CN118401139A - Article of footwear with sole structure - Google Patents

Abstract

A sole structure for an article of footwear includes a forefoot region and a heel region. The sole structure also includes a chassis plate; an outer bottom plate extending from the forefoot region to the heel region, the outer bottom plate comprising a recess disposed in the top surface, wherein the outer bottom plate is disposed below the chassis plate; and a cushioning element disposed within the recess.

Description

Footwear having a sole structure

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application No. 63/316,632, filed on March 4, 2022, which is incorporated herein by reference in its entirety.

Technical Field

The present disclosure relates generally to articles of footwear and, more particularly, to a sole structure for an article of footwear.

Background technique

This section provides background information related to the present disclosure which is not necessarily prior art.

Articles of footwear traditionally include an upper and a sole structure. The upper may be formed of any suitable material to accommodate, secure and support the foot on the sole structure. The upper may cooperate with laces, straps or other fasteners to adjust the fit of the upper around the foot. The bottom portion of the upper, proximate the bottom surface of the foot, is attached to the sole structure.

The sole structure generally includes a layered arrangement extending between the ground surface and the upper. One layer of the sole structure includes an outsole that provides wear resistance and traction with the ground surface. The outsole may be formed of a polymer or other materials that impart durability and wear resistance and enhance traction with the ground surface. Another layer of the sole structure includes a midsole disposed between the outsole and the upper. The midsole provides cushioning for the foot and is generally at least partially formed of a polymer foam material that elastically compresses under an applied load to cushion the foot by weakening ground reaction forces. The midsole may define a bottom surface on a side opposite to the outsole and define a footbed on the opposite side, the contour of which may conform to the contour of the bottom surface of the foot. The sole structure may also include an insole and/or a sockliner that enhances comfort in a cavity near the bottom portion of the upper.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings described herein are selected embodiments for illustration purposes only. Therefore, the drawings do not include all possible implementations and are not intended to limit the scope of the present disclosure.

FIG. 1 illustrates an exemplary article of footwear including a sole structure according to an embodiment of the present disclosure;

FIG. 2 illustrates an exploded view of the sole structure of the article of footwear of FIG. 1 ;

FIG. 3 a illustrates a top view of an outsole plate of the sole structure of the article of footwear of FIG. 1 ;

FIG. 3 b illustrates a bottom view of a studded moderat or plate of the sole structure of the article of footwear of FIG. 1 ;

FIG. 4 illustrates a partial exploded view of the sole structure of the article of footwear of FIG. 1 ;

FIG. 4 a illustrates a top view of a forefoot cushioning element of the sole structure of the article of footwear of FIG. 1 ;

FIG. 4 b illustrates a cross-sectional view of the sole structure of the article of footwear of FIG. 4 ;

FIG. 4 c illustrates a cross-sectional view taken along line A-A of the cushioning element of the sole structure of the article of footwear of FIG. 4 ;

FIG. 4d illustrates a cross-sectional view taken along line B-B of the cushioning element of the sole structure of the article of footwear of FIG. 4 ;

5 illustrates a top view of a forefoot cushioning element disposed in an outsole plate of the sole structure of the article of footwear of FIG. 1 ;

FIG. 6 illustrates a perspective view of the sole structure of the article of footwear of FIG. 1 ;

FIG. 7 illustrates an exploded view of an alternative embodiment of a sole structure for an article of footwear;

FIG. 8 illustrates a top view of an alternative embodiment of a forefoot cushioning element of the sole structure of the article of footwear of FIG. 7 ;

FIG. 9 illustrates a perspective view of a speed brake of the sole structure of the article of footwear of FIG. 7 ;

FIG. 10 illustrates a bottom view of the speed brake and shim of the sole structure of the article of footwear of FIG. 7 ;

FIG. 11 illustrates a perspective view of a liner of the sole structure of the article of footwear of FIG. 7 ;

FIG. 12 illustrates a perspective view of the sole structure of the article of footwear of FIG. 7 ;

FIG. 13 illustrates a bottom view of the sole structure of the article of footwear of FIG. 7 ;

FIG. 14 illustrates an exploded view of an alternative embodiment of a sole structure for an article of footwear;

FIG. 15 illustrates an exploded view of an alternative embodiment of a sole structure for an article of footwear;

FIG. 16 illustrates a cross-sectional view of the footwear of FIG. 15 ; and

FIG. 17 illustrates a bottom view of the sole structure of FIG. 15 .

Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.

Detailed ways

Example embodiments will now be described more fully with reference to the accompanying drawings. Example embodiments are provided so that the present disclosure will be thorough and will fully convey the scope of the present disclosure to those of ordinary skill in the art. Many specific details, such as examples of specific components, devices, and methods, are set forth to provide a thorough understanding of the embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, and that example embodiments may be embodied in many different forms and should not be construed as limiting the scope of the present disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known techniques are not described in detail.

The terms used herein are only used for the purpose of describing specific example embodiments and are not intended to be limiting. As used herein, the singular forms "a", "an" and "the" may also be intended to include plural forms unless the context clearly indicates otherwise. The terms "comprises", "comprising", "includng" and "having" are inclusive and therefore specify the presence of features, integers, steps, operations, elements and/or parts, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, parts and/or groups thereof. The method steps, processes and operations described herein should not be interpreted as necessarily requiring them to be performed in the specific order discussed or illustrated, unless they are specifically identified as an execution order. It should also be understood that additional or alternative steps may be adopted.

When an element or layer is referred to as being "on another element or layer," "engaged to," "connected to," or "coupled to" another element or layer, it may be directly on, engaged to, connected to, or coupled to the other element or layer, or there may be intermediate elements or layers. Conversely, when an element is referred to as being "directly on another element or layer," "directly engaged to," "directly connected to," or "directly coupled to" another element or layer, there may be no intermediate elements or layers. Other words used to describe the relationship between elements should be interpreted in a similar manner (e.g., "between" versus "directly between," "adjacent" versus "directly adjacent," etc.). As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed items.

Although the terms first, second, third, etc. can be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms can only be used to distinguish an element, component, region, layer or section from another region, layer or section. Terms such as "first", "second" and other numerical terms do not imply order or sequence when used in this article unless the context clearly indicates. Therefore, without departing from the teaching of the exemplary embodiment, the first element, component, region, layer or section discussed below can be referred to as the second element, component, region, layer or section.

Spatially relative terms, such as "inside", "outside", "below", "below", "down", "above", "on", etc., may be used herein to facilitate description of the relationship of one element or feature to another element or feature as illustrated in the figure. In addition to the orientation depicted in the figure, spatially relative terms may be intended to cover different orientations of the device in use or operation. For example, if the device in the figure is turned over, the elements described as "below" or "below" other elements or features will be oriented to be "above" other elements or features. Therefore, the example term "below" can cover the orientation above and below. The device can be oriented in other ways (rotated 90 degrees or in other orientations), and the spatially relative descriptors used herein are interpreted accordingly.

In the following discussion, unless otherwise indicated, the terms "about," "approximately," "substantially," etc., when used to describe a numerical value, represent a variation of +/- 10% of the value.

Examples of the present disclosure are particularly directed to footwear articles having sole structures. In one example, the footwear article can improve the performance of a user. Each example disclosed herein can include one or more features described in conjunction with any other disclosed example. Examples of the present disclosure can incorporate cushioning elements into the sole structure while maintaining the overall height of the footwear article relatively low/short.

Footwear

Referring to FIG. 1 , a footwear article 10 includes an upper 100 and a sole structure 101 (as shown in FIG. 2 ). The footwear article 10 may be divided into one or more regions. These regions may include a forefoot region 12, a midfoot region 14, and a heel region 16. The forefoot region 12 may be subdivided into a toe portion 12T corresponding to the phalanges and a ball portion 12B associated with the metatarsal bones of the foot. The midfoot region 14 may correspond to the arch region of the foot, and the heel region 16 may correspond to the rear portion of the foot (including the calcaneus). The footwear 10 may also include a front end 18 associated with the frontmost point of the forefoot region 12 and a rear end 20 associated with the rearmost point of the heel region 16. The longitudinal axis of the footwear 10 extends from the front end 18 to the rear end 20 along the length of the footwear 10, and generally divides the footwear 10 into a medial side 22 (shown in FIG. 3B ) and a lateral side 24 (also shown in FIG. 3B ). Thus, medial side 22 and lateral side 24 correspond to opposite sides of footwear 10 and extend through regions 12 , 14 , 16 , respectively.

vamp

With reference to Figure 1, upper 100 includes an inner surface that defines an inner cavity, and the inner cavity is configured to accommodate and fix the foot to be supported on sole structure 101. Upper 100 can be formed by one or more materials, and these materials are stitched or bonded together to form the inner cavity. Suitable materials of upper 100 can include but are not limited to nets, textiles, foams, leathers and synthetic leathers. Can select and position materials to give the performance of durability, breathability, wear resistance, flexibility and comfort. Ankle opening 110 in heel area 16 can provide the entrance to enter the inner cavity. For example, ankle opening 110 can accommodate foot, to fix foot in the cavity, and facilitate foot to enter the inner cavity and move out of foot from the inner cavity.

In some examples, the upper 100 includes a midsole fabric having a bottom surface opposite the sole structure 101 and an opposing top surface of a footbed defining an interior cavity. Stitching or adhesive can secure the midsole fabric to the upper 100. The contour of the footbed can conform to the contour of the bottom surface of the foot (e.g., the sole). Optionally, the upper 100 can also be combined with additional layers, such as an insole or sockliner, which can be disposed on the midsole fabric and reside within the interior cavity of the upper 100 to accommodate the plantar surface of the foot, thereby enhancing the comfort of the footwear article 10. The sockliner can include an elastic material to impart a desired level of support and stiffness.

In some examples, one or more fasteners 111 extend along the upper 100 to adjust the fit of the interior cavity around the foot and accommodate entry and removal of the foot from the interior cavity. The upper 100 may include holes such as eyelets and/or other engagement features such as fabric or mesh loops that accommodate the fasteners 111. The fasteners 111 may include laces, straps, cords, hooks and loops, or any other suitable type of fasteners. The upper 100 may include a tongue portion extending between the interior cavity and the fasteners 111. Additionally or alternatively, the upper 100 may be formed with a tensioning system that includes a series of cables routed through a cable locking device attached to the footwear article.

Sole construction

1 and 2 , sole structure 101 includes a chassis plate (chassis) 102 extending between medial side 22 and lateral side 24 from front end 18 to rear end 20. Sole structure 101 also includes a forefoot liner 103 disposed on an outsole plate (cleat plate) 104. Outsole plate 104 and forefoot liner 103 may be coupled to chassis plate 102. A bottom surface of outsole plate 104 may define a ground engaging surface of article of footwear 10.

Chassis

2 , the chassis plate 102 may extend continuously from the front end 18 to the rear end 20 of the sole structure 101 and may span the width of the sole structure 101 from the medial side 22 to the lateral side 24. The chassis plate 102 may also include a top (upper) surface 202 facing the bottom of the upper 100, and a bottom (lower) surface 204 formed on a side of the chassis plate 102 opposite the top surface 202 facing the direction of the ground surface. The distance from the top surface 202 to the bottom surface may define the thickness of the chassis plate 102. In this embodiment, the top surface 202 of the chassis plate 102 may be positioned against the midsole fabric of the upper 100 (shown in FIG. 1 ) from the front end 18 to the rear end 20. In some examples, the entire top surface 202 may be attached (e.g., directly attached) to the midsole fabric of the upper 100, so that the upper surface 202 of the chassis plate 102 may define the contour of the footbed.

The chassis panel 102 can be formed of a material that provides relatively high strength and stiffness, such as a polymer material and/or a composite material. In some examples, the chassis panel 102 can be a composite material manufactured using a fiber sheet or textile, including a pre-impregnated (i.e., "prepreg") fiber sheet or textile. Alternatively or additionally, the chassis panel 102 can be manufactured by a strand formed by a plurality of filaments of one or more types of fibers (e.g., a fiber tow), and a board having fiber strands arranged primarily at a predetermined angle or at a predetermined position is produced by attaching the fiber tows to a substrate or to each other. When fiber strands are used, the fiber types included in the strands can include synthetic polymer fibers that can be melted and resolidified to consolidate other fibers present in the strands and optional other components such as sutures or a substrate or both. Alternatively or additionally, the fibers of the strands and optional other components such as sutures or a substrate or both can be consolidated by applying a resin after the fiber strands are attached to a substrate and/or to each other.

In some configurations, the chassis plate 102 can be formed by one or more fiber tow layers and/or a fiber layer including at least one of carbon fiber, boron fiber, glass fiber and polymer fiber. In a specific configuration, the fiber includes carbon fiber, or glass fiber, or a combination of carbon fiber and glass fiber. The fiber tow can be attached to the substrate. The fiber tow can be attached by stitching or using an adhesive. Additionally or alternatively, the fiber tow and/or fiber layer can be consolidated with a thermosetting polymer and/or a thermoplastic polymer. Therefore, the chassis plate 102 can have tensile strength or flexural strength in a transverse direction substantially perpendicular to the longitudinal axis of the footwear article (i.e., an axis extending from the front end 18 to the rear end 20). The stiffness of the chassis plate 102 can be selected for a specific wearer based on the wearer's tendon flexibility, calf muscle strength and/or metatarsophalangeal (MTP) joint flexibility. In addition, the stiffness of the chassis plate 102 can also be customized based on the athlete's running motion. In other configurations, the chassis plate 102 can be formed by one or more layers/layers of unidirectional tape. In some examples, each layer in the stack includes a different orientation than the layer disposed below. The panel can be formed from a unidirectional tape including at least one of carbon fibers, boron fibers, glass fibers, and polymer fibers. In some examples, the one or more materials forming the chassis panel 102 can cause the chassis panel 102 to have a Young's modulus of at least 70 gigapascals (GPa).

In some embodiments, chassis plate 102 may have a substantially uniform thickness. In some examples, the thickness of chassis plate 102 may be in a range from about 0.6 millimeters (mm) to about 3.0 mm. In an exemplary embodiment, the thickness of chassis plate 102 is equal to 1.0 mm. In other embodiments, the thickness of chassis plate 102 may be non-uniform, such that chassis plate 102 may have a greater thickness in one of regions 12, 14, and 16 of sole structure 101 than in other regions 12, 14, and 16. In other words, chassis plate 102 may have a variable thickness in each of regions 12, 14, and 16. In some embodiments, chassis plate 102 may be replaced by an insole.

In alternative embodiments, described in further detail in the Alternative Embodiments section below, chassis plate 1402 may be disposed solely within forefoot region 12. Additionally, chassis plate 1402 may be located within toe portion 12T of forefoot region 12. It is contemplated that in other alternative embodiments, chassis plate 1402 may be disposed in forefoot region 12 and a portion of midfoot region 14. It is also contemplated that in other alternative embodiments, chassis plate 1402 may be disposed in any of forefoot region 12, midfoot portion 14, and heel portion 16 to provide desired levels of support, stability, and comfort to article of footwear 10.

Outer sole plate

3A and 3B , the outsole plate 104 may extend continuously from the front end 18 of the footwear article 10 to the rear end 20 of the footwear article. The outsole plate 104 may also include an upper surface 302 facing the upper 100 and a lower surface 304 formed on a side of the outsole plate 104 opposite the upper surface 302. A sidewall 306 (shown in FIG. 2 ) may extend vertically upward from the upper surface 302. The sidewall 306 may also define an outer perimeter of the outsole plate 104. The upper surface 302 of the outsole plate 104 may be attached to a bottom surface of the chassis 102.

The upper surface 302 may also include a recess 308. The recess 308 may be present in the forefoot of the outer sole plate 104. The recess 308 may form a depression in the outer sole plate 104. The recess 308 may extend outward from the center of the recess toward the front segment 310, the rear segment 312, the lateral segment 314, and the medial segment 316. The portion extending from the center toward the front segment 310 may extend in a direction toward the front end 18. The portion extending from the center toward the rear segment 312 may extend in a direction toward the rear end 20. The portion extending from the center toward the lateral segment 314 may extend in a direction toward the lateral side 24. The portion extending from the center toward the medial segment 316 may extend in a direction toward the medial side 22. Following a path along the outside of the recess 308, each of the segments 310 to 316 may be interconnected through the upper surface 302. The portion 317 of the path extending between the segments 310 to 316 may be inwardly curved. In other words, the recess 308 can be defined on its exterior by the upper surface 302, and the exterior of the recess 308 defined by the upper surface 302 can follow a path between the segments 310 to 316 that is concave when viewed from a radially outer position. Each of the incurved portions 317 of the path can be convex when viewed from the center of the recess 308, although other configurations are contemplated.

In addition, the outsole plate 104 can be divided into a front region and a rear region by an axis A114 perpendicular to the central longitudinal axis A104. The axis A114 can intersect the central longitudinal axis 104 at a point that is the longitudinal center between the frontmost portion and the rearmost portion of the outsole plate 104. Additionally, the axis A114 can divide the outsole plate 104 into a front region 322 and a rear region 324. The front region 322 and the rear region 324 may or may not have equal two-dimensional areas or area projections (when viewed from directly above). The front region 322 may include a recess 308 disposed therein. The area of the recess 308 may be less than about 80%, less than about 70%, less than about 60%, or less than about 50% of the total two-dimensional area of the front region 322.

The recess 308 can be substantially symmetrical about the axis A104, although asymmetrical configurations are contemplated. The lateral segment 314 and the medial segment 316 can be mirror images of each other. The front segment 310 and the rear segment 312 can be mirror images of each other. In an exemplary embodiment, each of the segments 310 to 316 can be a substantial mirror image of each other. In other words, the recess 308 can form a generally plus sign or cross shape. It is contemplated that the recess 308 can have a generally oval, diamond, or irregular shape.

Lower surface 304 of outsole plate 104 may form a ground engaging surface of article of footwear 10 and may include a plurality of traction elements 318. Lower surface 304 may also include a corresponding opposing face 320 of recess 308. Multiple traction elements 318 may be integrally molded with bottom surface 304 of outsole plate 104. Additionally, some of multiple traction elements 318 may be integrally molded with opposing face 320 of recess 308. In FIG. 3B , two traction elements 318 are shown extending directly from opposing face 320, but it is contemplated that fewer (e.g., zero or one) or more traction elements 318 may extend directly from opposing face 320. The remainder of multiple traction elements 318 in forefoot region 12 may surround opposing face 320 in various patterns to provide a desired form of traction. In the illustrated embodiment, there are six additional traction elements 318 in forefoot region 312, but other numbers and patterns different from those shown in FIG. 3B are also contemplated. Multiple traction elements 318 may all have the same size, or they may have different sizes to provide desired traction, stability, and/or other properties. It is contemplated that traction elements 318 may be attached to outsole plate 104 alternatively by snap fit, screw structure, etc. Opposing face 320 may have fewer traction elements 318 than the remainder of bottom surface 304 of outsole plate 104. Traction elements 318 may be disposed in forefoot region 12 and heel region 16. Traction elements 318 may extend from heel region 16 to midfoot region 14, and from forefoot region 12 to midfoot region 14. Portions of traction elements 318 may extend partially into midfoot region 14. In some embodiments, midfoot region 14 may be substantially free of traction elements 318.

Forefoot cushioning element

Referring to FIGS. 4 and 4A to 4D, the recess 308 of the outsole plate 104 may have a forefoot cushioning element 103 disposed therein. The forefoot cushioning element 103 may be, for example, a fluid-filled bladder that can expand to provide a desired form of cushioning and support. The forefoot cushioning element 103 may be formed by a pair of barrier layers that, when coupled together, may define a closed interior volume (or hollow interior) for receiving, for example, a pressurized fluid (e.g., a gas as further described below). The barrier layers may be coupled to each other at discrete locations to define the overall shape of the forefoot cushioning element 103. In an exemplary embodiment, the forefoot cushioning element 103 may include a first upper barrier layer 402 and a second lower barrier layer 404. The upper barrier layer 402 may be attached to the lower barrier layer 404 by applying heat and pressure to the periphery of the upper barrier layer 402 and the lower barrier layer 404 to define a peripheral seam 406. Peripheral seam 406 may seal forefoot cushioning element 103 and may define a peripheral contour of forefoot cushioning element 103 .

As used herein, the term "barrier layer" (e.g., barrier layers 402, 404) can encompass both monolayer films and multilayer films. In some embodiments, one or both of barrier layers 402, 404 can each be produced (e.g., thermoforming or blow molding) from a monolayer film (monolayer). In other embodiments, one or both of barrier layers 402, 404 can each be produced (e.g., thermoforming or blow molding) from a multilayer film (multiple sublayers). In any embodiment, each layer or sublayer can have a film thickness ranging from about 0.2 microns to about 1 millimeter. In further embodiments, the film thickness of each layer or sublayer can range from about 0.5 microns to about 500 microns. In yet further embodiments, the film thickness of each layer or sublayer can range from about 1 micron to about 100 microns. It is conceivable that forefoot cushioning element 103 can have a thickness ranging from 6mm to 10mm, although other suitable values can be conceived. In an exemplary embodiment, forefoot cushioning element 103 can have a thickness of 8mm.

One or both of the barrier layers 402, 404 may be independently transparent, translucent, and/or opaque. As used herein, the term "transparent" for the barrier layer and/or the fluid-filled chamber means that light passes through the barrier layer in a substantially straight line and an observer can see through the barrier layer. In contrast, for an opaque barrier layer, light does not pass through the barrier layer, and one cannot clearly see through the barrier layer at all. A translucent barrier layer is between a transparent barrier layer and an opaque barrier layer in that light passes through the translucent layer, but some of the light is scattered, making it impossible for an observer to clearly see through the layer.

The barrier layers 402, 404 may each be produced from an elastomeric material including one or more thermoplastic polymers and/or one or more cross-linkable polymers. In an embodiment, the elastomeric material may include one or more thermoplastic elastomeric materials, such as one or more thermoplastic polyurethane (TPU) copolymers, one or more ethylene-vinyl alcohol (EVOH) copolymers, and the like.

Forefoot cushioning 103 may be produced from barrier layers 402, 404 using any suitable technique, such as thermoforming (e.g., vacuum thermoforming), blow molding, extrusion, injection molding, vacuum molding, rotational molding, transfer molding, pressure molding, heat sealing, casting, low pressure casting, rotational casting, reaction injection molding, radio frequency (RF) welding, etc. In an embodiment, barrier layers 402, 404 may be produced by co-extrusion followed by vacuum thermoforming to produce forefoot cushioning element 103, which may optionally include one or more valves (e.g., one-way valves) that allow forefoot cushioning element 103 to be filled with a fluid (e.g., a gas).

Forefoot cushioning element 103 can be provided in a fluid-filled or unfilled state. Forefoot cushioning element 103 can be filled to include any suitable fluid, such as gas or liquid. In an embodiment, gas can include air, nitrogen ( _N2 ) or any other suitable gas. In other embodiments, forefoot cushioning element 103 can alternatively include other media, such as pellets, beads, ground recycled materials, etc. (e.g., foaming beads and/or rubber beads). The fluid provided to forefoot cushioning element 103 can cause forefoot cushioning element 103 to be pressurized. In some instances, forefoot cushioning element 103 can have a pressure ranging from 15psi (pounds per square inch) to 25psi. In other instances, forefoot cushioning element 103 can have a pressure ranging from 20psi to 25psi. In some instances, forefoot cushioning element 103 can have a pressure of 20psi. In other instances, forefoot cushioning element 103 can have a pressure of 25psi. Alternatively, the fluid provided to forefoot cushioning element 103 may be at atmospheric pressure such that forefoot cushioning element 103 is not pressurized, but rather simply contains a volume of fluid at atmospheric pressure.

Forefoot cushioning element 103 desirably has a low gas permeability to maintain the gas pressure it maintains. In some embodiments, forefoot cushioning element 103 can have a gas permeability for nitrogen that is at least about ten (10) times lower than the nitrogen permeability of a butyl rubber layer of substantially the same size. In an embodiment, forefoot cushioning element 103 can have a nitrogen permeability of 15 cubic centimeters per square meter.atmosphere.day (cm ³ /m ² ·atm·day) or less for an average film thickness of 500 microns (based on the thickness of barrier layers 402, 404). In further embodiments, the permeability can be 10 cm ³ /m ² ·atm·day or less, 5 cm ³ /m ² ·atm·day or less, or 1 cm ³ /m ² ·atm·day or less.

Forefoot cushioning element 103 may house stretch element 408 (or one or more stretch elements 408) therein. Each stretch element 408 may include a series of stretch strands extending between an upper stretch sheet (not shown) and a lower stretch sheet (not shown). The upper stretch sheet may be attached to upper barrier layer 402, and the lower stretch sheet may be attached to lower barrier layer 404. Thus, when forefoot cushioning element 103 accommodates pressurized fluid, the stretch strands of the stretch element are in tension. Because the upper stretch sheet is attached to upper barrier layer 402, and the lower stretch sheet is attached to lower barrier layer 404, the stretch strands maintain the desired shape of forefoot cushioning element 103 when pressurized fluid is injected into the chamber.

In an alternative embodiment, the forefoot cushioning element 103 may include polymer foam and/or particulate matter in one or more or all regions of the forefoot cushioning element 103, which corresponds to the closed internal volume of the forefoot cushioning element 103. For example, the forefoot cushioning element 103 may include a plurality of fluid-filled chambers arranged in the forefoot region, as described in more detail below. Additionally or alternatively, the forefoot cushioning element 103 may be replaced or supplemented with other cushioning elements. For example, the liner may include a foam block that replaces or supplements the pressurized fluid. The foam block may be contained in an internal cavity 408 defined by the upper barrier layer 402 and the lower barrier layer 404. Positioning the foam block in the internal cavity 408 defined by the upper barrier layer 402 and the lower barrier layer 404 may allow the barrier layer to limit the foam block from expanding beyond a predetermined amount when subjected to a predetermined load. Therefore, by allowing the foam block to interact with the barrier layers 402 and 404 during loading, the overall shape of the foam block and therefore the performance of the foam block may be controlled. Although the foam block is described as being contained within the interior cavity 408 of the barrier layers 402 and 404, the foam block may alternatively be positioned between the chassis plate 102 and the outer bottom plate 104 without the barrier layers 402 and 404. In this configuration, the foam block may be directly attached to the bottom surface of the chassis plate 102 and the outer bottom plate 104, respectively.

Forefoot cushioning element 103 may extend outward from its center toward front segment 410, rear segment 412, lateral segment 414, and medial segment 416. The portion extending from the center toward front segment 410 may extend in a direction toward front end 18. The portion extending from the center toward rear segment 412 may extend in a direction toward rear end 20. The portion extending from the center toward lateral segment 414 may extend in a direction toward lateral side 24. The portion extending from the center toward medial segment 416 may extend in a direction toward medial side 22. When viewing the exterior of forefoot cushioning element 103 from above, there may be a path that defines the outer boundary of forefoot cushioning element 103. The outer path may extend between each of segments 410 to 416, and may also include each of segments 410 to 416. When viewed from a radially outer position, the portion 417 of the path extending between the ends of the segments may be concave. When viewed from the center of forefoot cushioning element 103, each of the incurved portions 417 of the path may be convex, although other configurations may be contemplated.

Forefoot cushioning element 103 can be substantially symmetrical about axis A104, although asymmetrical configurations are contemplated. Lateral segment 414 and medial segment 416 can be mirror images of each other. Anterior segment 410 and posterior segment 412 can be mirror images of each other. In an exemplary embodiment, each of segments 410 to 416 can be substantially mirror images of each other. In other words, recess 308 can form a generally plus sign or cross shape. It is contemplated that recess 308 can have a generally oval, diamond, or irregular shape.

Referring to FIG. 5 , recess 308 (shown in FIG. 3A ) can accommodate forefoot cushioning element 103. Recess 308 and forefoot cushioning element 103 can have substantially corresponding geometries. Referring to FIGS. 4B to 4D , recess 308 can accommodate all or part of forefoot cushioning element 103. In an exemplary configuration, 100% of forefoot cushioning element 103 can be disposed within recess 308. When all of the forefoot cushioning element is disposed within recess 308, the top surface of forefoot cushioning element 103 and the top surface of outsole plate 104 can be substantially flush with each other, or the top surface of forefoot cushioning element 103 can be lower than the top surface of outsole plate 104. In other configurations, less than the entire forefoot cushioning element (e.g., about 90% or less, about 75% or less, about 50% or less) can be disposed within recess 308, such that the top surface of forefoot cushioning element 103 rests slightly above the top surface of outsole plate 104. The percentage of forefoot cushioning element 103 contained in recess 308 may be varied to impart the desired cushioning characteristics.

Assembly Configuration

4A-4D , when assembled, the top surface of forefoot cushioning element 103 may protrude slightly above upper surface 302 of outsole plate 104. In other embodiments, when forefoot cushioning element 103 is disposed within recess 308, the top surface of forefoot cushioning element 103 may rest substantially flush with upper surface 302 of outsole plate 104.

6, fully assembled sole structure 101 may include chassis plate 102, forefoot cushioning element 103, and outsole plate 104. Forefoot cushioning element 103 may be disposed within recess 308. Chassis plate 102 may be disposed along a major portion of outsole plate 104. Chassis plate 102 may be disposed over forefoot cushioning element 103. In other words, chassis plate 102 may span a majority (or substantially the entire) length of outsole plate 104 and may cover forefoot cushioning element 103 in the forefoot. Sole structure 101 may be adhered by stock mating, gluing, or any other suitable method for adhering elements of a sole structure made of different materials.

When the top surface of forefoot cushioning element 103 protrudes slightly above upper surface 302, there may be substantially no gap between chassis plate 102 and forefoot cushioning element 103. In an exemplary embodiment, forefoot cushioning element 103 is not subjected to compressive forces from chassis plate 102 during a resting state of article of footwear 10, or is otherwise subjected to substantially minimal compressive forces from chassis plate 102 during the resting state. The resting state may correspond to article of footwear 10 not being engaged by a user's foot. Alternatively, chassis plate 102 may apply a compressive force to forefoot cushioning element 103. In the alternative, the compressive force of chassis plate 102 applies a preload to forefoot cushioning element 103.

Alternative Embodiments

7 to 13 , an alternative embodiment of sole structure 101 may include chassis plate 102 , forefoot cushioning element 703 , outsole plate 704 , speed brake 105 , and spacer 106 .

7, chassis plate 102 can be substantially similar to that depicted and described with respect to FIGS. 1 to 6. When assembled, chassis plate 102 can be attached (e.g., directly attached) to forefoot cushioning element 703. There can be substantially no gap between chassis plate 102 and forefoot cushioning element 703.

8, forefoot cushioning element 703 can be similar to forefoot cushioning element 103. For example, forefoot cushioning element 703 can extend outward from its center toward front segment 710, rear segment 712, lateral segment 714, and medial segment 716. When viewed from a radially outer position, a portion 717 of the path extending between the ends of the segments can be concave. When viewed from the center of forefoot cushioning element 703, each of the portions of the path can be convex, although other configurations can be envisioned. In other words, the outer path can define forefoot cushioning element 103 and can follow an inwardly curved path between the ends of the segments of the forefoot cushioning element.

Segment 710 may have an area that is greater than the area of segment 712. Segment 714 may be similar to segment 716, but the forward-most portion of segment 714 may be forward of the forward-most portion of segment 716. In other words, segments 714 and 716 may be generally similar to each other, but the forward-most portions of segments 714 and 716 may be offset from each other. Additionally, each of segments 710, 714, and 716 may have a similar outer extension (i.e., width and length), which may be greater than the outer extension of segment 712. Thus, the shape of forefoot cushioning element 103 may be irregular.

9 and 10, airbrake 105 may have a cross or plus sign shape similar to forefoot cushioning element 703 and extend outwardly from its center toward front end 18, rear end 20, medial side 22, and lateral side 24. Airbrake 105 may have a top surface 726 and a bottom surface 728. The portion extending outwardly from the center of airbrake 105 may define the outer boundary of airbrake 105. Airbrake 105 may have a plurality of traction friction elements 724 disposed on its bottom surface. In addition, element 105 may be flexible in order to impart desired support characteristics to article of footwear 10.

11 , the shim 106 may include a lower perimeter 718, an upper perimeter 720, a sidewall 719, and an opening 722. The sidewall 719 may extend vertically upward from the lower perimeter 718 to the upper perimeter 720. When viewed from above, the upper perimeter 720 may follow an undulating path corresponding to the undulating path of the lower perimeter 718. The upper perimeter 720 and the lower perimeter 718 may form respective flanges of the shim 106. Thus, the lower perimeter 718 may receive and contact the speed brake 105. The lower perimeter 718 of the shim 106 may close the opening 722. The opening 722 may be defined by the path of the top surface 718. The upwardly facing surface of the sidewall 719 may receive the forefoot cushioning assembly 703.

Outsole plate 704 may extend continuously from front end 18 of article of footwear 10 to rear end 20 of article of footwear. Outsole plate 704 may include a narrow portion 705 in the midfoot region. Outsole plate 704 may also include an upper surface 702 facing upper 100 and a lower surface formed on a side of outsole plate 704 opposite upper surface 702. Outsole plate 104 may have a plurality of traction friction elements 318 disposed on lower surface 705 thereof. Sidewall 706 may extend vertically upward from upper surface 702. Sidewall 706 may also define an outer perimeter of outsole plate 704. Upper surface 702 of outsole plate 704 may be attached to a bottom surface of chassis 102.

Outsole plate 704 may also include opening 708. Opening 708 may be defined by an undulating path that is generally complementary in shape to forefoot cushioning element 703, speed brake 105, and shim 106. Opening 708 may be configured to receive shim 106, speed brake 105, and/or cushioning element 703.

Speed brake 105 can be attached to the ground-facing surface of forefoot cushioning element 703. Speed brake 105 and forefoot cushioning element 703 can have corresponding geometric shapes, and speed brake 105 can be placed within the inner boundary of the segment of forefoot cushioning element 703. Forefoot cushioning element 703 can be disposed on top surface 718 of pad 106. Speed brake 105 can be placed flush within the inner boundary of pad 106. In other words, each of forefoot cushioning element 703, speed brake 105 and pad 106 has corresponding geometric shapes to communicate with each other and place flush. The combination of pad 106 and speed brake 105 can form a portion of the ground engaging surface. Outsole plate 704 can form another portion of the ground engaging surface. In other words, outsole plate 704 together with speed brake 105 and pad 106 placed in opening 708 can form the entire ground engaging surface of the footwear article.

14 , an alternative embodiment of sole structure 101 may include a chassis plate 1402 , a forefoot cushioning element 1403 , an outer plate 1404 , a decelerator 1405 , and a spacer 1406 .

The chassis plate 1402 may extend continuously from the ball portion 12B of the forefoot region 12 through the toe portion 12T of the forefoot region 12 to the front end 18, and may span the width of the sole structure 101 from the medial side 22 to the lateral side 24. In other words, the chassis plate 1402 may be disposed only within the forefoot region 12. The chassis plate 1402 may also include a top (upper) surface facing the bottom of the upper 100, and a bottom (lower) surface formed on a side of the chassis plate 1402 opposite the top surface facing the direction of the ground surface. The distance from the top surface to the bottom surface may define the thickness of the chassis plate 1402. In this embodiment, the top surface of the chassis plate 1402 may be positioned against the midsole fabric of the upper 100 (shown in FIG. 1 ) from the front end 18 to the end closest to the ball portion 12B of the midfoot region 14. In some examples, the entire top surface of chassis plate 1402 can be attached (e.g., directly attached) to the midsole fabric of upper 100, such that the upper surface of chassis plate 1402 can define the contour of the footbed in forefoot region 12. It is contemplated that in other examples, chassis plate 1402 can be attached (e.g., directly attached) to sockliner 1401 of upper 100. Sockliner 1401 can include an elastic material to provide a desired form of support and stability when coupled with chassis plate 1402.

Chassis plate 1402 may be formed of an injection molded material. Although shown as a separate component, chassis plate 1402 may be integrally formed in upper 100. It is contemplated that chassis plate 1402 may be used in place of chassis 102. In alternative embodiments, chassis plate 1402 may be used in conjunction with chassis 102 to provide a desired form of cushioning, support, and stability.

It is contemplated that in other alternative embodiments, chassis plate 1402 may be disposed in a portion of forefoot region 12 and midfoot region 14. It is also contemplated that in other alternative embodiments, chassis plate 1402 may be disposed in any of forefoot region 12, midfoot portion 14, and heel portion 16 to provide a desired level of support, stability, and comfort to article of footwear 10.

Forefoot cushioning element 1403 may be substantially similar to that depicted and described with respect to FIGS. 1-6 .

Speedbrake 1405 may be substantially similar to speedbrake 106 depicted and described in connection with Figures 7, 9, 10, and 13. Speedbrake 1405 may have a generally cross or plus sign shape corresponding to forefoot cushioning element 1403.

Shim 1406 may be substantially similar to shim 106 depicted and described with respect to Figures 7, 11, and 13. Shim 1406 may have a geometry corresponding to the geometry of speed brake 1405 and forefoot cushioning element 1403.

The outer plate 1404 can be substantially similar to the outer bottom plate 104 depicted and described with respect to Figures 7, 12, and 13. The outer plate 1404 can provide desired levels of stiffness, structure, and flexibility.

Speed brake 1405, forefoot cushioning element 1403, and shim 1406 may be attached in a manner similar to that depicted and described with respect to FIGS. 7-13.

15 , an alternative embodiment of sole structure 101 may include chassis plate 1502 , forefoot cushioning element 1503 , and outer plate 1504 .

The chassis plate 1502 may be substantially similar to the chassis plate 1402 depicted and described with respect to FIG. 14 .

Forefoot cushioning element 1503 can be substantially similar to forefoot cushioning element 703 depicted and described with respect to FIGS. 7-13. In other embodiments, forefoot cushioning element 1503 can have a shape that is larger or smaller than forefoot cushioning element 703. For example, a corresponding segment of forefoot cushioning element 1503 can be narrower than any one or more of segments 710, 712, 714, and 716. As another example, a corresponding segment of forefoot cushioning element 1503 can be wider than any one or more of segments 710, 712, 714, and 716.

2. Receiver 1506 can have a geometry that corresponds to the geometry of forefoot cushioning element 1503. In the embodiment of FIG.

The outer plate 1504 can be substantially similar to the outer bottom plate 1404 depicted and described with respect to Figure 14. The outer plate 1504 can provide desired levels of rigidity, structure, and flexibility.

Chassis plate 1502, forefoot cushioning element 1503, and outer plate 1504 may be attached in a manner similar to that depicted and described with reference to FIGS. 1-6.

16 illustrates a cross-sectional view of an alternative embodiment of sole structure 101. The cross-sectional view may be taken perpendicular to a plane extending from front end 18 to rear end 20. Forefoot cushioning element 1503 is disposed within receiving portion 1506 of outsole plate 1504. Chassis plate 1502 is disposed on a side of forefoot cushioning element 1503 opposite receiving portion 1506.

FIG. 17 shows a bottom view of the outsole plate 1504 and the receiving portion 1506 including a set of primary spikes 1518 and secondary spikes 1522a and 1522b. The primary spikes 1518 and the secondary spikes 1522a and 1522 are disposed on the ground-facing surface 1520 of the receiving portion 1506. The primary spikes 1518 include a generally crescent shape. The primary spikes 1518 may be any other shape, such as an oval, a circle, a rectangle, etc. The secondary spikes 1522a and 1522b include a generally triangular shape. The secondary spikes 1522a and 1522b may be any other shape, such as an oval, a circle, a rectangle, etc. The secondary spikes 1522a and 1522b are disposed at opposite ends of the ground-facing surface 1520. The primary spikes 1518 are disposed between the opposing secondary spikes 1522a and 1522b. One or more of the primary cleats 1518 may be disposed adjacent to the secondary cleats 1522a, and another of the one or more primary cleats 1518 may be disposed adjacent to the secondary cleats 1522b. Opposite ones of the primary cleats 1518 may include opposing inner surfaces. For example, one primary cleat 1518 may have a concave inner surface, while the opposing primary cleat 1518 may have a convex inner surface. In another example, one primary cleat 1518 may have a concave inner surface, while the opposing primary cleat 1518 may have a concave inner surface. In another example, one primary cleat 1518 may have a convex inner surface, while the opposing primary cleat 1518 may have a convex inner surface.

Material

The barrier layers of forefoot cushioning element 103/703 can each be produced from an elastomeric material including one or more thermoplastic polymers and/or one or more cross-linkable polymers. In one aspect, the elastomeric material can include one or more thermoplastic elastomeric materials, such as one or more thermoplastic polyurethane (TPU) copolymers, one or more ethylene-vinyl alcohol (EVOH) copolymers, and the like.

As used herein, "polyurethane" refers to copolymers (including oligomers) containing urethane groups (-N(C=O)O-). In addition to urethane groups, these polyurethanes may also contain additional groups such as esters, ethers, ureas, allophanates, biuret, carbodiimide, oxazolidinyl, isocyanurate, uretdione, carbonate, and the like. In one aspect, one or more of the polyurethanes can be produced by polymerizing one or more isocyanates with one or more polyols to produce copolymer chains having (-N(C=O)O-) bonds.

Examples of suitable isocyanates for producing polyurethane copolymer chains include diisocyanates, such as aromatic diisocyanates, aliphatic diisocyanates, and combinations thereof. Examples of suitable aromatic diisocyanates include toluene diisocyanate (TDI), adducts of TDI and trimethylolpropane (TMP), methylene diphenyl diisocyanate (MDI), xylene diisocyanate (XDI), tetramethyl xylylene diisocyanate (TMXDI), hydrogenated xylene diisocyanate (HXDI), naphthalene 1,5-diisocyanate (NDI), 1,5-tetrahydronaphthalene diisocyanate, p-phenylene diisocyanate (PPDI), 3,3'-dimethyldiphenyl-4,4'-diisocyanate (DDDI), 4,4'-dibenzyl diisocyanate (DBDI), 4-chloro-1,3-phenylene diisocyanate, and combinations thereof. In some embodiments, the copolymer chain is substantially free of aromatic groups.

In certain aspects, the polyurethane polymer chain is derived from a diisocyanate comprising HMDI, TDI, MDI, H12 aliphatic compounds, and combinations thereof. In one aspect, the thermoplastic TPU may comprise a polyester-based TPU, a polyether-based TPU, a polycaprolactone-based TPU, a polycarbonate-based TPU, a polysiloxane-based TPU, or a combination thereof.

On the other hand, the polymer layer can be formed from one or more of EVOH copolymers, poly(vinyl chloride), polyvinylidene polymers and copolymers (e.g., polyvinylidene chloride), polyamides (e.g., amorphous polyamides), amide-based copolymers, acrylonitrile polymers (e.g., acrylonitrile-methyl acrylate copolymers), polyethylene terephthalate, polyetherimides, polyacrylimides, and other polymer materials known to have relatively low gas permeabilities. Blends of these materials and blends with the TPU copolymers described herein, and optionally including combinations of polyimides and crystalline polymers, are also suitable.

One or more of elements 102 and 103 may be formed of elastic polymer materials such as foam or rubber to impart cushioning, responsiveness, and energy distribution to the wearer's foot. Elements 102 and 103 may be attached to the sole structure using a fusion process, using an adhesive, or by suspending the elements in different elastic polymer materials. As discussed above, elements 102, 103, and 104 may be formed with a matching geometry (e.g., steps, projections) for limiting relative motion between elements 102, 103, and 104 of the sole structure.

Example elastic polymer materials for elements 102 and 103 may include those based on foaming or molding one or more polymers, such as one or more elastomers (e.g., thermoplastic elastomers (TPE)). The one or more polymers may include aliphatic polymers, aromatic polymers, or a mixture of the two; and may include homopolymers, copolymers (including terpolymers), or a mixture of the two.

In some respects, one or more polymers can include olefin homopolymers, olefin copolymers or their blends.The example of olefin polymers includes polyethylene, polypropylene and combinations thereof.In other respects, the one or more polymers can include one or more ethylene copolymers, such as ethylene-vinyl acetate (EVA) copolymer, EVOH copolymer, ethylene-ethyl acrylate copolymer, ethylene-unsaturated mono fatty acid copolymer, and combinations thereof.

In further aspects, the one or more polymers may include one or more polyacrylates, such as polyacrylic acid, esters of polyacrylic acid, polyacrylonitrile, polyacetic acid esters, polymethyl acrylate, polyethyl acrylate, polybutyl acrylate, polymethyl methacrylate, and polyvinyl acetate; including derivatives thereof, copolymers thereof, and any combinations thereof.

In yet other aspects, the one or more polymers may include one or more ionomer polymers. In these aspects, the ionomer polymer may include a polymer having a carboxylic acid functional group, a sulfonic acid functional group, a salt thereof (e.g., sodium, magnesium, potassium, etc.) and/or anhydrides thereof. For example, the ionomer polymer may include one or more fatty acid modified ionomer polymers, polystyrene sulfonates, ethylene-methacrylic acid copolymers, and combinations thereof.

In further aspects, the one or more polymers can include one or more styrenic block copolymers, such as acrylonitrile butadiene styrene block copolymers, styrene acrylonitrile block copolymers, styrene ethylene butylene styrene block copolymers, styrene ethylene butadiene styrene block copolymers, styrene ethylene propylene styrene block copolymers, styrene butadiene styrene block copolymers, and combinations thereof.

In other aspects, the one or more polymers can include one or more polyamide copolymers (e.g., polyamide-polyether copolymers) and/or one or more polyurethanes (e.g., cross-linked polyurethanes and/or thermoplastic polyurethanes). Alternatively, the one or more polymers can include one or more natural and/or synthetic rubbers, such as butadiene and isoprene.

When the elastic polymer material is a foamed polymer material, the foamed material can be foamed using a physical foaming agent that changes phase into a gas based on a change in temperature and/or pressure, or a chemical foaming agent that forms a gas when heated above its activation temperature. For example, the chemical foaming agent can be an azo compound such as azodicarbonamide, sodium bicarbonate and/or isocyanate.

In some embodiments, the foamed polymer material can be a cross-linked foamed material. In these embodiments, a peroxide-based cross-linking agent such as dicumyl peroxide can be used. In addition, the foamed polymer material can include one or more fillers such as pigments, modified or natural clays, modified or unmodified synthetic clays, talc glass fibers, powdered glass, modified or natural silica, calcium carbonate, mica, paper, wood chips, etc.

The elastic polymer material can be formed using a molding process. In one example, when the elastic polymer material is a molded elastomer, an uncured elastomer (e.g., rubber) can be mixed, calendered, shaped, placed in a mold, and vulcanized in a Banbury mixer with an optional filler and a cure package, such as a sulfur-based or peroxide-based cure package.

In another example, when the elastic polymer material is a foamable material, the material can be foamed during a molding process such as an injection molding process. The thermoplastic polymer material can be melted in the barrel of an injection molding system and combined with a physical or chemical foaming agent and an optional cross-linking agent, and then injected into a mold under conditions that activate the foaming agent to form a molded foam.

Optionally, when the elastic polymer material is a foamed material, the foamed material can be a compression molded foam. Compression molding can be used to change the physical properties of the foam (e.g., density, stiffness and/or hardness), or to change the physical appearance of the foam (e.g., fusing two or more sheets of foam, shaping the foam, etc.), or both.

The compression molding process is ideally started by forming one or more foam preforms, such as by injection molding and foaming the polymer material, by forming foamed particles or beads, by cutting foamed sheet stock, etc. The compression molded foam can then be made by placing one or more preforms formed by the foamed polymer material in a compression mold, and applying enough pressure to the one or more preforms to compress the one or more preforms in a closed mold. Once the mold is closed, enough heat and/or pressure is applied to the one or more preforms in the closed mold for a sufficient duration to change the preforms, fuse the individual foam particles to each other, permanently increase the density of the foam, or any combination thereof, by forming a skin on the outer surface of the compression molded foam. After heating and/or applying pressure, the mold is opened and the molded foam article is removed from the mold.

The barrier layers 402 and 404 may include two or more sublayers (multilayer films), such as shown in U.S. Pat. Nos. 5,713,141 to Mitchel et al. and 5,952,065 to Mitchel et al., the disclosures of which are incorporated herein by reference in their entirety. In embodiments where the barrier layers 402 and 404 include two or more sublayers, examples of suitable multilayer films include microlayer films, such as those disclosed in U.S. Pat. No. 6,582,786 to Bonk et al., which is incorporated herein by reference in its entirety. In further embodiments, the barrier layers 402 and 404 may each independently include alternating sublayers of one or more TPU copolymer materials and one or more EVOH copolymer materials, wherein the total number of sublayers in each of the barrier layers 402 and 404 includes at least four (4) sublayers, at least ten (10) sublayers, at least twenty (20) sublayers, at least forty (40) sublayers, and/or at least sixty (60) sublayers.

Forefoot cushioning element 103 can be provided in a fluid-filled (shown in FIG. 4A ) or unfilled state. Forefoot cushioning element 103 can be filled to include any suitable fluid, such as a gas or a liquid. In one aspect, the gas can include air, nitrogen (N ₂ ), or any other suitable gas. In other aspects, forefoot cushioning element 103 can alternatively include other media, such as pellets, beads, ground recycled materials, etc. (e.g., foam beads and/or rubber beads).

The following clauses provide exemplary configurations for the above-described articles of footwear and sole structures.

Item 1. A sole structure for a footwear article, the sole structure comprising a forefoot region and a heel region; a chassis plate; an outsole plate extending from the forefoot region to the heel region, the outsole plate comprising a recess disposed in a top surface, wherein the outsole plate is disposed beneath the chassis plate; and a cushioning element disposed within the recess.

Clause 2. The sole structure of Clause 1, wherein the cushioning element comprises a fluid-filled bladder.

Clause 3. The sole structure of Clause 1, wherein a top surface of the cushioning element is flush with the top surface of the outsole plate when the cushioning element is disposed within the recess.

Clause 4. The sole structure of Clause 1, wherein the outsole plate comprises: a bottom surface; and a plurality of traction elements disposed on the bottom surface of the outsole plate.

Clause 5. The sole structure of Clause 4, wherein the plurality of traction elements are integrally molded into the bottom surface of the outsole plate.

Clause 6. The sole structure of Clause 1, wherein a bottom surface of the outsole plate forms a ground contacting surface of the sole structure.

Clause 7. The sole structure of Clause 1, wherein the outsole plate has a longitudinal length and a midpoint along the longitudinal length, wherein the outsole plate includes a front region forward of the midpoint, and wherein the area of the cushioning element is less than about 70% of the front region.

Clause 8. The sole structure of Clause 1, wherein the chassis plate and outsole plate have substantially the same length.

Clause 9. An article of footwear comprising the sole structure according to Clause 1.

Item 10. A sole structure for a footwear article, the sole structure comprising a forefoot region and a heel region; a chassis plate; an outsole plate extending from the forefoot region to the heel region, the outsole plate comprising an opening in the forefoot region, wherein the outsole plate is disposed beneath the chassis plate; and a cushioning element disposed in the opening.

Clause 11. The sole structure of Clause 10, further comprising a speed brake disposed in the opening and in contact with the cushioning element.

Clause 12. The sole structure of Clause 11, wherein a bottom surface of the outsole plate and a bottom surface of the speed brake form a portion of a ground contacting surface of the sole structure.

Clause 13. The sole structure of Clause 12, further comprising a shim disposed within the opening, wherein the shim radially surrounds the speed brake and the cushioning element.

Clause 14. The sole structure of Clause 11, wherein a bottom surface of the speed brake includes one or more traction elements.

Clause 15. The sole structure of Clause 10, wherein a bottom surface of the outsole plate includes one or more traction elements.

Clause 16. The sole structure of Clause 10, wherein the cushioning element comprises a fluid-filled bladder.

Clause 17. An article of footwear comprising the sole structure according to Clause 10.

Item 18. A sole structure for a footwear article, the sole structure comprising a forefoot region and a heel region; an outsole plate extending from the forefoot region to the heel region, the outsole plate comprising an opening in the forefoot region; a speed brake disposed within the opening; and a gasket surrounding the speed brake.

Clause 19. The sole structure of Clause 18, wherein the outsole plate, the speed brake, and the spacer form a ground contacting surface of the sole structure.

Clause 20. An article of footwear comprising the sole structure according to Clause 18.

Claims (20)

1. A sole structure for a footwear article, the sole structure comprising: forefoot area and heel area; Chassis plate; an outsole plate extending from the forefoot region to the heel region, the outsole plate including a recess disposed in a top surface, wherein the outsole plate is disposed beneath the chassis plate; and A cushioning element is disposed within the recess. 2. The sole structure of claim 1, wherein the cushioning element comprises a fluid-filled bladder. 3. The sole structure of claim 1, wherein when the cushioning element is disposed within the recess, a top surface of the cushioning element is flush with the top surface of the outsole plate. 4. The sole structure according to claim 1, wherein the outsole plate comprises: a bottom surface; and A plurality of traction elements are disposed on the bottom surface of the outsole plate. 5. The sole structure of claim 4, wherein the plurality of traction elements are integrally molded into the bottom surface of the outsole plate. 6. The sole structure of claim 1, wherein a bottom surface of the outsole plate forms a ground contacting surface of the sole structure. 7. The sole structure of claim 1 , wherein the outsole plate has a longitudinal length and a midpoint along the longitudinal length, wherein the outsole plate includes a front region forward of the midpoint, and wherein the area of the cushioning element is less than about 70% of the front region. 8. The sole structure of claim 1, wherein the chassis plate and outsole plate have substantially the same length. 9. An article of footwear comprising the sole structure according to claim 1. 10. A sole structure for a footwear article, the sole structure comprising: forefoot area and heel area; Chassis plate; an outsole plate extending from the forefoot region to the heel region, the outsole plate including an opening in the forefoot region, wherein the outsole plate is disposed beneath the chassis plate; and A cushioning element is disposed in the opening. 11. The sole structure according to claim 10, further comprising a speed brake disposed in the opening and in contact with the cushioning element. 12. The sole structure of claim 11, wherein a bottom surface of the outsole plate and a bottom surface of the speed brake form a portion of a ground contacting surface of the sole structure. 13. The sole structure of claim 12, further comprising a shim disposed within the opening, wherein the shim radially surrounds the speed brake and the cushioning element. 14. The sole structure of claim 11, wherein a bottom surface of the speed brake includes one or more traction elements. 15. The sole structure of claim 10, wherein a bottom surface of the outsole plate includes one or more traction elements. 16. The sole structure of claim 10, wherein the cushioning element comprises a fluid-filled bladder. 17. An article of footwear comprising the sole structure according to claim 10. 18. A sole structure for a footwear article, the sole structure comprising: forefoot area and heel area; an outsole plate extending from the forefoot region to the heel region, the outsole plate including an opening in the forefoot region; a speed brake disposed within the opening; and Spacers surrounding the speed brake. 19. The sole structure of claim 18, wherein the outsole plate, the speed brake, and the shim form a ground contacting surface of the sole structure. 20. An article of footwear comprising the sole structure according to claim 18.