1F. However, as also best seen in fig. 2B, 2C, and 2E, the billows configurations 220 in this example sole structure 200 have different configurations extending forward along and from the lateral and medial heel areas. More specifically, as shown in fig. 2B, the new billows series 220B originates at the heel area within a void area 250 between the three billows atop the rear billows configuration 220 a. The origin of the new billows series 220B is shown in FIG. 2B at point 252 in void area 250. The three interstitial billows are tapered from their originating points 252 to a greater width and height to form outermost billows ridges to either side of their outermost points 254. Also, the interstitial billows of the new billows series 220b are tapered to a sufficiently large size so as to fully catch up with the rear heel billows series 220a (note, for example, that the rear heel billows 220a has an origination point 220f at a location within the interstitial area of the new billows series 220 b). Further, although not a requirement, in the exemplary sole structure 200 shown in FIG. 2B, the outer ridge 254 of the new billows series 220B tapers in size downward moving forward from its peak to an end point 256. Other support structures including another billows series configuration as shown in fig. 2B may originate from interstitial areas between the new billows configuration 220B and/or from outside of the new billows configuration 220B (e.g., from point 258) and move forward in the sole structure 200. Thus, at least on the lateral heel side shown in fig. 2B, the new billows series 220B may constitute a central billows configuration with a rear billows configuration (from origin point 220f) extending toward the heel and a forward billows configuration (from origin point 258) extending to the midfoot region.

As shown in FIG. 2C, at a medial side of the sole structure 200, another new billows series 220C originates at the heel area disposed within a void area 250 between the top three billows of the rear billows configuration 220 a. The origin of the new billows series 220C is shown in FIG. 2C at point 260 in void area 250. The three interstitial billows are tapered from their origination points 260 to a greater width and height in order to fully catch up with the rear heel billows series 220a (note, for example, that the rear heel billows 220a has an origination point 220f at a location within the void area of the new billows series 220 c).

The exemplary billows configurations of FIGS. 2A-2F show different interstitial billows configurations on the inboard side relative to the outboard side. This is not a requirement. Rather, if desired, a billow configuration like the billow configuration of FIG. 2B may be provided on the inboard side and/or a billow configuration like the billow configuration of FIG. 2C may be provided on the outboard side without departing from the invention.

Figure 2D also illustrates that the sole structure 200 has a slightly differently configured bottom surface on the protective component 204 as compared to the bottom surface of the protective component 104 of the sole structure 100 (shown in figure 1D). This results in a different pattern of exposed midsole material 102 at the bottom surface of sole structure 200. The area of engagement between the protective component 204 and the lightweight midsole material 202 is emphasized in fig. 2A-2F by line 206. Moreover, the junction between midfoot support element 208 (e.g., similar to support element 108 of figures 1A-1F) and lightweight midsole material 202 and/or protective component 204 is emphasized in figures 2A-2F by line 210. The bottom surface of the protective member 204 also includes traction elements and the like, as well as some features described in more detail below with respect to fig. 10A and 10B.

Another example alternative sole structure 300 in accordance with some examples of this invention is shown in conjunction with figures 3A and 3B. As with the other sole structures 100, 200 described above, the sole structure 300 includes a lightweight foam midsole material 302 joined with a protective component 304, for example, by an adhesive or cement. Protective component 304, which may be made of a denser or more durable polymer foam and/or outsole material, provides at least a portion of the bottom surface of sole structure 300. The sole structure 300 of fig. 3A and 3B may be substantially similar in structure and function to the sole structure 200 shown in fig. 2A-2F, although other structures and functions are possible without departing from this invention. For the sake of brevity, similar parts between the parts in fig. 2A-2F and fig. 3A-3B will not be described in detail in this specification. Rather, the following discussion will focus on the differences between the structures shown in FIGS. 3A-3B as compared to the structures shown in FIGS. 2A-2F. As will be appreciated by those skilled in the art, portions not described in detail below with respect to fig. 3A-3B may have the same or similar structures and/or the same or similar features and/or options as those similar portions and structures described above with respect to fig. 1A-2F.

In the example sole structures 100, 200 described above, the billows structure continues uninterrupted around the entire heel area of the lightweight midsole component 102, 202. This is not a requirement. Rather, as shown in fig. 3A and 3B, the rear heel region of the example lightweight midsole component 302 includes a cutout region or cut-away region 310 at a top side thereof. The cutaway area 310 may extend any desired vertical distance in the midsole component 302 without departing from the invention. As shown in FIG. 3B, in this example structure 300, the cutaway area 310 extends downwardly through at least two (and optionally more) of the individual billows structures, although other arrangements are possible without departing from this invention. Cut-away area 310 may also extend downward from 25% to 65% of the overall vertical height (H) of sole structure 300 (and/or midsole component 302) proximate cut-away area 310. Moreover, while figures 3A and 3B only show cut-away area 310 in midsole component 302, cut-away area 310 may also be provided in protective component 304, particularly for sole structures where protective component 304 has a greater presence in the vertical direction at the location of cut-away area 310.

The cut-away area 310 of this example sole structure 300 is somewhat V-shaped to provide an open V-shaped area at the rear edge of the midsole component 302. Other shapes for the cutaway area 310 are possible without departing from the invention, such as a U-shape, a rectangular or square shape, a circular shape, a star shape, a logo shape, and/or any other desired configuration. This exemplary cut-away area 310 helps provide flexibility in the lateral to medial direction for the overall sole structure 300, and in particular for the midsole component 302. This may provide a more natural motion or feel when the user is engaged in walking or other activities such as running, landing a jump, or the like. These types of additional or alternative cut-away regions may be provided at other locations around sole structure 300 (i.e., not limited to the rear heel region). For example, cut-away regions 310 along a lateral side and/or a medial side of sole structure 300 (e.g., in a forefoot region) may help provide and establish a flexion line for the sole structure (optionally, to enhance flexibility of sole structure 300 to more closely correspond with or support a natural tendency for the foot to flex).

At cut-away area 310 of this example sole structure 300, the exposed edges of the foam midsole material 302 are covered by edge elements 312 (e.g., a molded thermoplastic polyurethane member, another plastic member, etc.). This edge element 312 shaped as a heel clip helps protect the exposed edges of the foam midsole material 302 and helps provide an interesting aesthetic or design opportunity. This type of edge element 312 also allows a person to change the shape of the cutaway area 310, if desired. When present, the edge element 312 may be secured to the foam midsole component 302 and/or the overall sole structure 300 and/or another portion of the footwear structure in any desired manner without departing from this invention. As some more specific examples, these components may be joined together using adhesives or cements, mechanical connectors, or the like. Edge elements 312 may also be used to affect the flex characteristics or stiffness characteristics of sole structure 300.

As further shown in FIG. 3B, some of the various billows areas of the foam midsole component 302 of this structure 300 have origination points 360 located at or near the edges of the cutaway area 310. While an individual billows interrupted by cut-away area 310 may have their origination points 360 at the edges of cut-away area 310, in this illustrated example sole structure 300, additional billows areas located below cut-away area 310 also have their origination points 360 at the rear heel area. Alternatively, if desired, the lower billows area may extend continuously and uninterrupted around the rear heel area (although optionally varying in size) without departing from the invention. Other billows configurations above and/or below cutaway area 310 may also be used without departing from this invention.

Although described above as a "cut" or "cut-away" area 310, this area 310 need not be provided in any portion of sole structure 300 by a cutting action. Rather, regions 310 may be provided in desired components of sole structure 300 in any desired manner without departing from this invention, including by utilizing a cutting action, such as by a laser, knife, blade, die, or other cutting system. Alternatively, region 310 may be formed directly into a sole structure component (e.g., component 302 and/or component 304) during its manufacturing process, such as by molding directly into the structure of foam midsole component 302 and/or protective component 304. Thus, the term "cutaway area" as used herein in this context and/or for this type of component or structure should be interpreted to include a region of this type of structure, regardless of how the region is disposed in the component.

Fig. 3A and 3B also show that, in this example structure 300, some of the areas between the billows adjacent the cutaway area 310 at the rear heel area have windows 362 that extend completely through the sidewalls of the midsole component 302. In the illustrated example 300, the window 362 extends along the billow edge above and below it (as the billows taper to their origination points 360), although other shapes for the window 362 may be used without departing from the invention. The window 362 may affect the flexibility of the midsole component 302 at the rear heel region of this example sole structure 300. More or fewer windows 362 may be provided in sole structure 300 without departing from this invention, including more or fewer windows 362 on either side of cut-away region 310 (including no windows 362 on one or both sides).

Windows 362 may be disposed in any desired manner in desired components of sole structure 300 without departing from this invention, including by utilizing a cutting action (e.g., by a laser, knife, blade, die, or other cutting system), by integrally forming windows 362 directly in sole structure components (e.g., component 302 and/or component 304) during their manufacturing process (such as by molding windows 362 directly into the structure of foam midsole component 302 and/or protective component 304), and so forth.

Although the sole structures 100, 200, 300 of fig. 1A-3B all show billows structures having three to five separate billows structures that are relatively uniformly shaped over various areas, this is not a requirement. As another example, FIG. 4 shows a portion of another exemplary sole component 400 in which a billows structure 402 includes three billows oriented in a vertical or top-to-bottom direction. The view of FIG. 4 shows a lateral side view of this example billows structure 402, but similar structures may be disposed on, for example, a medial side of sole element 400 and/or at a rear heel area of sole element 400. This example billows structure 402 may be provided in a foam midsole component as shown in fig. 4 (e.g., similar to components 102, 202, and/or 302 discussed above), or it may be provided in a protective component, such as a polymer foam protective component and/or a component like components 104, 204, 304 discussed above in connection with fig. 1A-3B. Moreover, although only the heel region of sole element 400 is shown in FIG. 4, those skilled in the art, having benefit of this disclosure, will readily appreciate that a sole element for supporting the entire plantar surface of a wearer's foot (or any portion thereof) may be provided without departing from the invention.

The billows structure 402 of FIG. 4 differs from some of the other billows structures in the billows shape described above with respect to FIGS. 1A-3B. More specifically, as shown in fig. 4, the central billows 402b of this example billows structure 402 is concave (or flared) in both an upward direction and a downward direction. As shown in fig. 4, the valley of the void area 404a between the central billows 402b and the top billows 402a is curved in an upwardly concave direction such that the high point of the curve is at the central side heel area. Similarly, the valley of void area 404b between central billows 402b and bottom billows 402c is curved in a concave downward direction such that the low point of the curve is at the central side heel area. Due to this configuration, the top billows 402a are shaped to curve in an upward direction with the upper highest point of the curve being located in the central area of the top billows 402a in the arrangement shown in FIG. 4. Similarly, bottom billows 402c is shaped to curve in a downward direction with the lower lowest point of the curve being located in the central area of bottom billows 402c in the arrangement shown in FIG. 4. This gives the overall billows structure 402a slightly more convex shape than at least some of the billows structures shown in fig. 1A-3B.

Notably, the billows configuration 402 has smoother side walls (as with the billows structures of FIGS. 2A-3B) than the more stepped side walls in the billows structures shown in FIGS. 1A-1F. Also, the billows configuration of FIGS. 2A-4 has individual billows outer ridges shaped as sharp corners. However, other structural options for the sidewalls and/or corners are possible without departing from the invention.

Figures 5, 6, and 7 show side views of various examples of articles of footwear 550, 650, and 750 that include sole structures 500, 600, and 700 according to other examples of this invention. Fig. 5 shows basketball shoe 650, fig. 6 shows running shoe 650, and fig. 7 shows cross-training shoe 750. Sole structures 500, 600, and 700 are engaged with upper 552, 652, and 752, respectively, to provide unitary footwear structures 550, 650, and 750. Uppers 552, 652, and 752 may be engaged with their respective sole structures 500, 600, and 700 in any desired manner, including in conventional manners as are known and used in the art, without departing from this invention. As some more specific examples, upper 552, 652, and 752 and sole structures 500, 600, and 700 may be joined together by adhesives or cements, by mechanical connectors, by stitching or sewing, and/or by other connection techniques.

In further describing footwear structures 500, 600, and 700 of fig. 5-7, various features of the example upper (including potential features of upper 552, 652, and 752) will be described. This description includes examples of features of uppers that may be included in footwear structures according to at least some examples of this invention, including examples of uppers that may be engaged with sole structures 100, 200, 300, and 400 of figures 1A-4. Since the sole structures 500, 600, and 700 of fig. 5-7 have substantially similar structures, some differences between these sole structures 500, 600, and 700 will be described in conjunction with fig. 5-7. Thereafter, more detailed features of the construction and portions of the sole structures 500, 600, and 700 of FIGS. 5-7 will be described in greater detail in connection with FIGS. 8A-8F.

Uppers 552, 652, and 752 for footwear structural articles 550, 650, and 750 according to the present invention may be constructed of one or more component parts that may be joined together in any desired manner, including in conventional manners known and used in the footwear art, including by the use of cements or adhesives, by the use of mechanical connectors, and/or by fusing techniques (e.g., melting or fusion bonding of hot melt materials, etc.). Some non-limiting examples of construction techniques are described in more detail below.

Upper 552, 652, 752 may be made of any desired material and/or combination of materials without departing from this invention. For example, upper 552, 652, 752 may include a multi-layer construction, wherein each layer covers all or some portion of the overall upper area. In some more specific examples, upper 552, 652, 752 may include an intermediate mesh layer covered and/or sandwiched between an inner textile or fabric layer (e.g., for comfortable contact with the foot) and an outer "skin" layer (e.g., made of a thermoplastic polyurethane film to provide better support at certain areas, to provide wear-resistance or abrasion-resistance in certain areas, to provide a desired aesthetic, etc.) in at least some areas. Any of the interior textile or textile layers, mesh layers, and/or skin layers need not extend to cover the entire surface of upper 552, 652, 752. Rather, the location of the various layers may be selected to control the properties of upper 552, 652, 752, for example, by omitting skin layers at certain areas to improve breathability, to improve flexibility, to provide a different aesthetic appearance (such as openings in skin layers to create "LOGO" or other design features from the underlying mesh material), and so forth. Also, as is known in the art, upper 552, 652, 752 may define an ankle opening, around which a comfort-enhancing foam or fabric loop may be disposed, if desired. The bottom surface of upper 552, 652, 752 may include internal strobel members (e.g., which may be stitched to the medial and lateral side edges of the upper) that connect the medial and lateral sides of the upper material to thereby enclose upper 552, 652, 752. Sole structures 500, 600, 700 may be engaged with upper 552, 652, 752 at a bottom edge of upper 552, 652, 752 and the strobel structure, for example, using cements or adhesives, stitching or sewing, mechanical connectors, and the like.

The multi-layer upper construction may be produced in any desired manner without departing from this invention, including in conventional manners as are known and used in the footwear art. For example, if desired, the skin layers may be made of a "stitchless" type material that can be adhered to the underlying mesh layer (or other layer) in a conventional manner (e.g., by the application of heat and/or pressure) using an adhesive or hot melt material. As further examples, skin layers may be joined with underlying mesh layers (or other layers) by cements or adhesives and/or by stitched seams, if desired. As still further examples, if desired, upper 552, 652, 752 (or portions thereof) may be constructed by joining the various layers of material using a fusing technique, for example, as described in U.S. patent application publication No. 2011/0088282 and U.S. patent application publication No. 2011/0088285 (each of which is incorporated herein by reference in its entirety).

Upper 552, 652, 752 may include other support elements at desired locations (e.g., sandwiched between the outer skin layer and the underlying mesh layer). For example, a heel counter may be provided in the heel region to provide more support to the wearer's heel. When present, the heel counter may be made of a rigid, thin plastic material, such as PEBAX, TPU, or other polymeric material, and it may include one or more openings (e.g., to control flexibility, breathability, support characteristics; to reduce weight; etc.). Additional supports may be provided in other areas of the shoe 550, 650, 750, if necessary or desired, such as in the forefoot or toe areas (to provide protection and wear resistance, etc.), at lateral side areas proximate the fifth metatarsal head, etc.

Other potential materials that may be used in upper 552, 652, 752 according to at least some examples of this invention include one or more of the following: synthetic leather, natural leather, textiles, any combination of these materials, and/or any combination of these materials with any of the other materials described above. As another potential feature, at least some portions of upper 552, 652, 752 may be formed through a knitting process, if desired. Optionally, in at least some examples of this invention, at least a majority (or even all) of upper 552, 652, 752 may be formed using a knitting process. The woven textile component may be utilized to provide a lightweight, breathable, and comfortable upper construction.

Turning now to fig. 5, additional details of the example footwear structure 550 will be described. The example footwear structure 550 is a basketball shoe. Upper 552 may have a configuration similar to any conventional basketball shoe configuration, including configurations made from leather, multiple layers of fusion bonded materials, or other materials, and/or configurations as known and used in the art. The sole structure 500 of this example has a general appearance similar to the sole structure 100 shown in fig. 1A-1F as described in detail above, e.g., including a series of five stacked billows extending continuously around the sole structure 500 from a forefoot lateral side region, around a rear heel region, to a forefoot medial side region of the sole structure 500. The five billows configuration of this example sole structure 500 is well suited for basketball shoes because it results in a somewhat higher heel structure as is common in today's basketball shoes.

However, although similar in appearance, the sole structure 500 of FIG. 5 differs significantly in construction from the sole structure 100 of FIGS. 1A-1F. While a detailed description of the construction of this sole structure 500 will be retained for the discussion of fig. 8A-8F below, at this point, it is appropriate that the exposed rear portion 504 of the sole structure 500 constitute a protective element that at least partially retains and contains a portion of the midsole component 502. The rear protective member 504 may be made of a material like the various protective members 104, 204, 304 described above (e.g., including a polymer foam material having one or more billows structures formed on the outer sidewall edges thereof). The forward portion 502 of the sole structure 500 in this example constitutes an exposed portion of a lightweight foam midsole material 502, which foam midsole material 502 may be similar to the lightweight midsole components 102, 202, 302 described above (including the same or similar materials). While the midsole component 502 may still extend to support all or substantially all of the plantar surface of the wearer's foot, in this illustrated example structure 500, at least some, and optionally most, of the lightweight midsole component 502 is contained within the protective component 504. In this manner, at the rear of the footwear structure 550, the protective component 504 acts as a cage or carrier for the lightweight foam component 502. As will be described in greater detail below, the foam midsole component 502 extends from a forward (open) end of the protective component 504.

Turning now to fig. 6, additional details of the example footwear structure 650 will be described. The example footwear structure 650 is a running shoe. Upper 652 may have a configuration like that of any conventional running shoe, including configurations made from multiple layers of fusion bonded materials, textiles, mesh, braided materials, or other materials, and/or configurations as are known and used in the art. The sole structure 600 of this example has a general appearance similar to the sole structure 200 shown in fig. 2A-2F described in detail above, e.g., including a first series of stacked billows 610 extending around a rear heel area of the sole structure 600 and a series of staggered, forward billows 612 extending forward from the heel area of the sole structure 600 toward a midfoot area and a forefoot area. The forward billows series 612 originates in the interstitial areas between the billows of the rear heel billows series 610. The top billows of the forward billows series 612 originate above the top billows of the rear heel billows series 610. The rear heel billows series 610 terminate in a heel-to-midfoot area, e.g., between individual billows of the forward billows series 612 or void areas along individual billows of the forward billows series 612. Although FIG. 6 only shows a lateral side view, a medial side view of the shoe structure 650 may have a similar void billows configuration.

The sole structure 600 for this example running shoe 650 is slightly shorter and lower profile than the sole structure 200 of figures 2A-2F and the sole structure 500 of figure 5. Notably, sole structure 600 includes three vertically stacked billows 610 at the rear heel area (instead of the five billows shown in fig. 2A-2F) and three vertically stacked forward billows 612 staggered from heel billows 610. Although this would not be necessary, this reduced billows count provides a slightly less vertical height in the heel area of sole structure 600.

Moreover, like the sole structure 500 of FIG. 5, the exposed rear portion 604 of the sole structure 600 constitutes a protective element that at least partially retains and contains a portion of the lightweight foam midsole component 602. The rear protective component 604 may be made of a material like the various protective components 104, 204, 304 described above (e.g., including a polymer foam material having one or more billows structures formed on the outer sidewall edges thereof). The forward portion 602 of the sole structure 600 in this example constitutes an exposed portion of a lightweight foam midsole material 602, which foam midsole material 602 may be similar to the lightweight midsole components 102, 202, 302 described above (including the same or similar materials). While the midsole component 602 may still extend to support all or substantially all of the plantar surface of the wearer's foot, in this example structure 600, at least some, and optionally most, of the lightweight midsole component 602 is contained within the protective component 604. In this manner, at the rear of the footwear structure 650, the protective component 604 acts as a cage or carrier for the lightweight foam midsole component 602. As will be described in greater detail below, the foam midsole component 602 extends from a forward (open) end of the protective component 604.

Relative to the vertical orientation shown in fig. 6 (e.g., with the shoe 650 oriented on a horizontal contact surface), the heel and/or midfoot areas include interwoven billows from the rear heel billows series 610 and the forward billows series 612. In other words, as a person moves in a vertical direction in at least some portions of the heel area and/or midfoot area of sole structure 600 (e.g., shown by line 614), it will encounter surfaces of individual billows of the forward billows series 612 that are located between surfaces of individual billows of the rear heel billows series 610. These series of stacked and/or interwoven billows provide increased support in the heel/midfoot area and good support for the sole of the running shoe.

Fig. 7 shows a training shoe 750. Upper 752 may have a configuration like that of any conventional training shoe, including configurations made from fusion-bonded materials, textiles, mesh, knitted materials, or other materials, and/or configurations as are known and used in the art. Sole structure 700 of this example has a configuration with void billows, which will be described in greater detail below. Like sole structure 500 of figure 5, exposed rear portion 704 of sole structure 700 constitutes a protective element that at least partially retains and contains a portion of midsole component 702. The rear protective member 704 may be made of a material like the various protective members 104, 204, 304 described above (e.g., including a polymeric foam material having a billows structure formed on the outer sidewall edges thereof). The forward portion 702 of the sole structure 700 in this example constitutes an exposed portion of the lightweight foam midsole material 702, which foam midsole material 702 may be similar to the lightweight midsole components 102, 202, 302 described above (including the same or similar materials). While the midsole member 702 may still extend to support all or substantially all of the plantar surface of the wearer's foot, in this example structure 700, at least some, and optionally most, of the lightweight midsole member 702 is contained within the protective member 704. In this manner, at the rear of the footwear structure 750, the protective component 704 acts as a cage or carrier for the lightweight foam midsole component 702. As will be described in greater detail below, the foam midsole member 702 extends from a forward (open) end of the protective member 704.

In this example sole structure 700, both a rear heel area of the protective component 704 and a front toe area of the midsole foam component 702 include three billows structures stacked vertically (with a heel billow slightly deeper than a forefoot billows). However, a variety of different types of support features are provided at least along the lateral side of the footwear 750 in the midfoot to forefoot region (although similar structures may be provided on the medial side if desired). Moving in the vertical direction in fig. 7, a first support rib or element 710 is provided along the bottom of the lateral side of the sole structure 700 (in this example, in the foam midsole component 702). The first support rib or element 710 is positioned vertically downward from and proximate to a fifth metatarsal head support region of sole structure 700. The second support rib or element 712 is disposed slightly rearwardly and upwardly from the first support rib or element 710. This second support rib or element 712 bridges the junction between the foam midsole component 702 and the protective component 704 in this example structure 700 and peaks more in the midfoot or arch region of the sole structure 700. The second support rib or element 712 may have an overall longitudinal dimension from end to end that is longer than the longitudinal dimension of the first support rib or element 710. A third support rib or element 714 is provided slightly forward and upward from the second support rib or element 712. At least a majority (and potentially all) of this third support rib or element 714 is formed in the foam midsole component 702. Third support rib or element 714 vertically overlaps first support rib or element 710 and is positioned vertically downward from and proximate to a fifth metatarsal head support region of sole structure 700. The third support rib or element 714 may have a shorter longitudinal dimension (end-to-end) than the first support rib or element 710. A fourth support rib or element 716 is provided slightly rearwardly and upwardly from the third support rib or element 714. This fourth support rib or element 716 also bridges the junction between the foam midsole component 702 and the protective component 704 and is located mostly in the midsole component 702 and forward of the second support rib or element 712. A fifth support rib or element 718 is provided slightly forward and upward from the fourth support rib or element 716. At least a majority (and potentially all) of this fifth support rib or element 718 is formed in the foam midsole component 702. Fifth support rib or element 718 vertically overlaps first support rib or element 710 and third support rib or element 714 and is located proximate a fifth metatarsal head support region of sole structure 700. The fifth support rib or element 718 may have a shorter longitudinal dimension than the first support rib or element 710 and/or the third support rib or element 714.

Thus, the first support rib or element 710, the second support rib or element 712, the third support rib or element 714, the fourth support rib or element 716, and the fifth support rib or element 718 create a billow structure discontinuity between the billow structures in the rear heel protection component 704 and the forward foam midsole component 702. The support ribs or elements 710, 712, 714, 716, and/or 718 provide additional support to the midfoot region and/or forefoot region of the lateral side of the sole structure 700 (e.g., in an area proximate the fifth metatarsal head of a wearer's foot). This provides additional support to the wearer during training activities (such as when pushing off the outside of the foot, for example, when making a sharp turn or a swerving motion).

Although other specific structures are possible, in this illustrated example, the support ribs or elements 710, 712, 714, 716, 718 are shaped as raised pyramid-like structures that extend outwardly from the side surfaces of the sole structure 700. The support ribs or elements 710, 712, 714, 716, 718 may be oriented somewhat like the interwoven billows structures shown in the various other figures described above. More specifically, as shown in fig. 7, support ribs or elements 712 and 716 originate in the interstitial regions between support ribs or elements 710, 714, and 718. The support ribs or elements 710, 712, 714, 716, 718 may also originate in interstitial areas between billows located forward and/or rearward of the support ribs or elements. Notably, the outwardly extending peaks of the support ribs or elements 712, 716, and 718 are generally aligned in a top front to bottom rear direction. Also, the outwardly extending peaks of the support ribs or elements 710, 714 and 718 are generally aligned in a vertical direction from top to bottom.

The support ribs or elements of fig. 7 merely constitute examples of structures for providing lateral and/or medial side support (and/or for altering or controlling the support characteristics of sole 700). Other support variations configurations may be used, including different numbers of ribs, different arrangements of ribs, different shapes of ribs, and/or different relative orientations of ribs with respect to one another, without departing from this invention. Also, if desired, simple gaps may be provided between structures of adjacent billows, for example, to change the support or feel at the gaps. "gaps" may include actual spaces in the foam or smooth foam between billows structures.

One exemplary configuration of the sole structures 500, 600, and 700 of figures 5-7 is described in greater detail in conjunction with figures 8A-8F. Fig. 8A illustrates a bottom perspective view of an example sole structure 800, the example sole structure 800 including a rear protective component 804 and a foam midsole component 802 that extends forward of a free end of the protective component 804 and away from the free end of the protective component 804. Fig. 8A shows a protective component 804 and a foam component 802 that fit together but prior to being secured to one another, for example, using an adhesive or glue. Fig. 8B shows a bottom view of the two parts separated from each other, and fig. 8C shows a top view of the two parts separated from each other. As can be seen from these figures, the protective component 804 acts as a cage or carrier containing the rear portion of the foam midsole component 802. The foam midsole component 802 has an upper support surface 802a for supporting all or substantially all of a plantar surface of a wearer's foot (although the protective component 804 may also provide a surface for directly supporting at least some portion of a plantar surface of a wearer's foot, if desired). The foam midsole component 802 is exposed through a heel opening 806 defined in a bottom surface of the protective component 804, except for a free front end portion that extends out of the protective component 804. Providing this bottom opening 806 may both reduce weight and allow one to control and change the flexibility characteristics of the overall sole structure 800.

In this example structure 800, the foam midsole component 802 may be made of any desired foam material (or combination of foam materials) without departing from this invention, including lightweight foam materials of the type described above in connection with the components 102, 202, 302. Optionally, if desired, the foam midsole component 802 may include one or more fluid-filled bladders, mechanical cushioning structures, and/or other structures for providing impact force attenuation embedded or included therein. However, in this illustrated example, the foam midsole component 802 is constructed of a single, solid piece of foam material (preferably one of the lightweight and/or less dense foam materials described above).

The protective component 804 of the illustrated example sole structure 800 may also be constructed of a polymer foam material, including conventional polymer foam materials as midsole materials as are known and used in the footwear art. As some more specific examples, protective component 804 may be made of polyurethane foam, ethylene vinyl acetate ("EVA") foam, phylon, or other known midsole foams or materials. In some example structures according to this invention, the polymer foam material used for the protective component 804 will be a heavier, denser, and/or more durable foam material (e.g., more abrasion resistant, etc.) than the foam material used for the foam midsole component 802.

8A-8C, the polymeric foam material of protective component 804 may include a billows structure formed around at least one or more portions of a peripheral edge thereof. More specifically, fig. 8A-8C illustrate that the protective member 804 may form an outer shell including a billows structure (such as the billows structures of fig. 5-7), wherein the outer shell includes: a lateral side wall 804a, a medial side wall 804b, a rear heel wall 804c connecting the medial side wall 804b and the lateral side wall 804a, and a bottom wall 804d connecting the medial side wall 804b, the lateral side wall 804a, and the rear heel wall 804 c. In at least some examples of the invention, the billows structure of the polymer foam material of protective component 804 will extend continuously around the outer surface of at least a portion of outer side wall 804a, rear heel wall 804c, and at least a portion of inner side wall 804 b. The billows structure of the polymer foam material of protective component 804 may also include interwoven billows; a support rib or support element; a vertical rib; a gap; and/or any of the other billows structures, features, and/or options described above.

Fig. 8A-8C also show that at least the heel portion of the foam midsole component 802 is received in a space defined between the lateral sidewall 804a, medial sidewall 804b, rear heel wall 804C, and bottom wall 804d of the protective component 804. In this example structure 800, the forefoot end of the foam midsole component 802 extends beyond the forward ends of the lateral side wall 804a and the medial side wall 804 b. This forefoot end of the foam midsole component 802 may be at least partially exposed in the finished sole structure 800.

As described above with respect to at least fig. 7, both an outer lateral edge surface of the protective component 804 and an outer lateral edge surface of the foam midsole component 802 may include a billows structure. For example, a billow structure of protective component 804 may extend (continuously or discontinuously (e.g., due to interwoven billows, other supports, and/or other features)) around a lateral side to a rear heel-to-medial side of the sole structure. Additionally or alternatively, foam midsole component 802 may include a billows structure extending around a forward toe area of sole structure 800. In this particular illustrated example, the billows structure of the foam midsole component 802 includes three billow outer ridges connected by two billow void areas.

When both components 802 and 804 have billows structures, the billows structure of the foam midsole component 802 may or may not extend continuously with the billows structure of the protective component 804. These billows structures may be interrupted without departing from the invention, for example, by support ribs or other elements, by interstitial billows, by gaps in the sole structure, by smooth foam, by an external plastic or composite support, by transition zones, or the like. Such "interruptions" of the billows structure may be provided at any desired location, such as at the lateral forefoot region of the sole structure and at the medial forefoot region of the sole structure (e.g., to provide a location that supports more natural athletic flex), at the lateral forefoot region of the sole structure (e.g., to provide increased support for a cutting or turning action), and/or at other desired locations (e.g., to provide desired support and/or flexibility, including natural athletic flexibility characteristics).

The bottom surface of either or both of the foam midsole component 802 and/or the protective component 804 may be provided with additional components. For example, for at least some portions of sole structure 800 that will contact the ground in use, an anti-wear or abrasion-resistant material may be applied to at least portions of the bottom surfaces of these components in order to improve their wear-resistance and durability characteristics. Fig. 8D illustrates an example outsole component 820 that may be applied to a bottom surface of the protective component 804, optionally in a receptacle 822 formed (e.g., molded or cut) in a heel region of the protective component 804. Fig. 8E illustrates an example outsole component 824 that may be applied to the bottom surface of the foam midsole component 802, optionally in a receptacle or other area that is formed (e.g., molded or cut) in a forefoot region (area 826) of the foam midsole component 802. Fig. 8F shows these parts and how they fit together. These outsole components 820 and 824 may be made of any desired outsole material (or combination of outsole materials) including rubber, thermoplastic polyurethane, and the like, without departing from this invention. Additionally or alternatively, one or more of the outsole components 820, 824 may constitute cleat structures or receptacles for receiving removable cleat structures.

Figure 9 provides an exploded view of another example sole structure 900 according to some examples of this invention. In this sole structure 900, a lightweight foam midsole component 902 (e.g., of the type described above) includes a support surface 902a for supporting all or substantially all of a plantar surface of a wearer's foot. A foam protective component 904 (optionally including billows structures of any desired type) extends around at least a side of the midsole component 902 and acts as a cage or carrier for that portion of the foam midsole component 902 it contains (in this example, from a lateral midfoot or forefoot region, around a rear heel region, to a medial midfoot or forefoot region). A plurality of outsole protective elements 906a, 906b, 906c, and 906d are provided to protect various areas of the bottom of foam midsole element 902 (and/or the bottom of protective element 904, which should be exposed at the outer bottom surface of sole structure 900). In this illustrated example, outsole component 906a protects one heel side of foam midsole component 902 (and/or protective component 904), outsole component 906b protects the rear heel area of foam midsole component 902 (and/or protective component 904), and outsole component 906c protects the other heel side of foam midsole component 902 (and/or protective component 904). The relatively large outsole protective element 906d at the forefoot region covers most, if not all, of the forefoot region of the bottom of foam midsole element 902 (and/or protective element 904). These various components may be engaged with one another in any desired manner, for example, by cements or adhesives, by mechanical connectors, or in any other manner as is known and used in the art. These components may be made of any of the materials described above for the corresponding parts, for example. Also, any of the individual components shown or described above in fig. 9 may be made of one or more individual parts without departing from this invention.

While fig. 5-9 illustrate sole structures in which lightweight midsole components are at least partially covered by protective components in the heel region and/or midfoot region (and extend out to be exposed at the forefoot region of the sole structure), other configurations are possible without departing from this invention. For example, if desired, the lightweight midsole component and the exposed portions of the protective component may essentially "flip-flop" end up in the structures of fig. 5-9 such that the lightweight midsole component is covered by the protective component in the forefoot region and/or midfoot region (and extends out to be exposed at the heel region of the sole structure). Modifications in the size, shape and/or connection areas between the lightweight midsole element and the protective element may also be made without departing from the invention in its broader aspects.

Figures 10A and 10B illustrate additional features that may be included in sole structures according to at least some examples of this invention. Fig. 10A shows a bottom surface 1002a of a lightweight midsole component 1002 that is similar to those described in detail above. The bottom surface 1002a of this example lightweight midsole component 1002 includes a plurality of protruding or "bulging" regions at various locations of the midsole component 1002. One bulge region 1004a is provided in the rear heel region of midsole component 1002 and provides additional impact force attenuation and/or a comfortable soft feel (e.g., for when the wearer steps or lands on a jump). Additional bulging regions are provided in the forefoot region of sole structure 1000. More specifically, for example, the bulge region 1004b is disposed on the lateral side of the midsole component 1002 below the fifth metatarsal head region. The third tympanites area 1004c is positioned slightly forward and medially centered relative to the center of the tympanites area 1004b (e.g., below the first metatarsal head support region of the sole at the lateral side (i.e., below the metatarsal head region of the big toe)). The fourth bulge region 1004d is located anterior to the third bulge region 1004c (e.g., under the big toe and/or adjacent toe at the lateral side).

The raised areas 1004a-1004b in this example structure 1002 are arranged to provide additional impact force attenuation and/or a comfortable soft feel under the wearer's foot during certain activities, such as running (or walking), stepping or jumping landing, take-off, and the like. During a typical gait cycle, the runner takes a step toward the lateral heel side of the foot. A bulging region 1004a is provided in the rear heel region of the midsole component 1002 to provide additional impact force attenuation and/or a comfortable soft feel at the time of the heel strike. As the stride continues, the foot rolls forward and the lateral side edges of the sole contact the ground. The bulge region 1004b is disposed at a lateral side region of the midsole component 1002 (under the small toe) to provide additional impact force attenuation and/or a comfortable soft feel at this point in the gait cycle. As the foot continues to roll forward, it also begins to roll inward toward the medial side, and eventually, the runner pushes away from the ground using the first metatarsal head region and/or the big toe (and possibly the adjacent toes). The bulges 1004c and 1004d are disposed at the medial forefoot side region of the midsole component 1002 (under the ball and/or toe regions) to provide additional impact force attenuation and/or a comfortable soft feel at these times in the gait cycle.

Fig. 10B shows a representation of a bottom surface 1000A of a sole structure 1000 having included therein a midsole component 1002 of the type described above with respect to fig. 10A. As shown in this figure, the bottom of sole structure 1000 includes traction elements and/or other features that are located below the bulbous regions 1004a-1004d (e.g., shaped as part of a thin mesh-type protective component as will be described in greater detail below). The bulging properties of sole structure 1000 at various locations and the foam material over those locations help provide good impact force attenuation at the bulging regions 1004a-1004 d. Additionally or alternatively, if the foam material of the midsole component 1002 is sufficiently responsive, at least some of these bulges 1004a-1004d can provide return energy to the foot (e.g., apply a foot lifting force to the plantar surface of the wearer when the impact force is reduced (when the foot is lifted for the next step) and the foam midsole component 1002 returns to its original shape).

While four different bulge regions are described and spaced apart in the manner described above with respect to fig. 10A, this is not a requirement. Rather, any desired pattern of bulges can be provided in the midsole component, including more or less bulges, without departing from this invention. A sole structure according to an example of the invention may include any number of bulbous zones, including a non-bulbous zone; one, two or more raised areas (arranged in any desired manner). Alternatively, the bulging regions may be arranged to provide impact force attenuation, a soft feel, and/or return energy at any desired location, depending on the intended use of the shoe. These types of bulges are visible at the bottom of the sole structure shown in fig. 2B-2F, 3A, 3B, and 7, and may be included in any desired sole structure.

Figures 11A-11C illustrate another example basketball shoe 1150 that includes a sole structure 1100 in accordance with at least some examples of this invention. Fig. 11A is a lateral side view of footwear 1150, fig. 11B is a medial side view of footwear 1150, and fig. 11C is a rear heel view of footwear 1150. The footwear 1150 includes an upper 1152 having a multi-layer, fusion-bonded upper configuration, although other configurations may be used without departing from this invention. Upper 1152 is engaged with a sole structure 1100 that includes features according to at least some examples of this invention. Upper 1152 may be engaged with sole structure 1100 in any desired manner without departing from this invention, including in conventional manners as are known and used in the art. As some more specific examples, upper 1152 and sole structure 1100 may be joined to one another by glue or adhesive, by mechanical connectors, by stitching or sewing, or the like, for example.

The sole structure 1100 of the illustrated example includes three primary component portions. For example, the first portion constitutes a lightweight (and low-density) midsole component 1102 of the various types described above. The foam midsole component 1102 may extend to support all or substantially all of a plantar surface of a wearer's foot. Portions of the midsole component 1102 are exposed at an exterior surface of the footwear structure 1150 at various locations in this illustrated example, including: (a) along the lateral side edges, at least at the midfoot region (see FIG. 11A); (b) at the front toe region (optionally, at least at the lateral side; see fig. 11A); (c) along all or substantially all of the medial side edge (see fig. 11B); and (d) at a portion of the upper heel region on the medial side (see fig. 11C). The foam midsole component 1102 provides a soft and comfortable feel to the foot of the wearer, as generally described above with respect to other lightweight foam midsole structures.

The second portion of this example sole structure 1100 is a protective component 1104 that at least partially contains a foam midsole component 1102. The protective component 1104 of the illustrated example constitutes a polymer foam-type protective component that may have a foam construction that is denser or heavier than the foam material of the lightweight foam midsole component 1102. In this illustrated example, a portion of protective component 1104 extends from a midfoot region and/or a heel region of a lateral side of sole structure 1100, around a rear heel region of sole structure 1100, and over a heel region of a medial side of sole structure 1100 to a heel region of a medial side of sole structure 1100. As best shown in fig. 11C, the foam midsole component 1102 extends outward from behind the protective component 1104 and is exposed at an exterior surface of the footwear 1150 at a rear heel region of the sole structure 1100. Another portion of protective component 1104 is positioned at a forefoot region on a lateral side of footwear 1150, as shown in FIG. 11A. This lateral forefoot portion of protective component 1104 may be integrally formed with protective component 1104 at the rear heel region as a unitary, one-piece construction, or it may be a separate part. Another portion of protective component 1104 of this example is disposed at a toe region of an extreme forward portion of sole structure 1100, extending from a medial side around a forward toe region to a lateral side. This forward toe lateral forefoot portion of protective component 1104 may be integrally formed (as a unitary, one-piece construction) with one or more of the other protective component portions 1104 described above, or it may be a separate portion.

A third portion of this example sole structure 1100 is an outsole element 1106 that engages a bottom side of midsole foam component 1102 and/or one or more of polymer foam protective components 1104, which may also serve as protective components. The outsole element 1106 of this example sole structure 1100 covers a majority of the bottom surface of the shoe 1150. Which may include traction elements such as grooves, ridges, nodules, chevrons, and/or other traction enhancing components. One or more outsole nubs, such as nub 1108, may cover and directly contact a bulging region of the bottom surface of foam midsole component 1102 (like the bulging regions described above in connection with fig. 10A) to provide a soft contact area of sole structure 1100. As also shown in fig. 11B, this example outsole component 1106 includes an opening defined therethrough at which a bottom surface of the midsole member 1102 is exposed.

Outsole element 1106 may be made of a thin, highly flexible material, which may have a base surface thickness (i.e., the thickness of its base sheet or web surface at locations that do not penetrate nodules, raised ribs, traction elements, or the like) of less than 3mm, and in some examples less than 2mm, less than 1.5mm, or in some examples even less than 1 mm. The thin, flexible outsole element 1106 may be formed of an elastomer having a hardness and other properties similar to those of elastomer compounds conventionally used in footwear outsoles. This thin outsole web structure allows the outsole elements 1106 to flex significantly between adjacent lugs 1108 and/or other structural components. In some sole structures, portions of outsole element 1106 may be formed from a rubber compound that is harder and more durable than other portions of outsole element 1106. For example, a higher durability rubber may be used in a crash pad located in the heel region and/or on the bottom of a boss located in some other high pressure region that typically wears faster.

As shown in fig. 11A, the protective component 1104 of this example sole structure 1100 has a billows structure (with three outer billows ridges) that appears similar, at least in some respects, to the billows structure described above in connection with fig. 4. As shown in FIG. 11A, the central billows of the protective element 1104 extending around the heel area terminate between billows ridges of the billows structure provided in the foam midsole component 1102 at the lateral midfoot area (at termination point 1110). A portion of another forward billow structure for lateral forefoot protective component 1104 originates at point 1112 in a void area between the two billow ridges of foam midsole component 1102. The billows structure of foam midsole component 1102 originates from the interstitial areas between the billows of protective element 1104 located forward and rearward of the billows structure of foam midsole component 1102 (see point 1114).

As shown in fig. 11C, the three billows structures at the lateral side of protective member 1104 are reduced to two billows structures at the bottom medial heel side of protective member 1104. When foam midsole component 1102 is present at the rear heel region from under protective component 1104, foam midsole component 1102 forms a dual billows structure that covers the dual billows structure of protective component 1104 at a medial side of sole structure 1100. Thus, in this example sole structure 1100, the billows structure extending around the heel changes from three billows structures on one side to four billows structures on the other side. At the medial side of sole structure 1100, as shown in fig. 11B, the billows structure of protective component 1104 terminates at a low, medial heel area of sole structure 1100. The billows structure of the foam midsole component 1102 extends further forward, and the top outer ridge of the billows structure extends forward in a slightly wavy or curved manner. The separate and shallower billows structure continues along the side edges of the protective member 1104 and/or the exposed foam midsole member 1102, around the forward toe area, as shown in fig. 11A and 11B.

Although several of the example sole structures described above include: (a) for example, a foam midsole component made of a lightweight foam material, and (b) another foamed polymer material as a protective element, optionally made of a heavier and denser polymer foam material, although it is not a requirement that the sole structure according to the present invention have two different polymer foam materials. Rather, as described above with respect to, for example, fig. 1A-2F, if desired, a protective component in the form of an outsole component may be provided on at least a portion of the bottom of a lightweight and less dense foam midsole component, without the need for another polymer foam protective component in the sole structure. Figures 12A-12C illustrate another example sole structure 1200 in which a lightweight and less dense foam midsole component 1202 (e.g., of the type described above) is protected over at least a portion of its bottom surface using an outsole component 1206, while not including another polymer foam protective material at any other location in sole structure 1200.

Fig. 12A shows a lateral side view, fig. 12B shows a medial side view, and fig. 12C shows a bottom view of the example sole structure 1200 and article of footwear 1250 in accordance with an example of this invention. This example article of footwear 1250 is a running shoe and includes an upper 1252 constructed, for example, from any of the various materials described above. As some more specific examples, upper 1252 may be at least partially formed from a textile material, such as a mesh material, a braided material, or the like. Upper 1252 may be engaged with sole structure 1200 in any conventional manner (e.g., using adhesives or cements).

While not required to have any billows structure, the side surface 1202a of the lightweight midsole component 1202 of this example structure 1200 does include various billows structures, although the overall billows structure of this sole 1200 differs in some respects from the various other billows structures described above. As shown in fig. 12A, the heel area of this example midsole component 1202 includes a three-layer billows structure 1210 that extends from a rear heel area to a lateral side of the shoe 1250. A double billows structure 1212 is provided at a midfoot area of the midsole component 1202, and the double billows structure 1212 is separated from a rear heel triple billows structure 1210 by a smooth section 1214 of polymer foam material (part of the lightweight midsole component 1202) providing a gap in the billows structure on a lateral side of the shoe 1200. Midfoot double billows series 1212 terminates at a midfoot/forefoot area of sole structure 1200. Another smooth segment 1216 of polymer material (part of the lightweight midsole component 1202) creates a gap between the midfoot double billows series 1212 and a single billow 1218 (or raised rib structure) that extends around the toe area of the shoe 1250.

A single forefoot raised rib 1218 of this example structure extends from a lateral side of the shoe 1250 around the forward toe region to a medial side, as shown in fig. 12A and 12B. As shown therein, a single billows 1218 terminates at the medial forefoot region. After another short gap 1220 without billows (in which the smooth polymer foam segment 1220 of the midsole component 1202 is disposed), a double billows series 1222 begins and extends rearwardly through the forefoot region. The lower billows of the double billows series 1222 terminate in the midfoot area where another smooth section 1224 of midsole material 1202 is disposed. However, the top billows of the double billows series 1222 extend continuously along an upper edge of the midsole component 1202 at a connection between the midsole component 1202 and the upper 1252. Following smooth section 1224, heel billows area 1210 begins on the medial side of sole structure 1200. Notably, the upper billows of forefoot billows series 1222 forms the upper billows of rear heel billows series 1210.

The smooth polymer foam material segments of midsole component 1202 (e.g., segments 1214, 1216, 1220, and 1224) provide areas that are somewhat stiffer in the vertical direction than areas supported by various billows structures. In this example structure 1200, notably, one smooth gap segment 1214 is provided in the lateral heel region of sole structure 1200. This section 1214 provides additional support for the runner's foot when stepping down during the running step cycle. The smooth gap segment 1216, which is also on the lateral side of sole structure 1200, is positioned at or near the fifth metatarsal head region of sole structure 1200. As the foot rolls forward for the duration of the gait cycle, in this position the somewhat rigidized smooth segment 1216 provides additional support under the fifth metatarsal head region. Smooth gap segment 1220 is located at a forefoot region or toe region of the medial side of sole structure 1200 and provides additional support to the large toe region of the wearer, for example, during the push-off phase of the gait cycle. Smooth clearance segments 1224 are provided in the arch region of footwear 1250 and provide additional arch support to the wearer.

The heel billow structure 1210 of this example sole structure 1200 is interrupted in the medial heel side region by a series of angularly oriented support ribs 1230. In this illustrated example, the support ribs 1230 are angled in a top-rear-to-bottom-front direction. However, the ribs 1230 may be oriented at any desired angle without departing from the invention, including at a vertical angle (90 ° from horizontal) when the sole 1200 rests on a horizontal surface. As a further example, the ribs 1230 may be oriented at an angle in the range of 25 ° to 90 ° relative to horizontal (when the sole 1200 is resting on a horizontal surface). When the ribs 1230 are angled rather than vertical, the ribs 1230 may be angled in a direction opposite to that shown in fig. 12B (i.e., in a rear bottom to front top direction). Not all ribs in a series where there is more than one rib need extend at the same angle as another rib (although all ribs may be parallel if desired).

For example, these ribs 1230 provide additional support to the medial side of the foot during the step cycle to prevent over pronation during the step cycle. Although other arrangements are possible, in this illustrated example sole structure 1200, the ribs of area 1230 extend from a top billows element to a bottom billows element of the rear heel billows series 1210. In this manner, ribs 1230 extend integrally from the top and bottom billows ridges, and ribs 1230 interrupt the central billows of the three-layer billows series 1210. Also, while three supporting rib elements 1230 are shown in fig. 12B, one, two or more rib elements 1230 of this type may be provided as a medial heel support of this type without departing from this invention.

Moreover, the series of ribs 1230 on the individual footwear 1250 may have any desired shape without departing from this invention, including triangular cross-sectional shapes, dome-shaped cross-sectional shapes, flat or rectangular cross-sectional shapes, and the like. When more than one rib is present in a series on sole structure 1200, individual ribs 1230 of the series need not all have the same shape and/or even the same general shape. Rather, the shape of the rib elements 1230 may vary widely, even in individual shoes 1250, without departing from this invention.

Turning now to fig. 12C, the outsole structure 1206 (or protective element) of the example article of footwear 1250 will be described in greater detail. Outsole element 1206 may be engaged with a bottom side of midsole foam component 1202, e.g., using glue or adhesive. The outsole element 1206 of this example sole structure 1200 covers a majority of the bottom surface of the shoe 1250. While it may include any desired type of traction elements and/or traction element configurations, in this illustrated example, the traction elements primarily constitute raised nubs (or projections) 1240 that are spaced around the bottom of sole structure 1200 in a generally matrix pattern. If desired, one or more outsole nubs 1240 may cover and directly contact the bulges of the bottom surface of foam midsole component 1202 (like the bulges described above in connection with FIG. 10A) to provide a soft contact area of sole structure 1200.

This outsole element 1206 is made of a thin, highly flexible material, which may have a base surface thickness (i.e., the thickness of its base sheet or web surface at locations 1242 between the nubs 1240) of less than 3mm, and in some examples, a thickness of the base sheet or web surface of less than 2mm, less than 1.5mm, or even less than 1 mm. Although fig. 12C illustrates the nubs 1240 as being generally square or rectangular and generally arranged in rows or columns (e.g., a matrix), any desired nub shape and/or nub arrangement and/or spacing may be provided on the sole structure without departing from this invention. The outsole element 1206 of this example sole structure 1202 may also have any of the structures, features, or characteristics of similar thin sole components as described in U.S. patent application No. 13/693,596, filed 12/4/2012 and entitled "Article of footwear," which is incorporated herein by reference in its entirety.

The thin, flexible outsole element 1206 may be formed, for example, from an elastomer having a hardness and other properties similar to those of elastomer compounds conventionally used for footwear outsoles, as a sheet material. This thin outsole web structure allows the outsole element 1206 to be very lightweight and flex significantly between adjacent nubs 1242. In some sole structures, portions of outsole element 1206 may be formed of a harder and more durable rubber compound than other portions of outsole element 1206, or outsole component web regions 1242 may be made slightly thicker in some areas than others. For example, higher durability or thicker rubber may be used along the lateral edge of the outsole 1206, on the bottom of lugs located in certain other high pressure areas that typically wear faster, in the crash pad area 1244 located in the heel area, and so on. Fig. 12C also shows that the example thin mesh-type outsole structure 1206 is perforated at certain locations (e.g., in the forefoot and midfoot regions in this example). Also, as further shown, the nub size (e.g., height, cross-sectional size, cross-sectional shape, etc.) may vary with different areas of the outsole structure 1206.

Thin mesh outsole member 1206 is engaged with the polymer foam member to cover at least 60%, and in some examples, at least 80%, at least 90%, or even at least 95% of the surface area of the bottom surface of midsole component 1202. At least a majority of the mesh substrate surface (a majority of the surface area between the traction elements) will have a thickness of less than 2mm thick, and in some examples less than 1.5mm thick or even less than 1mm thick. If desired, at least 75%, at least 85%, at least 90%, or even at least 95% of the web substrate surface (the surface area between the traction elements) will have the above-mentioned thickness characteristics.

Conclusion III

The invention is disclosed above and in the accompanying drawings with reference to a variety of examples. The purpose served by the disclosure, however, is to provide an example of the various features and concepts related to the invention, not to limit the scope of the invention. Features of one example structure may be provided, used, and/or interchanged in some of the other structures, even if a particular combination of structures and/or features is not described. One skilled in the relevant art will recognize that numerous variations and modifications may be made to the structures described above without departing from the scope of the present invention, as defined by the appended claims.

Claims

1. An article of footwear comprising:

a shoe upper; and

a sole structure engaged with the upper, wherein the sole structure includes a first polymeric foam member configured to support at least a heel area and a midfoot area of a wearer's foot, wherein exposed outer edges of the first polymeric foam member include a billows structure extending continuously from a midfoot area or a forefoot area inboard of the first polymeric foam member, a midfoot area or a forefoot area proximate an outboard side of the first polymeric foam member, and wherein the billows structure includes five billows outer ridges connected by four billow void areas between adjacent ones of the five billows outer ridges,

wherein the five outer billows ridges extend angularly upwardly from front ends thereof to rear ends thereof, an

Wherein the sole structure further includes a second polymeric foam member, and wherein an exposed outer edge of the second polymeric foam member includes a billows structure extending around a front toe area of the sole structure.

2. An article of footwear according to claim 1, wherein, at a rear heel area of the first polymeric foam member, a highest billows outer ridge is vertically separated from a lowest billows outer ridge by a vertical distance of at least 1.5 inches when the sole structure is oriented on a horizontal surface.

3. An article of footwear according to claim 1, wherein a central billows outer ridge extends rearwardly a maximum distance at a rear heel area of the first polymeric foam member when the sole structure is oriented on a horizontal surface.

4. The article of footwear of claim 1, wherein the sole structure supports an entire plantar surface of a wearer's foot.

5. An article of footwear according to claim 1, wherein the first polymeric foam member constitutes an outer shell that includes the billows structure, wherein the outer shell includes:

the outer side of the wall is provided with a wall,

the inner side of the inner side wall is provided with a wall,

a rear heel wall connecting the medial and lateral side walls, an

6. The article of footwear of claim 5, wherein the second polymer foam member has a heel portion received in a space defined between the lateral side wall, the medial side wall, the rear heel wall, and the bottom wall of the first polymer foam member, and wherein a forefoot end of the second polymer foam member extends beyond a forward end of the lateral side wall and a forward end of the medial side wall.

7. An article of footwear according to claim 6, wherein the billows structure of the second polymeric foam member includes three billows outer ridges connected by two billows void areas located between adjacent ones of the three billows outer ridges of the second polymeric foam member.

8. An article of footwear according to claim 7, wherein the billows structure of the second polymeric foam member is not continuous with the billows structure of the first polymeric foam member.

9. An article of footwear according to claim 7, wherein the billows structures of the second polymeric foam member are separated from the billows structures of the first polymeric foam member at a lateral forefoot area of the sole structure and at a medial forefoot area of the sole structure.

10. The article of footwear according to claim 6, wherein a bottom surface of the second polymer foam member is exposed at least at a forefoot portion of a bottom surface of the sole structure.

11. The article of footwear of claim 10, wherein the sole structure further includes a first outsole member engaged with a bottom surface of the second polymeric foam member.

12. The article of footwear of claim 11, wherein the sole structure further includes a second outsole member engaged with a bottom surface of the first polymeric foam member.

13. The article of footwear of claim 6, wherein the bottom wall of the outer shell of the first polymeric foam member has an opening defined therethrough, and wherein a bottom surface of the second polymeric foam member is exposed through the opening.

14. The article of footwear of claim 1, wherein the sole structure further includes an outsole member engaged with a bottom surface of the first polymeric foam member.

15. An article of footwear according to claim 1, wherein the billows structure of the first polymeric foam member includes: a first outer billowed ridge, a second outer billowed ridge, a third outer billowed ridge, a fourth outer billowed ridge, a fifth outer billowed ridge, a first interstitial area between the first outer billowed ridge and the second outer billowed ridge, a second interstitial area between the second outer billowed ridge and the third outer billowed ridge, and a third interstitial area between the fourth outer billowed ridge and the fifth outer billowed ridge,

wherein the fourth billow outer ridge originates in the first void area and the fifth billow outer ridge originates in the second void area.

16. An article of footwear according to claim 15, wherein the sole structure further includes an outsole component engaged with a bottom surface of the first polymer foam member.

17. The article of footwear of claim 15, wherein the first polymer foam member includes a foam having a thickness of less than 0.25g/cm³The density of (a).

18. An article of footwear according to claim 15, wherein a window element extends through the first polymeric foam member at a location between the first billow outer ridge and the second billow outer ridge.

19. An article of footwear according to claim 15, wherein the exposed outer edge of the first polymeric foam member further includes a sixth billow outer ridge, wherein the sixth billow outer ridge originates in the third void area.