US20260000156A1

US20260000156A1 - Article of footwear having a resilient dynamic cushioning system

Info

Publication number: US20260000156A1
Application number: US18/758,074
Authority: US
Inventors: Michael Andrews; Jeffrey J. Acheson
Original assignee: Reebok International Ltd Great Britain
Current assignee: Reebok International Ltd Great Britain
Priority date: 2024-06-28
Filing date: 2024-06-28
Publication date: 2026-01-01
Also published as: CN121220852A

Abstract

The present disclosure is directed to an article of footwear having an upper and a sole coupled to the upper. The sole includes an outsole that extends along a length of the sole to engage the ground. The sole includes a sidewall, such as a midsole rim, projecting upwardly from the outsole to define a sole chamber. The sole includes a plurality of hollow pillars projecting upwardly from the base and disposed within the sole chamber to support the wearer's foot.

Description

BACKGROUND

Field

The present disclosure relates to footwear, and more particularly relate to a sole and article of footwear having a resilient dynamic cushioning system for supporting a foot of a wearer.

Background Art

The human foot possesses natural cushioning and rebounding characteristics. However, the foot alone is incapable of effectively overcoming many of the forces encountered during every day activity. Unless an individual is wearing shoes which provide proper cushioning and support, the soreness and fatigue associated with every day activity is more acute, and its onset accelerated. The discomfort for the wearer that results may diminish the incentive for further activity.
Proper footwear should complement the natural functionality of the foot, in part, by incorporating a sole, which absorbs shocks. Therefore, a continuing need exists for innovations in providing cushioning to articles of footwear.

BRIEF SUMMARY

The present disclosure includes various embodiments of a sole for an article of footwear that provides a desired cushioning effect to a wearer's foot.
In accordance with one embodiment, an article of footwear includes an upper and a sole coupled to the upper. In some embodiments, the sole includes an upper and a sole coupled to the upper. In some embodiments, the sole includes a sole unit configured to support the foot of the wearer. In some embodiments, the sole unit includes a base extending along a length of the sole and configured to contact the ground. In some embodiments, the sole unit includes a sidewall projecting upwardly from the base and extending along a perimeter of the base, in which the base and the sidewall define a sole chamber. In some embodiments, the sole unit includes a plurality of hollow pillars projecting upwardly from the base and disposed within the sole chamber. In some embodiments, the sole includes a clip received on the base of the sole unit in a heel region of the sole. In some embodiments, the clip extends from a first end of the sidewall to a second end of the sidewall, in which the clip includes a grid of ducts extending in a transverse direction. In some embodiments, the sole unit is made of a first material having a first modulus of elasticity, and the clip is made of a second material having a second modulus of elasticity that is less than first modulus of elasticity.
In some embodiments, the ducts of the clip include openings disposed on a lateral side of the sole.
In some embodiments, the clip includes a casing coupled to the base and the first and second ends of the sidewall. In some embodiments, the clip includes a plurality of strips disposed in the casing and extending in the transverse direction from the lateral side of the sole such that the strips define the grid of ducts. In some embodiments, the casing of the clip defines a window disposed on the lateral side of the sole, the window exposing the openings of the ducts of the clip.
In some embodiments, the first end of the sidewall is disposed at a back end of the heel region of the sole, and the second end of the sidewall is disposed on the lateral side of the sole between the back end of the heel region and the forefoot region of the sole.
In some embodiments, the sole unit comprises a partition wall projecting upwardly from the base and disposed between the clip and the plurality of pillars. In some embodiments, the partition wall includes a first segment extending in a longitudinal direction from the first end of the sidewall disposed at a back end of the heel region of the sole to a location between the back end of the heel region and the forefoot region of the sole. In some embodiments, the partition wall includes a second segment extending from a front end of the first segment to the second end of the sidewall disposed on the lateral side of the sole between the back end of the heel region and the forefoot region of the sole.
In some embodiments, the plurality of pillars each includes a curved sidewall and a dome-shaped lid extending from an upper end of the curved sidewall, in which the curved sidewall and the lid define a cavity. In some embodiments, the plurality of pillars each include an aperture disposed at a center of the lid and opening into the cavity.
In some embodiments, the first material of the sole unit comprises rubber, and the second material of the clip comprises thermoplastic polyurethane.
In some embodiments, the plurality of pillars are arranged rows extending in a transverse direction. In some embodiments, the rows of pillars are arranged along the length of the sole from the heel region of the sole to the forefoot region of the sole.
In accordance with one embodiment, an article of footwear includes an upper and a sole coupled to the upper. In some embodiments, the sole includes an outsole configured to engage the ground. In some embodiments, the sole includes a midsole rim disposed on an upper surface of the outsole and extending along a perimeter of the outsole. In some embodiments, the midsole rim includes an exterior surface defining a sidewall of the sole. In some embodiments, the midsole rim and the outsole define a sole chamber. In some embodiments, the sole includes a midsole core disposed within the sole chamber. In some embodiments, the midsole core includes a base plate disposed on the upper surface of the outsole and a plurality of hollow pillars projecting upwardly from the base plate and filled with air. In some embodiments, the plurality of pillars are arranged along the length of the sole from the heel region of the sole to the forefoot region of the sole. In some embodiments, the plurality of pillars include a first set of pillars fluidly connected together such that air is permitted to flow between the first set of pillars.
In some embodiments, the plate includes a plurality of channels defined on the bottom surface of the plate, interconnecting the first set of pillars. In some embodiments, the first set of pillars are arranged along a length of the sole from the heel region of the sole to the forefoot region of the sole.
In some embodiments, the plurality of pillars include a second set of pillars. In some embodiments, each pillar of the second set is fluidly isolated from the remainder of the pillars.
In some embodiments, the plurality of pillars include a lateral row of pillars extending from the heel region of the sole to the forefoot region of the sole. In some embodiments, the plurality of pillars include a medial row of pillars extending from the heel region of the sole to the forefoot region of the sole. In some embodiments, the plurality of pillars include a central row of pillars disposed between the medial and lateral row of pillars and extending from the heel region of the sole to the forefoot region of the sole.
In some embodiments, the first set of pillars include the central row of pillars. In some embodiments, the first set of pillars include one or more pillars disposed in the lateral row located in the forefoot and heel region of the sole and one or more pillars disposed in the medial row located in the forefoot and heel region of the sole.
In some embodiments, the midsole core includes a first flange extending from a lateral side of the base plate in the forefoot region of the sole and a plurality of lateral forefoot pillars projecting upwardly from the first flange. In some embodiments, the midsole core includes a second flange extending from the lateral side of the base plate in the heel region of the sole and a plurality of lateral heel pillars projecting upwardly from the second flange.
In some embodiments, the midsole rim includes a first recess disposed on a lateral side of the midsole rim in the forefoot region of the sole and a second recess disposed on the lateral side of the midsole rim in the heel region of the sole. In some embodiments, the lateral forefoot pillars are received in the first recess of the midsole rim, and the lateral heel pillars are received in the second recess of the midsole rim.

BRIEF DESCRIPTION OF THE DRAWINGS/FIGURES

The accompanying drawings, which are incorporated herein and form a part of the specification, illustrate the present disclosure and, together with the description, further serve to explain the principles thereof and to enable a person skilled in the pertinent art to make and use the same.

FIG. 1 shows a side view of an article of footwear according to embodiments.

FIG. 2 shows a bottom view of the article of footwear shown in FIG. 1 according to embodiments.

FIG. 3 shows a top view of the sole of the article of footwear shown in FIG. 1 according to embodiments.

FIG. 4 shows a cross-section view of the sole of the article of footwear taken along line 4-4 in FIG. 2 according to embodiments.

FIG. 5 shows a cross-section view of the sole of the article of footwear taken along line 5-5 in FIG. 2 according to embodiments.

FIG. 6 shows a cross-section view of the sole of the article of footwear taken along line 6-6 in FIG. 2 according to embodiments.

FIG. 7 shows an enlarged side view of a clip of the sole taken along line 7-7 in FIG. 1 according to embodiments.

FIG. 8 shows an enlarged cross-section view of a clip of the article of footwear taken along line 8-8 in FIG. 7 (with other elements of the sole removed) according to embodiments.

FIG. 9 shows an enlarged cross-section view of the sole of the article of footwear taken along line 9-9 in FIG. 7 according to embodiments.

FIG. 10 shows a top view of the sole unit of the article of footwear shown in FIG. 1 according to embodiments.

FIG. 11 shows a side view of an article of footwear according to embodiments.

FIG. 12 shows a bottom view of the article of footwear shown in FIG. 11 according to embodiments.

FIG. 13 shows a top view of the sole of the article of footwear shown in FIG. 11 according to embodiments.

FIG. 14 shows a cross-section view of the sole of the article of footwear taken along line 14-14 in FIG. 12 according to embodiments.

FIG. 15A shows a cross-section view of the sole of the article of footwear taken along line 15-15 in FIG. 12 according to embodiments.

FIG. 15B shows a cross-section view of the sole of the article of footwear taken along line 15-15 in FIG. 12 according to embodiments

FIG. 16A shows a cross-section view of the sole of the article of footwear taken along line 16-16 in FIG. 12 according to embodiments.

FIG. 16B shows a cross-section view of the sole of the article of footwear taken along line 16-16 in FIG. 12 according to embodiments.

FIG. 17 shows an exploded view of the sole of the article of footwear according to embodiments.

FIG. 18 shows an exploded view of the sole of the article of footwear according to embodiments.

FIG. 19 shows a bottom view of a midsole core according to embodiments.

FIG. 20 shows a cross-section view of midsole core taken along line 20-20 in FIG. 19 according to embodiments.

FIG. 21 shows a cross-section view of midsole core taken along line 21-21 in FIG. 19 according to embodiments.

DETAILED DESCRIPTION

Representative embodiments will now be described in detail with reference the accompanying drawings, in which like reference numerals are used to indicate identical or functionally similar elements. References to “one embodiment”, “an embodiment”, “an example embodiment”, etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to affect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described.
The following examples are illustrative, but not limiting. Other suitable modifications and adaptations of the variety of conditions and parameters normally encountered in the field, and which would be apparent to those skilled in the art, are within the spirit and scope of the disclosure.
One attempt over the years to improve cushioning and resiliency of shoes, particularly athletic shoes, is incorporating a midsole component formed primarily from a polymer foam material due to the polymer foam material's ability to compress resiliently under an applied load, which attenuates forces impacted by the sole striking the ground during the wearer's gait cycle. However, the performance of foam-based midsoles may suffer over time due to dynamic fatigue. That is, the polymer foam may lose its initial elasticity and firmness as the polymer foam midsole is subjected to stress by repeated use of the shoe. Furthermore, including foam-based materials in the sole may increase the cost of manufacturing.
Accordingly, there is a need for an improved sole that minimizes or eliminates the use of polymer foam, while still providing adequate support and cushioning to the wearer's foot.
According to some embodiments described herein, the sole of the present disclosure may overcome one or more of the deficiencies noted above by including a wear-resistant sole unit configured to support a foot of the wearer and a resilient clip received on a base of the sole unit in a heel region of the sole. The clip is configured to deform at a faster rate than any section of the sole unit when compressive force is applied by the wearer during the gait cycle, thereby attenuating shock from ground reaction forces.
According to some embodiments described herein, the sole of the present disclosure may overcome one or more of the deficiencies noted above by including a midsole core including pillars filled with air. The pillars include a first set of pillars fluidly connected together that permits air to flow between a heel region and a forefoot region of the sole to provide dynamic cushioning for the wearer's foot.
FIG. 1 illustrates an article of footwear 10 having an upper 20 and a sole 100 coupled to upper 20 according to one embodiment of the present disclosure. As shown in FIGS. 2 and 3 , sole 100 may include a heel region 101, a midfoot or arch region 102, and a forefoot region 103 extending between a lateral side 104 and a medial side 105 of sole 100. Sole 100 may include an insole configured to receive a wearer's foot. Sole 100 may include a sole unit 110 configured to support the foot of the wearer and to contact the ground. In some embodiments, sole 100 may include a collapsible, elastic clip 160 received in sole unit 110 to provide a desirable cushioning effect to the wearer's foot. Clip 160 may be located in heel region 101 of sole 100 to further cushion the heel of the wearer's foot. For example, clip 160 may be configured to deform at a faster rate than any section of the sole unit 110 when compressive force is applied by the wearer during the gait cycle, thereby providing a crash pad that attenuates ground force shock and reinforces adjacent sections of sole unit 110 to counter overpronation or supination. For example, clip 160 may be located along lateral side 104 in heel region 101 of sole 100 to cushion heel impact, particularly for supination.
In some embodiments, sole unit 110 may include a base (an outsole) 120 extending along a length of sole 100 from heel region 101 to forefoot region 103 of sole 100. Base 120 may include a bottom surface 122 configured to contact the ground and provide traction for the wearer. As shown in FIGS. 4-6 (upper 20 is shown schematically in broken lines for simplicity), base 120 may include an upper surface 124 located opposite to bottom surface 122. Base 120 may include a thickness defined between bottom surface 122 and upper surface 124 suitable for stabilizing the wearer's foot, for example, a thickness in a range from 1.5 mm to 5 mm, such as 3.5 mm.
In some embodiments, sole unit 110 may include a sidewall 130 projecting upwardly from base 120. Sidewall 130 may extend along a perimeter of base 120 such that base 120 and sidewall 130 define a sole chamber 112. Sidewall 130 may be coupled to upper 20 by stitching, adhesive bonding, thermal bonding, or a combination thereof, thereby securing sole unit 110 to upper 20.
With reference to FIGS. 3 and 10 , sidewall 130 may extend partially along the perimeter of base 120. For example, sidewall 130 may include a first end 132 disposed at a first location along the perimeter of base 120 and a second end 134 disposed at a second location along the perimeter of base 120, whereby first end 132 and second end 134 define a gap 114 therebetween. First end 132 of sidewall 130 may be disposed at a back end of heel region 101. Second end 134 of sidewall 130 may be disposed on lateral side 104 of sole 100 between the back end of the heel region 101 and forefoot region 103 of sole 100. In some embodiments, second end 134 of sidewall 130 may be disposed in heel region 101. In some embodiments, second end 134 of sidewall 130 may be disposed in midfoot region 102.
In some embodiments, sole unit 110 may include a partition wall 140 projecting upwardly from upper surface 124 of base 120. With reference to FIG. 10 , partition wall 140 may be disposed between lateral side 104 and medial side 105 of sole 100. Partition wall 140 may extend from first end 132 of sidewall 130 to second end 134 of sidewall 130. Partition wall 140 may include a first segment 142 extending in a longitudinal direction Y from first end 132 of sidewall 130 to a location between the back end of the heel region 101 and forefoot region 103. For example, first segment 142 may include a front end 143 disposed in midfoot region 102 or heel region 101. Partition wall 140 may include a second segment 144 extending in a transverse direction X from front end 143 of first segment 142 to second end 134 of sidewall 130 disposed on lateral side 104 of sole 100.
Sole unit 110 may include a midsole core element that is configured to support and cushion the wearer's foot. For example, in some embodiments, sole unit 110 may include a plurality of hollow pillars 150 projecting upwardly from upper surface 124 of base 120 to provide support for the wearer's foot. The plurality of pillars 150 are configured to deflect or buckle when compressive force is applied by the wearer's foot striking the ground and return to their original shape (e.g., stand upright) upon a removal of the compressive force, such that the plurality of pillars 150 absorb shock imparted from the ground surface during the wearer's gait cycle. For example, in some embodiments, the plurality of pillars 150 may be configured to compress, deflect, flex, bend, and/or deform at a compressed state (e.g., when sole 100 strikes the ground) and configured to stand upright at a relaxed state (e.g., when sole 100 elevates above the ground). In some embodiments, the plurality of pillars 150 are configured to return from the compressed state to the relaxed state without incurring permanent buckling or plastic deformation.
The shape of pillars 150 may be tuned to achieve optimum cushioning and support to the foot of the wearer. For example, as shown in FIGS. 4-6 , the plurality of pillars 150 may each include a curved sidewall 152, such as a cylindrical-shaped sidewall. In some embodiments, the plurality of pillars 150 may each include a lid 154 extending from an upper end of the curved sidewall 152. In some embodiments, curved sidewall 152 and lid 154 may collectively define a cavity 158 filled with ambient air. In some embodiments, the plurality of pillars 150 may each include an aperture 156 disposed at a center of lid 154 and opening into cavity 158. Locating aperture 156 at the center of lid 154 provides more flexibility to a section of lid 154 surrounding aperture 156, thereby allowing the plurality of pillars 150 to be deflect force away more effectively. The diameter of apertures 156 of pillars 150 may vary along the length or width of sole 100 to tune the flexibility of pillars 150. In some embodiments, lid 154 may have a curved-shaped profile, such as, for example, being dome-shaped. In some embodiments, lid 154 may not include an aperture such that pillar 150 seals air held in cavity 158, thereby making pillar 150 more resilient. The plurality of pillars 150 may include one or more sealed pillars 150 and one or more pillars 150 with apertures 156 to tune the cushioning of sole 100. For example, one particular region of the sole (heel region 101 adjacent to lateral side 104) may include sealed pillars 150 and/or pillars 150 with smaller-sized apertures 156 to add stability to the wearer's foot, while another particular region of the sole (forefoot region 103) may include pillars 150 with larger-sized apertures 156 to provide more resiliency, thereby allowing the foot to flex more.
The spatial arrangement and number of pillars 150 may be tuned to provide a desired cushioning effect to the wearer's foot. In some embodiments, two or more pillars 150 may be disposed in a linear arrangement to form a row extending from lateral side 104 to medial side 105 of sole 100. In some embodiments, the plurality of pillars 150 may be arranged in a series of rows arranged from heel region 101 to forefoot region 103 of sole 100. As shown in FIG. 10 , for example, rows of pillars 150 in heel region 101 may extend from medial side 105 of sole 100 to first segment 142 of partition wall 140 such that partition wall 140 separates pillars 150 in chamber 112 from gap 114.
The size (e.g., diameter and height) of pillars 150 may be varied to provide a desired cushioning effect to the wearer's foot. For example, in some embodiments, the diameter and/or width of pillars 150 may generally decrease from the heel region 101 to the forefoot region 103. For example, as shown in FIG. 6 , one or more pillars 150 in heel region 101 may include a first height 159A, and as shown in FIG. 5 , pillars 150 in forefoot region 103 may include a second a second height 159B that is less than the first height 159A, thereby providing increased cushioning in the heel region 101. In the context of the present disclosure, a height corresponds to the vertical dimension defined from an exterior surface of the dome of the pillar to a plane defined by upper surface 124 of the base 120. In some embodiments, at least adjacent two pillars 150 oriented in a transverse direction X along sole 100 from lateral side 104 to medial side 105, have generally the same diameter and/or width and/or define cavities 158 having the same volume. In some embodiments, the height of pillars 150 at a relaxed state (e.g., when no loads are applied to pillars 150) may be greater than the height chamber 112 defined within sole unit 110 such that pillars 150 are configured to sink to a profile of the bottom of the wearer's foot at a compressed state (e.g., when a load is applied by the wearer's foot to sole 100), thereby providing more cushioning to the wearer's foot. The height of pillars 150 at the compressed state is less than the height of pillars 150 at the relaxed state.
In some embodiments, as shown in FIGS. 3, 4, and 6 , sole unit 110 may include a plurality of braces 126 interconnecting pillars 150. For example, in some embodiments, a brace 126 can extend between a pair of adjacent pillars 150 such that pillars 150 are supported adequately in an upright position. In some embodiments, brace 126 can extend from a respective pillar 150 to sidewall 130 to support the respective pillar 150 in an upright position. The number and placement of braces 126 can be modified to adjust the support of pillars 150. For example, in some embodiments, braces 126 may be disposed between every pair of adjacent pillars 150. In some embodiments, braces 126 may be disposed between only the sidewall of sole 100 and pillars 150 located proximate to the sidewall of sole 100. In some embodiments, braces 126 may be disposed between adjacent pillars 150 disposed only in heel region 101 of sole 100. In some embodiments, braces 126 may be disposed between adjacent pillars 150 disposed only in midfoot region 102 of sole 100. In some embodiments, braces 126 may be disposed between adjacent pillars 150 disposed only in forefoot region 103 of sole 100.
In some embodiments, base 120, sidewall 130, partition wall 140, and pillars 150 of sole unit 110 are unitary (e.g., a single-piece configuration), such that base 120, sidewall 130, partition wall 140, and pillars 150 are integrally made from the same material. In some embodiments, sole unit 110 is made from a first elastomeric material having a first modulus of elasticity that configures base 120 to be wear-resistant and durable while configuring the plurality of pillars 150 to flex or deform when compressive force is applied by the wearer's foot during the gait cycle. In some embodiments, the first elastomeric material may include a blend of natural and synthetic rubber, such as a styrene-butadiene rubber, a silicone rubber, a nitrile rubber, a carbon rubber, a crystal rubber, a thermoplastic rubber/elastomer, and/or a combination thereof. For example, in some embodiments, the first elastomeric material may include a high concentration of synthetic rubber (e.g., greater than 50% by weight) so that first elastomeric material is more wear resistant.
In some embodiments, a clip 160 may be located in heel region 101 of sole 100 (e.g., a heel clip) to provide a softer cushioning zone for the heel of the wearer's foot. For example as shown in FIG. 3 , clip 160 may be disposed on upper surface 124 of base 120 in heel region 101 of sole 100 and engaged against partition wall 140. Partition wall 140 is disposed between clip 160 and the plurality of pillars 150. Clip 160 may be received in gap 114, where clip 160 extends along the perimeter of base 120 from first end 132 of sidewall 130 to second end 134 of sidewall 130. In some embodiments, clip 160 may extend along lateral side 104 of heel region 101 of sole 100. In some embodiments, clip 160 may extend along medial side 105 of heel region 101 of sole 100.
With reference to FIGS. 6-9 , clip 160 may include a case 162 defining an exterior of clip 160. Case 162 is coupled to base 120 and first and second ends 132, 134 of sidewall 130. Case 162 may include a bottom section 164 received on upper surface 124 of base 120. Bottom section 164 may extend from partition wall 140 to perimeter of base 120 and may extend from first end 132 of side wall 130 to second end 134 of sidewall 130. Case 162 may include a side section 166 projecting upward from bottom section 164 and engaged against first and second ends 132, 134 of sidewall 130. Side section 166 may be disposed flushed against first and second ends 132, 134 of sidewall 130 such that sidewall 130 and side section 166 define a continuous surface extending along the perimeter of base 120. Case 162 may include a top section 168 extending from an upper portion of side section 166 such that top section 168 is spatially-separated from bottom section 164 by side section 166. Top section 168 may extend from partition wall 140 to perimeter of base 120 and from first end 132 of side wall 130 to second end 134 of sidewall 130. Case 162 may define a window 163 disposed along perimeter of base 120, for example, on lateral side 104 of sole 100. Window 163 exposes the interior of clip 160.
The interior structure of clip 160 may be tuned to provide a desirable degree of deformability and resiliency that allows clip 160 to buckle at a faster rate than pillars 150 of sole unit 110. For example, with reference to FIGS. 6-9 , clip 160 comprises a grid of ducts 170 within case 162 that are configured to deform, collapse, or buckle when compressive force is applied against clip 160 during ground strike by the heel region 101 of sole 100. The plurality of ducts 170 may extend in transverse direction X. Each duct 170 may include an opening 172 disposed on lateral side 104 of sole 100 and exposed by window 163 of case 162. The plurality of ducts 170 are filled with ambient air. Clip 160 may include a network of interconnected strips 174 disposed in case 162. Each strip 174 extends in transverse direction X from lateral side 104 of sole 100 to define the boundary of a respective duct 170. Strips 174 may be spatially arranged to provide each duct 170 with a polygonal-shaped opening 172, such as for example, hexagonal-shaped openings 172. Strips 174 may be spatially arranged to provide other shapes, such as squares and pentagons.
In some embodiments, case 162 and strips 174 of clip 160 are unitary (e.g., a single-piece configuration), such that case 162 and strips 174 are integrally made from the same material. In some embodiments, clip 160 is made from a second elastomeric material having a second modulus of elasticity that is less than the first modulus of elasticity such that ducts 170 of clip 160 collapse, deform, or buckle at a faster rate than pillars 150 of sole unit 110 when compressive force is applied by the wearer's foot during ground strike. In some embodiments, the second elastomeric material may include a blend of thermoplastic and rubber material, such as a thermoplastic polyurethane, thermoplastic polyolefin, thermoplastic vulcanizates, thermoplastic polyamides, styrenic block copolymers and/or a combination thereof. The second elastomeric material provides ducts 170 with adequate resiliency to return to their original shape upon a removal of the compressive force (e.g., a relaxed state). The resiliency of the ducts 170 allows clip 160 to absorb a significant amount of shock that occurs when the heel region 101 of sole 100 strikes the ground, thereby providing a desirable cushioning effect to the heel of wearer's foot.
In some embodiments, the sole of the article of footwear may include a plurality of sealed cavities and channels filled with air that is configured to promote airflow at a restricted rate between the heel region and the forefoot region of the sole to provide dynamic cushioning to the wearer's foot. For example, FIGS. 11-16B illustrate an article of footwear 200 having an upper 210 and a sole 220 coupled to the upper 210, in which sole 220 includes sealed air-filled cavities and channels according to embodiments of the present disclosure. As shown in FIGS. 11-13 , sole 220 may include a heel region 201, a midfoot or arch region 202, and a forefoot region 203 extending between a lateral side 204 and a medial side 205 of sole 220.
In some embodiments, sole 220 may include an outsole 230 configured to engage the ground. Sole 220 may include a midsole rim, such as midsole rim 240 shown in FIGS. 15A and 16A or midsole rim 340 shown in FIGS. 15B and 16B, disposed above and coupled to outsole 230. Sole 220 may include a midsole core, such as midsole core 250 shown in FIGS. 15A and 16A or midsole core 350 shown in FIGS. 15B and 16B, disposed above and coupled to outsole 230. Sole 220 may include an insole disposed above the midsole rim and midsole core to receive a wearer's foot. FIG. 17 illustrates an exploded view of outsole 230, midsole rim 240, and midsole core 250 implemented in the article of footwear 200 shown in FIGS. 15A and 16A. FIG. 18 illustrates an exploded view of outsole 230, midsole rim 340, and midsole core 350 implemented in the article of footwear 200 shown in FIGS. 15B and 16B. FIG. 19 illustrates a bottom view of midsole core 250 implemented in the article of footwear 200 shown in FIGS. 15A and 16A. In FIGS. 14-16B, upper 210 is shown schematically in broken lines for simplicity.
As shown in FIGS. 12-14 , outsole 230 may extend from heel region 201 to forefoot region 203 of sole 220. Outsole 230 may be coupled to a bottom surface of the midsole rim (e.g., midsole rim 240, 340) and/or the midsole core (e.g., midsole core 250, 350). Outsole 230 may include one or more texture levels 234, 236 to promote grip with the ground and provide aesthetic appeal. In some embodiments, outsole 230 may be made of a first elastomeric material having a first modulus of elasticity that configures outsole 230 to be wear-resistant and durable when compressive force is applied by the wearer's foot during the gait cycle. In some embodiments, the first elastomeric material may include a blend of natural and synthetic rubber, such as a styrene-butadiene rubber, a silicone rubber, a nitrile rubber, a carbon rubber, a crystal rubber, a thermoplastic rubber/elastomer, and/or a combination thereof. For example, in some embodiments, the first elastomeric material may include a high concentration of synthetic rubber (e.g., greater than 50% by weight) so that first elastomeric material is more wear resistant.
With reference to FIGS. 14, 15A, 16A, and 17 , midsole rim 240 may be disposed on an upper surface 232 of outsole 230. Midsole rim 240 may be coupled to upper surface 232 of outsole 230 through any suitable process, such as applying an adhesive or thermal bonding. Midsole rim 240 may extend along a perimeter of outsole 230, including along lateral side 204 and medial side 205 of sole 220, such that outsole 230 and midsole rim 240 define a sole chamber 222. Midsole rim 240 may include an exterior surface 242 that defines a sidewall of sole 220.
Midsole rim 240 may include one or more recesses disposed on lateral side 204 of sole 220 to provide a desirable cushioning effect to the wearer's foot. For example, midsole rim 240 may include a first recess 246 disposed on lateral side 204 of sole 220 and in forefoot region 203 of sole 220. Midsole rim 240 may include a second recess 248 disposed on lateral side 204 of sole 220 and in heel region 201 of sole 220. First and second recesses 246, 248 define an opening receding from a bottom surface 241 and exterior surface 242 of midsole rim 240. In some embodiments, as shown in FIGS. 15A and 16A, sole 220 may include a filler 280 received in first and second recesses 246, 248 to provide a desirable cushioning effect.
Midsole rim 240 may be made of a material configured to cushion the wearer's foot and absorb shock from ground-reaction forces. For example, midsole rim 240 may be made of a foam-based material, such as, for example, an EVA foam material and/or a polyurethane foam material. Filler 280 may be made of an elastomeric material, such as a natural rubber, a synthetic rubber, a thermoplastic elastomer, or a combination thereof.
With reference to FIG. 13 , midsole core 250 may be disposed within sole chamber 222 such that midsole rim 240 extends around midsole core 250. With reference to FIGS. 13, 14, 15A, 16A, and 17 , midsole core 250 may include a base plate 252 disposed on upper surface 232 of outsole 230. Base plate 252 may be coupled to upper surface 232 of outsole 230 through any suitable process, such as being integrally molded together, applying an adhesive, or thermal bonding. Base plate 252 may extend in a longitudinal direction Y from heel region 201 of sole 220 to forefoot region 203 of sole 220. Base plate 252 may extend in a transverse direction X from a medial interior surface 243 of midsole rim 240 to a lateral interior surface 244 of midsole rim 240.
Midsole core 250 may include a plurality of pillars 260 projecting upwardly from base plate 252 to provide support for the wearer's foot. The plurality of pillars 260 are configured to compress, deflect, flex, bend and/or deform upon an application of a compressive force by the wearer's foot (e.g., when sole 220 strikes the ground during a the wearer's gait cycle) and return to their original shape (e.g., stand upright) upon a removal of the compressive force, such that pillars 260 absorb shock imparted from the ground surface during the wearer's gait cycle. For example, in some embodiments, the pillars 260 may be configured to compress, deflect, flex, bend, and/or deform at a compressed state (e.g., when sole 220 strikes the ground) and configured to stand upright at a relaxed state (e.g., when sole 220 elevates above the ground). By demonstrating high resiliency-flexing or bending at a compressed state and returning to stand upright at a relaxed state-pillars 260 absorb a significant amount of shock that provides a desirable cushioning effect to wearer's foot.
Similar to pillars 150 described above, the shape of second pillars 260 may be tuned to achieve optimum cushioning and support to the foot of the wearer. For example, the plurality of pillars 260 may each include a curved sidewall 262 and a dome-shaped lid 264 extending from an upper end of curved sidewall 262, in which sidewall 262 and lid 264 define a cavity 268 that is sealed from the ambient air. In some embodiments, cavity 268 may be filled with air above ambient pressure (e.g., 3 psi to 8 psi above ambient pressure) to provide support and cushioning for the wearer's foot. In some embodiments, cavity 268 may be filed with a solid material, such as, a foam-based material or elastomeric-based material.
Similar to pillars 150 described above, the size (e.g., diameter and height) of pillars 260 may be varied to provide a desired cushioning effect to the wearer's foot. For example, as shown in FIG. 14 , the width and height of pillars 260 may generally decrease from heel region 201 to the forefoot region 203, thereby providing additional cushioning for the wearer's heel.
In some embodiments, base plate 252 and pillars 260 of midsole core 250 are unitary (e.g., a single-piece configuration), such that base plate 252 and pillars 260 are integrally made from the same material. In some embodiments, midsole core 250 is made of a second elastomeric material having a second modulus of elasticity that is less than the first modulus of elasticity of the first elastomeric material of outsole 230. The second elastomeric material of midsole core 250 configures the pillars 260 to flex or deform upon an application of a compressive force by the wearer and return to their original shape upon a removal of the compressive force. In some embodiments, the first elastomeric material may include a natural rubber, an ethylene propylene diene monomer (EPDM) rubber, a neoprene rubber, a silicone rubber, a nitrile rubber, a styrene-butadiene rubber, a thermoplastic rubber/elastomer, and/or a combination thereof. For example, in some embodiments, the second elastomeric material may include a high concentration of natural rubber (e.g., greater than 50% by weight) so that second elastomeric material possesses greater resiliency.
The arrangement and number of pillars 260 may be tuned to provide a desired cushioning effect to the wearer's foot. Two or more pillars 260 may be disposed in a linear arrangement to form a row extending from medial interior surface 243 of midsole rim 240 to lateral interior surface 244 of midsole rim 240. The plurality of pillars 260 may be arranged in a series of rows arranged from heel region 201 to forefoot region 203 of sole 220. In some embodiments, two or more pillars 260 may be disposed in a linear arrangement to form a row extending from heel region 201 to forefoot region 203 of sole 220. As shown in FIG. 19 , for example, a lateral row 270 of pillars 260 may extend from heel region 201 to forefoot region 203. A medial row 274 of pillars 260 may extend from heel region 201 to forefoot region 203. A central row 272 of pillars 260 disposed between the medial and lateral row of pillars 260 may extend from heel region 201 to forefoot region 203.
The spacing between adjacent pillars 260 may be varied to provide a desired cushioning effect to wearer's foot. For example, in some embodiments, the spacing between adjacent pillars 260 along the length of sole 220 may be uniform. In some embodiments, the spacing between adjacent pillars 260 located in forefoot region 203 of sole 220 may be less than the spacing between adjacent pillars 260 located in heel region 201 of sole 220, such that there is a greater number of pillars 260 in forefoot region 203 of sole 220 than heel region 201 of sole 220.
Multiple pillars 260 may be fluidly connected to provide dynamic cushioning that complements the motion of the wearer's foot. For example, as shown in FIG. 19 , midsole core 250 may include a plurality of channels 256 that fluidly connect a first set 278 of pillars 260 that allows fluid to flow between the heel region 201 and forefoot region 203 of sole 220. The plurality of channels 256 are sealed between outsole 230 and midsole core 250. In some embodiments, as shown in FIGS. 20 and 21 , the plurality of channels 256 may be defined on the bottom surface 255 of base plate 252, such as a groove molded or etched into base plate 252, which is bounded by upper surface 232 of outsole 230. In some embodiments, the plurality of channels 256 may be defined on the upper surface 232 of outsole, such as a groove molded or etched into outsole 230, which is bounded by bottom surface 255 of base plate 252.
The arrangement of channels 256 along base plate 252 of midsole core 250 may be arranged to promote more cushioning for the wearer's heel and forefoot. For example, one or more pillars 260 in lateral row 270, central row 272, and medial row 274 in heel region 201 may be interconnected by channels 256 extending in transverse direction X. One or more pillars 260 in lateral row 270, central row 272, and medial row 274 in forefoot region 203 may be interconnected by channels 256 extending in transverse direction X. In some embodiments, each pillar 260 in lateral row 270 and medial row 274 in a midfoot region 202 of sole 220 may be fluidly isolated from the remainder of pillars 260. In some embodiments, only pillars 260 of central row 272 are fluidly connected by channels 256 extending in longitudinal direction Y, and midfoot region 202 of base plate 252 does not include any channels 256 extending in the transverse direction X, which restricts airflow from heel region 201 to forefoot region 203 at a desirable rate without diminishing air pressure in pillars 260 located in one of heel region 201 and forefoot region 203 too quickly. For example, a single row of pillars 260 are connected in series in longitudinal direction Y along midfoot region 202 of sole 220, and multiple rows of pillars 260 in heel region 201 of sole 220 and multiple rows of pillars 260 in forefoot region 203 of sole 220 are connected in parallel in transverse direction X. Fluidly connecting the first set 178 of plurality of pillars 160 in the arrangement shown in FIG. 19 provides a larger volume of air in heel region 201 of sole 220 to cushion heel strike of wearer's foot and in forefoot region 203 of sole 220 to cushion forefoot strike of wearer's foot, while allowing an adequate volume of air to transfer between heel region 201 and forefoot region 203 of sole 220 during the wearer's gait cycle.
The sizing of channels 256 may be tuned to provide a desirable airflow distribution along sole 220 in response to compressive force applied by the wearer's foot striking the ground. For example, with reference to FIGS. 20 and 21 , the height, width, and/or cross-sectional area of channels 256 extending in the transverse direction X may be larger than the height, width, and/or cross-sectional area of channels 256 extending in the longitudinal direction Y. Providing smaller-sized channels 256 extended in longitudinal direction Y restricts the airflow rate between pillars 260 located in heel region 201 and pillars 260 located in forefoot region 203 of sole 220. Providing larger-sized channels 256 extended in transverse direction X increases the airflow rate between pillars 260 located in heel region 201 or between pillars 260 located in forefoot region 203.
In some embodiments, midsole core 250 may include a layer of open-cell foam disposed on bottom surface 255 of base plate 252 and engaged against upper surface 232 of outsole 230 to control the airflow rate between pillars 260. For example, the open-cell foam layer may restrict the airflow rate at a level that prevents the air pressure in first set 278 of pillars 260 being diminished rapidly in response to ground contact force.
In some embodiments, as shown in FIG. 17 , midsole core 250 may include a plurality of strips 258 interconnecting the plurality of pillars 260. For example, in some embodiments, a strip 258 can extend between a pair of adjacent pillars 260 such that pillars 260 are supported adequately in an upright position. The number and placement of strips 258 can be modified to adjust the support of pillars 260.
With reference to FIGS. 15B, 16B, and 18 , midsole core 350 may include the same or similar features of midsole core 250, for example including a base plate 352 disposed on upper surface 232 of outsole 230, a plurality of pillars 360 projecting upwardly from base plate 352 and being filled with air, and a plurality of strips 358 interconnecting pillars 360. Similar to the plurality of pillars 260 of midsole core 250 described above, the plurality of pillars 360 of midsole core 350 may include a first set of pillars 260 that are fluidly connected by a plurality of channels, such as, channels defined on a bottom surface of base plate 352.
Midsole core 350 may further include one or more pillars disposed on lateral side 204 of sole 220 to provide a desired cushioning effect. For example, midsole core 350 may include a first flange 370 extending from a lateral side 354 of base plate 352 to the perimeter of outsole 230 in forefoot region 203 of sole 220. Midsole core 350 may include a plurality of lateral forefoot pillars 372 projecting upwardly from first flange 370. Midsole core 350 may include a second flange 380 extending from lateral side 354 of base plate 352 to the perimeter of outsole 230 in heel region 201 of sole 220. Midsole core 350 may include a plurality of lateral heel pillars 382 projecting upwardly from second flange 382. Lateral forefoot and heel pillars 372, 382 may include the same or similar features of pillars 260, including being filled with air to provide a desirable cushioning effect.
With reference to FIGS. 15B, 16B, and 18 , midsole rim 340 may include the same or similar features of midsole rim 240, such as, for example, being disposed on upper surface 232 of outsole 230 and extending along the perimeter of outsole 230 to define sole chamber 222. Exterior surface 342 of midsole rim 340 defines a sidewall of sole 220. Midsole rim 340 may also include a first recess 346 disposed on lateral side 204 of sole 220 and in forefoot region 203 of sole 220 and a second recess 348 disposed on lateral side 204 of sole 220 and in heel region 201 of sole 220.
As shown in FIGS. 15B and 16B, first and second recesses 346, 348 each define a through-opening along a bottom surface 341 that extends from exterior surface 342 to lateral interior surface 344 of midsole rim 340. First recess 346 of midsole rim 340 is superimposed with respect to first flange 370 of midsole core 350 such that bottom surface 341 of midsole rim 340 engages first flange 370 and lateral forefoot pillars 372 are received in first recess 346 of midsole rim 340. Second recess 348 of midsole rim 340 is superimposed with respect to second flange 380 of midsole core 350 such that bottom surface 341 of midsole rim 340 engages second flange 380 and lateral heel pillars 382 are received in second recess 348 of midsole rim 340. The arrangement of first and second recesses 346, 348 with respect to lateral forefoot and heel pillars 372, 382 exposes lateral forefoot and heel pillars 372, 382 on lateral side 204 of sole 220.
The foregoing description of the specific embodiments will so fully reveal the general nature of the disclosure that others can, by applying knowledge within the skill of the art, readily modify and/or adapt for various applications such specific embodiments, without undue experimentation, without departing from the general concept of the present disclosure. Therefore, such adaptations and modifications are intended to be within the meaning and range of equivalents of the disclosed embodiments, based on the teaching and guidance presented herein. It is to be understood that the phraseology or terminology herein is for the purpose of description and not of limitation, such that the terminology or phraseology of the present specification is to be interpreted by the skilled artisan in light of the teachings and guidance.
The breadth and scope should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the claims and their equivalents.

Claims

What is claimed is:

1. An article of footwear, comprising:

an upper; and

a sole coupled to the upper, the sole comprising:

a sole unit configured to support the foot of the wearer, the sole unit comprising:

a base extending along a length of the sole and configured to contact the ground,

a sidewall projecting upwardly from the base and extending along a perimeter of the base, wherein the base and the sidewall define a sole chamber, and

a plurality of hollow pillars projecting upwardly from the base and disposed within the sole chamber,

a clip received on the base of the sole unit in a heel region of the sole, the clip extending from a first end of the sidewall to a second end of the sidewall, wherein the clip comprises a grid of ducts extending in a transverse direction,

wherein the sole unit is made of a first material having a first modulus of elasticity and the clip is made of a second material having a second modulus of elasticity that is less than first modulus of elasticity.

2. The article of footwear of claim 1, wherein the ducts of the clip include openings disposed on a lateral side of the sole.

3. The article of footwear of claim 2, wherein the clip includes:

a casing coupled to the base and the first and second ends of the sidewall, and

a plurality of strips disposed in the casing and extending in the transverse direction from the lateral side of the sole such that the strips define the grid of ducts.

4. The article of footwear of claim 3, wherein the casing of the clip defines a window disposed on the lateral side of the sole, the window exposing the openings of the ducts of the clip.

5. The article of footwear of claim 1, wherein the first end of the sidewall is disposed at a back end of the heel region of the sole, and the second end of the sidewall is disposed on the lateral side of the sole between the back end of the heel region and the forefoot region of the sole.

6. The article of footwear of claim 1, wherein the sole unit comprises a partition wall projecting upwardly from the base and disposed between the clip and the plurality of pillars.

7. The article of footwear of claim 6, wherein the partition wall comprises:

a first segment extending in a longitudinal direction from the first end of the sidewall disposed at a back end of the heel region of the sole to a location between the back end of the heel region and the forefoot region of the sole,

a second segment extending from a front end of the first segment to the second end of the sidewall disposed on the lateral side of the sole between the back end of the heel region and the forefoot region of the sole.

8. The article of footwear of claim 1, wherein the plurality of pillars each comprises:

a curved sidewall,

a dome-shaped lid extending from an upper end of the curved sidewall, wherein the curved sidewall and the lid define a cavity, and

an aperture disposed at a center of the lid and opening into the cavity.

9. The article of footwear of claim 1, wherein the first material of the sole unit comprises rubber, and the second material of the clip comprises thermoplastic polyurethane.

10. The article of footwear of claim 1, wherein the plurality of pillars are arranged rows extending in a transverse direction, the rows of pillars are arranged along the length of the sole from the heel region of the sole to the forefoot region of the sole.

11. An article of footwear, comprising:

an upper; and

a sole coupled to the upper, the sole comprising:

an outsole configured to engage the ground,

a midsole rim disposed on an upper surface of the outsole and extending along a perimeter of the outsole, the midsole rim comprises an exterior surface defining a sidewall of the sole, wherein the midsole rim and the outsole define a sole chamber, and

a midsole core disposed within the sole chamber, the midsole core comprising:

a base plate disposed on the upper surface of the outsole, and

a plurality of hollow pillars projecting upwardly from the base plate and filled with air, the plurality of pillars are arranged along the length of the sole from the heel region of the sole to the forefoot region of the sole,

wherein the plurality of pillars include a first set of pillars fluidly connected together such that air is permitted to flow between the first set of pillars.

12. The article of footwear of claim 11, wherein the plurality of pillars include a second set of pillars, each pillar of the second set being fluidly isolated from the remainder of the pillars.

13. The article of footwear of claim 11, wherein the first set of pillars are arranged along a length of the sole from the heel region of the sole to the forefoot region of the sole.

14. The article of footwear of claim 11, wherein the plurality of pillars include:

a lateral row of pillars extending from the heel region of the sole to the forefoot region of the sole,

a medial row of pillars extending from the heel region of the sole to the forefoot region of the sole, and

a central row of pillars disposed between the medial and lateral row of pillars and extending from the heel region of the sole to the forefoot region of the sole.

15. The article of footwear of claim 14, wherein the first set of pillars include the central row of pillars.

16. The article of footwear of claim 15, wherein the first set of pillars include one or more pillars disposed in the lateral row located in the forefoot and heel region of the sole and one or more pillars disposed in the medial row located in the forefoot and heel region of the sole.

17. The article of footwear of claim 11, wherein the plate includes a plurality of channels defined on the bottom surface of the plate, interconnecting the first set of pillars.

18. The article of footwear of claim 11, wherein the midsole core comprises:

a first flange extending from a lateral side of the base plate in the forefoot region of the sole and a plurality of lateral forefoot pillars projecting upwardly from the first flange, and

a second flange extending from the lateral side of the base plate in the heel region of the sole and a plurality of lateral heel pillars projecting upwardly from the second flange.

19. The article of footwear of claim 18, wherein the midsole rim comprises a first recess disposed on a lateral side of the midsole rim in the forefoot region of the sole and a second recess disposed on the lateral side of the midsole rim in the heel region of the sole, and wherein the lateral forefoot pillars are received in the first recess of the midsole rim and the lateral heel pillars are received in the second recess of the midsole rim.