US20260007204A1

US20260007204A1 - Sole structure for an article of footwear

Info

Publication number: US20260007204A1
Application number: US19/326,157
Authority: US
Inventors: Patrick Donovan; Mauro BONIN; Sidney Fauconnier; Romain GIRARD; Andreas Siegismund; Christopher Dunning
Original assignee: Puma SE
Current assignee: Puma SE
Priority date: 2024-04-10
Filing date: 2025-09-11
Publication date: 2026-01-08

Abstract

An article of footwear includes an upper attached to a sole structure, a forefoot region, a midfoot region, a heel region, a longitudinal axis, a plate, and a gap. The longitudinal axis intersects a toe end and a heel end. The plate includes a top plate and a bottom plate joined at a hinge. The top plate has a first anterior end disposed adjacent a toe end and a first posterior end disposed within the heel region. The bottom plate has a second anterior end disposed adjacent the toe end and a second posterior end disposed in the midfoot region. The gap is defined between the top plate and the bottom plate and extends from the hinge toward the first posterior end. The top plate includes a convex portion in each of the heel region and the forefoot region.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. application Ser. No. 18/631,427, filed on Apr. 10, 2024, which is herein incorporated by referenced in its entirety.

REFERENCE REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable

SEQUENCE LISTING

Not applicable

BACKGROUND

1. Field of the Disclosure

The present disclosure relates generally to an article of footwear that includes a sole structure having a plurality of plates and a plurality of cushions.

2. Description of the Background

Many conventional shoes or other articles of footwear generally comprise an upper and a sole attached to a lower end of the upper. Conventional shoes further include an internal space, i.e., a void or cavity, which is created by interior surfaces of the upper and sole, that receives a foot of a user before securing the shoe to the foot. The sole is attached to a lower surface or boundary of the upper and is positioned between the upper and the ground. As a result, the sole typically provides stability and cushioning to the user when the shoe is being worn. In some instances, the sole may include multiple components, such as an outsole, a midsole, and a top portion. The outsole may provide traction to a bottom surface of the sole, and the midsole may be attached to an inner surface of the outsole and may provide cushioning or added stability to the sole. For example, a sole may include a particular foam material that may increase stability at one or more desired locations along the sole, or a foam material that may reduce stress or impact energy on the foot or leg when a user is running, walking, or engaged in another activity. The sole may also include additional components, such as plates, embedded with the sole to increase the overall stiffness of the sole and reduce energy loss during use.
The upper generally extends upward from the sole and defines an interior cavity that completely or partially encases a foot. In most cases, the upper extends over the instep and toc regions of the foot, and across medial and lateral sides thereof. Many articles of footwear may also include a tongue that extends across the instep region to bridge a gap between edges of medial and lateral sides of the upper, which define an opening into the cavity. The tongue may also be disposed below a lacing system and between medial and lateral sides of the upper, to allow for adjustment of shoe tightness. The tongue may further be manipulatable by a user to permit entry or exit of a foot from the internal space or cavity. In addition, the lacing system may allow a user to adjust certain dimensions of the upper or the sole, thereby allowing the upper to accommodate a wide variety of foot types having varying sizes and shapes.
The upper of many shoes may comprise a wide variety of materials, which may be utilized to form the upper and chosen for use based on one or more intended uses of the shoc. The upper may also include portions comprising varying materials specific to a particular area of the upper. For example, added stability may be desirable at a front of the upper or adjacent a heel region so as to provide a higher degree of resistance or rigidity. In contrast, other portions of a shoe may include a soft woven textile to provide an area with stretch-resistance, flexibility, air-permeability, or moisture-wicking properties.
However, conventional shoes generally have a unitary midsole that extends continuously from a heel region to a forefoot region. Moreover, conventional shoes have a unitary outsole that extends continuously from the heel region to the forefoot region and, when rested upright and unworn, contacts a ground surface in both the heel region and the forefoot region. In addition, many conventional shoes have a single plate that is embedded within the sole structure. As a result, conventional shoes are limited to the properties offered by the heel region and forefoot region having the same midsole and outsole, and the single plate construction. Thus, there is a need for an improved sole structure.

SUMMARY

An article of footwear, as described herein, may have various configurations. In one aspect of the present disclosure, an article of footwear includes an upper attached to a sole structure. The article of footwear further includes a forefoot region, a midfoot region, and a heel region. Further, article of footwear includes a longitudinal axis that intersects a toe end located in the forefoot region and a heel end located in the heel region, with a longitudinal direction being parallel with the longitudinal axis. Additionally, the article of footwear includes a plate including a top plate that is integrally joined to a bottom plate at a hinge. The top plate has a first anterior end disposed within the heel region. The bottom plate has a second anterior end disposed adjacent the toe end and a second posterior end disposed in the midfoot region. The article of footwear also includes a gap that is defined between the top plate and the bottom plate. The gap extends from the hinge toward the first posterior end of the top plate. A vertical distance of the gap is measured between the top plate and the bottom plate. The top plate includes a convex portion in each of the heel region and the forefoot region.
In some embodiments, the hinge has a rear-facing wall that is curved between the top plate and the bottom plate. The vertical distance is greatest proximate the second posterior end of the bottom plate. The top plate includes a slot that extends continuously from the midfoot region through the first posterior end to define a lateral posterior leg and a medial posterior leg. The top plate includes a plurality of ridges extending from the forefoot region toward the heel region. The bottom plate defines a width between a lateral edge and a medial edge, where the width is greater in the forefoot region than in the midfoot region. A midplane bisects the article of footwear between the heel end and the toe end. A center of mass point of the article of footwear is located between the toe end and the midplane. The hinge defines a flex axis extending in a lateral-medial direction that is perpendicular to the longitudinal direction. The top plate and the bottom plate are configured to be disposed in a first position in an unloaded state. The top plate and the bottom plate are configured to rotate toward one another about the flex axis to a second position of the hinge when a load is applied. The hinge is configured to return the top plate and the bottom plate to a first position when the load is removed.
In some aspects, an article of footwear includes an upper attached to a sole structure. The article of footwear further includes a forefoot region including a toe end at a distal end of the forefoot region, a midfoot region, and a heel region including a heel end at a distal end of the heel region. Additionally, the article of footwear includes a plate having a top plate, a bottom plate, and a hinge located at a toe end of the plate. The top plate and bottom plate diverge relative to one another to define a gap therebetween. The article of footwear also includes a midsole having an upper midsole cushion, an intermediate midsole cushion, and a lower midsole cushion that further includes a top surface that is attached to the bottom plate. The upper midsole cushion extends continuously from the forefoot region to the heel region. The intermediate cushion includes a forefoot cushion and a heel cushion that has a forwardmost point spaced rearwardly of the forefoot cushion. The article of footwear further includes an outsole. The outsole is attached to a bottom surface of the lower midsole cushion. The forefoot cushion includes a medial cushion pod and a lateral cushion pod that are arranged between the top plate and the bottom plate.
In some embodiments, a portion of an upper surface of each of the medial cushion pod and the lateral cushion pod is distanced from and not in contact with the top plate. An expansion zone is formed between the medial cushion pod and the lateral cushion pod. The forefoot cushion is directly inContact with the top plate and the bottom plate. The bottom plate is at least partially recessed into the top surface of the lower midsole cushion. The bottom plate has a curved portion extending between a lateral edge and a medial edge. The curved portion is convexly curved relative to the top plate. The top plate is at least partially recessed into a bottom surface of the upper midsole cushion.
In some aspects, an article of footwear includes an upper attached to a sole structure. The article of footwear further includes a forefoot region including a toe end at a distal end of the forefoot region, a midfoot region, and a heel region including a heel end at a distal end of the heel region. The article of footwear also includes a plate including a top plate, a bottom plate, and a hinge located at a distal end of the plate in the forefoot region. The top plate and bottom plate are integrally formed of a common material. The top plate includes a lateral ridge extending from the forefoot region to the heel region, a medial ridge extending from the forefoot region to the heel region, and a central ridge extending from the forefoot region to the midfoot region. The article of footwear further includes a gap that extends between the top plate and the bottom plate. Additionally, the article of footwear includes an upper midsole cushion that continuously extends from the forefoot region to the heel region and is positioned adjacent to and above the top plate. The article of footwear further includes an intermediate cushion including a forefoot cushion and a heel cushion. The forefoot cushion is disposed within the gap between the top plate and the bottom plate. Additionally, the article of footwear includes a lower midsole cushion that continuously extends from the forefoot region to the midfoot region. The lower midsole cushion includes a top surface that contacts a bottom surface of the bottom plate. The article of footwear also includes an outsole. The outsole is attached to a bottom surface of the heel cushion.
In some embodiments, the upper midsole cushion contacts the lower midsole cushion proximate the toe end and does not contact the intermediate midsole cushion. The upper midsole cushion includes a plurality of pockets arranged within at least the forefoot region and the heel region. When the article of footwear is resting on a flat ground surface in an unloaded state, the outsole, comprising rubber, is cantilevered above the ground surface.
Other aspects of the article of footwear, including features and advantages thereof, will become apparent to one of ordinary skill in the art upon examination of the figures and detailed description herein. Therefore, all such aspects of the article of footwear are intended to be included in the detailed description and this summary.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a bottom and medial side of an article of footwear configured as a right shoe that includes an upper and a sole structure, according to an embodiment of the disclosure;

FIG. 2 is a top view of the article of footwear of FIG. 1 ;

FIG. 3 is a top plan view of the article of footwear of FIG. 1 , with an upper removed and a user's skeletal foot structure overlaid thereon;

FIG. 4 is a perspective view of a top and lateral side of an article of footwear configured as a right shoe that includes an upper and a sole structure, according to another embodiment of the disclosure;

FIG. 5 is an exploded view of the sole structure of FIG. 4 ;

FIG. 6 is a bottom plan view of the article of footwear of FIG. 4 ;

FIG. 7 is a cross-sectional view of the article of footwear along 7-7 of FIG. 6 ;

FIG. 8 is a cross-sectional view of the article of footwear along 8-8 of FIG. 6 ;

FIG. 9 is a cross-sectional view of the article of footwear along 9-9 of FIG. 6 ;

FIG. 10 is a cross-sectional view of the article of footwear along 10-10 of FIG. 6 ;

FIG. 11 is a cross-sectional view of the article of footwear along 11-11 of FIG. 6 ;

FIG. 12 is a cross-sectional view of the article of footwear along 12-12 of FIG. 6 ;

FIG. 13 is a cross-sectional view of the article of footwear along 12-12 of FIG. 6 ; and

FIG. 14 is a rear elevational view of the article of footwear of FIG. 4 .

FIG. 15 is a front isometric view of a sole structure of an article of footwear configured as a right shoe, according to another embodiment of the disclosure;

FIG. 16 is an exploded view of the sole structure of FIG. 15 ;

FIG. 17 is a side view of the sole structure of FIG. 15 ;

FIG. 18 is a bottom view of the sole structure of FIG. 15 ;

FIG. 19 is a cross-sectional view of the sole structure of the article of footwear along 19-19 of FIG. 18 ;

FIG. 20 is a cross-sectional view of the sole structure of the article of footwear along 20-20 of FIG. 18 ;

FIG. 21 is a cross-sectional view of the sole structure of the article of footwear along 21-21 of FIG. 18 ;

FIG. 22 is a cross-sectional view of the sole structure of the article of footwear along 22-22 of FIG. 18 ;

FIG. 23 is a cross-sectional view of the sole structure of the article of footwear along 23-23 of FIG. 18 ;

FIG. 24 is a cross-sectional view of the sole structure of the article of footwear along 24-24 of FIG. 18 ;

FIG. 25 is a cross-sectional view of the sole structure of the article of footwear along 25-25 of FIG. 18 ;

FIG. 26 is a front elevational view of the sole structure of FIG. 15 ;

FIG. 27 is a rear elevational view of the sole structure of FIG. 15 ;

FIG. 28 is a depiction of a four-phase gait cycle;

FIG. 29 is a top view of the sole plate of the sole structure of FIG. 15 ; and

FIG. 30 is a stress simulation of the sole plate of the sole structure of FIG. 15 during the second phase of the gait cycle

DETAILED DESCRIPTION OF THE DRAWINGS

The following discussion and accompanying figures disclose various embodiments or configurations of a shoe and a sole structure. Although embodiments of a shoe or sole structure are disclosed with reference to a sports shoe, such as a running shoe, tennis shoe, basketball shoe, etc., concepts associated with embodiments of the shoe or the sole structure may be applied to a wide range of footwear and footwear styles, including cross-training shoes, football shoes, golf shoes, hiking shoes, hiking boots, ski and snowboard boots, soccer shoes and cleats, walking shoes, and track cleats, for example. Concepts of the shoe or the sole structure may also be applied to articles of footwear that are considered non-athletic, including dress shoes, sandals, loafers, slippers, and heels. In addition to footwear, particular concepts described herein may also be applied and incorporated in other types of apparel or other athletic equipment, including helmets, padding or protective pads, shin guards, and gloves. Even further, particular concepts described herein may be incorporated in cushions, backpack straps, golf clubs, or other consumer or industrial products. Accordingly, concepts described herein may be utilized in a variety of products.
The term “about,” as used herein, refers to variation in the numerical quantity that may occur, for example, through typical measuring and manufacturing procedures used for articles of footwear or other articles of manufacture that may include embodiments of the disclosure herein; through inadvertent error in these procedures; through differences in the manufacture, source, or purity of the ingredients used to make the compositions or mixtures or carry out the methods; and the like. Throughout the disclosure, the terms “about” and “approximately” refer to a range of values ±5% of the numeric value that the term precedes.
The terms “weight percent,” “wt-%,” “percent by weight,” “% by weight,” and variations thereof, as used herein, refer to the concentration of a substance or component as the weight of that substance or component divided by the total weight, for example, of the composition or of a particular component of the composition, and multiplied by 100. It is understood that, as used herein, “percent,” “%,” and the like may be synonymous with “weight percent” and “wt-%.”
As used herein in the context of geometric descriptions, unless otherwise limited or defined, “substantially” indicates correspondence to a particular shape or dimension within conventional manufacturing tolerances for components of a similar type or that are formed using similar processes. In this regard, for example, “substantially round” can indicate a profile that deviates from a circle to within acceptable manufacturing tolerances.
Unless otherwise specified or limited, the term “substantially” can indicate a variation in one numerical direction relative to a reference value. For example, the term “substantially less” than a reference value (and the like) indicates a value that is reduced from the reference value by 30% or more (e.g., 35%, 40%, 50%, 65%, 80%), and the term “substantially more” than a reference value (and the like) indicates a value that is increased from the reference value by 30% or more (e.g., 35%, 40%, 50%, 65%, 80%).
Further, as used herein, unless otherwise defined or limited, directional terms are used for convenience of reference for discussion of particular figures or examples. For example, references to “downward,” or other directions, or “lower” or other positions, may be used to discuss aspects of a particular example or figure, but do not necessarily require similar orientation or geometry in all installations or configurations. The terms first, second, third, etc. may 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 may be only used to distinguish one element, component, region, layer, or section from another region, layer, or section. Terms such as “first,” “second,” and other numerical terms do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer, or section discussed below could be termed a second element, component, region, layer, or section without departing from the teachings of the example configurations.
The present disclosure is directed to an article of footwear or specific components of the article of footwear, such as an upper or a sole or a sole structure. The upper may comprise a knitted component, a woven textile, a non-woven textile, leather, mesh, suede, or a combination of one or more of the aforementioned materials. The knitted component may be made by knitting of yarn, the woven textile by weaving of yarn, and the non-woven textile by manufacture of a unitary non-woven web. Knitted textiles include textiles formed by way of warp knitting, weft knitting, flat knitting, circular knitting, or other suitable knitting operations. The knit textile may have a plain knit structure, a mesh knit structure, or a rib knit structure, for example. Woven textiles include, but are not limited to, textiles formed by way of any of the numerous weave forms, such as plain weave, twill weave, satin weave, dobbin weave, jacquard weave, double weaves, or double cloth weaves, for example. Non-woven textiles include textiles made by air-laid or spun-laid methods, for example. The upper may comprise a variety of materials, such as a first yarn, a second yarn, or a third yarn, which may have varying properties or varying visual characteristics.
The present disclosure is related to an article of footwear that includes an upper and a sole structure having a plurality of plates arranged to provide various performance and cushioning effects. In some embodiments, the plurality of plates includes a first plate extending from a forefoot region to a heel region of the footwear to support a user's foot from toe to heel, while a second plate extends from the forefoot region to a midfoot region of the footwear to provide to provide propulsion and energy return during use. The second plate may be coupled to the first plate at an anterior end and configured to flex or bend relative to the first plate during use. A forefoot cushion may be disposed between the first plate and the second plate, such that the first and second plates may be spaced apart from one another between the anterior end and posterior ends thereof. In some embodiments, the first plate and the second plate are coupled at the anterior end by the forefoot cushion. The plurality of plates may include a third plate that is coupled to first plate or the second plate at the anterior end and extends through the forefoot region to the midfoot region or the heel region. Further, the plurality of plates may include a fourth plate that is coupled to the first plate, the second plate, or the third plate and extends through the forefoot region to the midfoot region or the heel region. In some embodiments, the third plate is coupled directly to the second plate and the fourth plate.
In some embodiments, the plurality of plates is arranged with the first plate and the second plate being at least partially coplanar in the forefoot region. In some embodiments, the plurality of plates are arranged with the second plate and the third plate being at least partially coplanar in the forefoot region. In some embodiments, at least two plates of the plurality of plates are not separated by cushions, such as, e.g., the second plate and the third plate. In some embodiments, the plurality of plates are curved from the anterior ends to the posterior ends thereof. For example, the first plate may have a first curvature in the forefoot region and the second plate may have a second curvature in the forefoot region. In some embodiments, the first curvature and the second curvature are different from one another, such that the first plate and the second plate diverge from one another. In some embodiments, the first curvature and the second curvature are identical to one another, such that the first plate and the second plate extend in parallel with one another along at least a portion of their respective lengths.
The sole structure of the present disclosure may include a bifurcated cushion arrangement. In some embodiments, the sole structure includes a forefoot cushion and a heel cushion that are separate and distinct from one another. The bifurcated arrangement may include a bridge or link between the forefoot cushion and the heel cushion, which may be provided by one or more of the plurality of plates. In some embodiments, the first plate is coupled to the forefoot cushion and the heel cushion and serves as a bridge or link between the forefoot cushion and the heel cushion. In some embodiments, the second plate is coupled to the forefoot cushion and the heel cushion and serves as an auxiliary bridge or link between the forefoot cushion and the heel cushion.
In some embodiments, the first plate, the second plate, and the third plate each connect or link the forefoot cushion to the heel cushion. A gap may be formed between a posterior end of the forefoot cushion and an anterior end of the heel cushion. The gap may extend uninterrupted from a lateral side to a medial side of the sole structure. In some embodiments, the gap is exposed on the lateral side or the medial side of the sole structure. In some embodiments, the gap is at least partially defined by a portion of the first plate, a portion of the second plate, a portion of the third plate, or some combination thereof. In some embodiments, the gap is positioned entirely in the midfoot region. In some embodiments, the gap extends into the forefoot region or the heel region. Additionally, the gap may provide a channel or pathway through which airflow is permitted, which can reduce the impact of drag forces on the sole structure during use.
The bifurcated arrangement may afford the sole structure various advantages, such as, e.g., weight savings, improved aerodynamic characteristics, and a performance differential between the decoupled cushions or sections of the sole structure. For example, the first plate may be formed of a material having a high strength-to-weight ratio and may serve as a bridge or connection between the separated forefoot and heel cushions, such that the sole structure can provide similar cushioning and support properties as a comparable sole structure but with less material and, thus, less mass. Further, the heel cushion may be formed of a different material than the forefoot cushion, which can allow the heel cushion to have different properties than the forefoot cushion. For instance, the heel cushion and forefoot cushion may differ from one another in stiffness, abrasion resistance, electrical resistance, texture, or other properties, which acts as a performance differential that can be selected or customized to suit a particular user.
FIGS. 1-3 depict an exemplary embodiment of an article of footwear 100 including an upper 102 and a sole structure 104. The upper 102 is attached to the sole structure 104 and together define an interior cavity 106 (see FIGS. 2 and 3 ) into which a foot may be inserted. For reference, the article of footwear 100 defines a forefoot region 108, a midfoot region 110, and a heel region 112 (see FIGS. 2 and 3 ). The forefoot region 108 generally corresponds with portions of the article of footwear 100 that encase portions of the foot that includes the toes, the ball of the foot, and joints connecting the metatarsals with the toes or phalanges. The midfoot region 110 is proximate and adjoining the forefoot region 108, and generally corresponds with portions of the article of footwear 100 that encase the arch of the foot, along with the bridge of the foot. The heel region 112 is proximate and adjoining the midfoot region 110 and generally corresponds with portions of the article of footwear 100 that encase rear portions of the foot, including the heel or calcaneus bone, the ankle, and/or the Achilles tendon.
While only a single shoe 100 is depicted, i.e., a shoe that is worn on a left foot of a user (see FIGS. 2 and 3 ), it should be appreciated that the concepts disclosed herein are applicable to a pair of shoes (not shown), which includes a left shoe and a right shoe that may be sized and shaped to receive a left foot and a right foot of a user, respectively. For ease of disclosure, however, a single shoe will be referenced to describe aspects of the disclosure, but the disclosure below with reference to the article of footwear 100 is applicable to both a left shoe and a right shoe. However, in some aspects there may be differences between a left shoe and a right shoe other than the left/right configuration. Further, in some aspects, a left shoe may include one or more additional elements that a right shoe does not include, or vice versa.
Many conventional footwear uppers are formed from multiple elements, e.g., textiles, polymer foam, polymer sheets, leather, and synthetic leather, which are joined through bonding or stitching at a scam. In some embodiments, the upper 102 of the article of footwear 100 is formed from a knitted structure or knitted components. In various embodiments, a knitted component may incorporate various types of yarn that may provide different properties to an upper. For example, one area of the upper 102 may be formed from a first type of yarn that imparts a first set of properties, and another area of the upper 102 may be formed from a second type of yarn that imparts a second set of properties. Using this configuration, properties of the upper 102 may vary throughout the upper 102 by selecting specific yarns for different areas of the upper 102.
With reference to the material(s) that comprise the upper 102, the specific properties that a particular type of yarn will impart to an area of a knitted component may at least partially depend upon the materials that form the various filaments and fibers of the yarn. For example, cotton may provide a soft effect, biodegradability, or a natural aesthetic to a knitted material. Elastane and stretch polyester may each provide a knitted component with a desired elasticity and recovery. Rayon may provide a high luster and moisture absorbent material, wool may provide a material with an increased moisture absorbance, nylon may be a durable material that is abrasion-resistant, and polyester may provide a hydrophobic, durable material.
Other aspects of a knitted component may also be varied to affect the properties of the knitted component and provide desired attributes. For example, a yarn forming a knitted component may include monofilament yarn or multifilament yarn, or the yarn may include filaments that are each formed of two or more different materials. In addition, a knitted component may be formed using a particular knitting process to impart an area of a knitted component with particular properties. Accordingly, both the materials forming the yarn and other aspects of the yarn may be selected to impart a variety of properties to particular areas of the upper 102.
In some embodiments, an elasticity of a knit structure may be measured based on comparing a width or length of the knit structure in a first, non-stretched state to a width or length of the knit structure in a second, stretched state after the knit structure has a force applied to the knit structure in a lateral direction. In further embodiments, the upper 102 may also include additional structural elements. For example, in some embodiments, a heel plate or cover (not shown) may be provided on the heel region 112 to provide added support to a heel of a user. In some instances, other elements, e.g., plastic material, logos, trademarks, etc., may also be applied and fixed to an exterior surface using glue or a thermoforming process. In some embodiments, the properties associated with the upper 102, e.g., a stitch type, a yarn type, or characteristics associated with different stitch types or yarn types, such as elasticity, aesthetic appearance, thickness, air permeability, or scuff-resistance, may be varied.
Referring again to FIG. 1 , the sole structure 104 is connected or secured to the upper 102 and extends between a foot of a user and the ground when the article of footwear 100 is worn by the user. The sole structure 104 may include one or more components, which may include an outsole, a midsole, a heel, a vamp, and/or an insole. For example, in some embodiments, a sole structure may include an outsole that provides structural integrity to the sole structure, along with providing traction for a user, a midsole that provides a cushioning system, and an insole that provides support for an arch of a user. In addition, the insole may be a strobel board, a forefoot board, a lasting board, etc., or a combination thereof, and the insole may be provided between the upper 102 and the sole structure 104, or the insole may be provided as part of the upper 102.
Furthermore, the insole can be positioned within the interior cavity 106 of the upper 102, which can be in direct contact with a user's foot while an article of footwear 100 is being worn. Moreover, the upper 102 may also include a liner (not shown) that can increase comfort, for example, by reducing friction between the foot of the user and the upper 102, the sole 104, the insole, or the like, and/or by providing moisture wicking properties. The liner may line the entirety of the interior cavity 106 or only a portion thereof. In some embodiments, a binding (not shown) may surround an opening of the interior cavity 106 to secure the liner to the upper 102 and/or to provide an aesthetic element on the article of footwear 100.
In some aspects, various layers of the upper 102 are heat pressed together so as to bond the various layers of the upper 102. For example, layers that comprise the upper 102 are heat pressed together all at once and at a single temperature. The upper 102 can be further attached to a strobel board by strobel stitching (not shown). During manufacturing of the upper 102, locating pins (not shown) can be used to align with various holes (not shown) within the upper 102. In some aspects, different layers of the upper 102 are waterproof or semi-waterproof, and include a plurality of layers of mesh or other materials. The materials that comprise the upper 102 include an inner mesh layer, a thermoplastic polyurethane (TPU) film, and/or an outer mesh layer. In some aspects, a TPU skin is applied along the other surface of the upper.
Referring to FIGS. 2 and 3 , the article of footwear 100 also defines a lateral side 116 and a medial side 118. When a user is wearing the shoes, the lateral side 116 corresponds with an outside-facing portion of the article of footwear 100 while the medial side 118 corresponds with an inside-facing portion of the article of footwear 100. As such, the article of footwear 100 has opposing lateral sides 116 and medial sides 118. The medial side 118 and the lateral side 116 adjoin one another along a longitudinal central plane or axis 120 of the article of footwear 100, which is coplanar with the longitudinal axis L of FIG. 1 . As will be further discussed herein, the longitudinal central plane or axis 120 may demarcate a central, intermediate axis between the medial side 118 and the lateral side 116 of the article of footwear 100. Put differently, the longitudinal plane or axis 120 may extend between a rear, proximal end 122 of the article of footwear 100 and a front, distal end 124 of the article of footwear 100 and may continuously define a middle of an insole 126, the sole structure 104, and/or the upper 102 of the article of footwear 100, i.e., the longitudinal plane or axis 120 is a straight axis extending through the rear, proximal end 122 of the heel region 112 to the front, distal end 124 of the forefoot region 108.
Unless otherwise specified, and referring to FIGS. 2 and 3 , the article of footwear 100 may be defined by the forefoot region 108, the midfoot region 110, and the heel region 112. The forefoot region 108 may generally correspond with portions of the article of footwear 100 that encase portions of a foot 128 that include the toes or phalanges 130, the ball of the foot 132, and one or more of the joints 134 that connect the metatarsals 136 of the foot 128 with the toes or phalanges 130. The midfoot region 110 is proximate and adjoins the forefoot region 108. The midfoot region 110 generally corresponds with portions of the article of footwear 100 that encase an arch of a foot 128, along with a bridge of the foot 128. The heel region 112 is proximate to the midfoot region 110 and adjoins the midfoot region 110. The heel region 112 generally corresponds with portions of the article of footwear 100 that encase rear portions of the foot 128, including the heel or calcaneus bone 138, the ankle (not shown), and/or the Achilles tendon (not shown).
Still referring to FIGS. 2 and 3 , the forefoot region 108, the midfoot region 110, the heel region 112, the medial side 118, and the lateral side 116 are intended to define boundaries or areas of the article of footwear 100. To that end, the forefoot region 108, the midfoot region 110, the heel region 112, the medial side 118, and the lateral side 116 generally characterize sections of the article of footwear 100. Certain aspects of the disclosure may refer to portions or elements that are coextensive with one or more of the forefoot region 108, the midfoot region 110, the heel region 112, the medial side 118, and/or the lateral side 116. Further, both the upper 102 and the sole structure 104 may be characterized as having portions within the forefoot region 108, the midfoot region 110, the heel region 112, and/or along the medial side 118 and/or the lateral side 116. Therefore, the upper 102 and the sole structure 104, and/or individual portions of the upper 102 and the sole structure 104, may include portions thereof that are disposed within the forefoot region 108, the midfoot region 110, the heel region 112, and/or along the medial side 118 and/or the lateral side 116.
Still referring to FIGS. 2 and 3 , the forefoot region 108, the midfoot region 110, the heel region 112, the medial side 118, and the lateral side 116 are shown in detail. The forefoot region 108 extends from a toe end 140 to a widest portion 142 of the article of footwear 100. The widest portion 142 is defined or measured along a first line 144 that is perpendicular with respect to the longitudinal axis 120 that extends from a distal portion of the toe end 140 to a distal portion of a heel end 146, which is opposite the toe end 140. The midfoot region 110 extends from the widest portion 142 to a thinnest portion 148 of the article of footwear 100. The thinnest portion 148 of the article of footwear 100 is defined as the thinnest portion of the article of footwear 100 measured across a second line 150 that is perpendicular with respect to the longitudinal axis 120. The heel region 112 extends from the thinnest portion 148 to the heel end 146 of the article of footwear 100.
It should be understood that numerous modifications may be apparent to those skilled in the art in view of the foregoing description, and individual components thereof, may be incorporated into numerous articles of footwear. Accordingly, aspects of the article of footwear 100 and components thereof, may be described with reference to general areas or portions of the article of footwear 100, with an understanding the boundaries of the forefoot region 108, the midfoot region 110, the heel region 112, the medial side 118, and/or the lateral side 116 as described herein may vary between articles of footwear. However, aspects of the article of footwear 100 and individual components thereof, may also be described with reference to exact areas or portions of the article of footwear 100 and the scope of the appended claims herein may incorporate the limitations associated with these boundaries of the forefoot region 108, the midfoot region 110, the heel region 112, the medial side 118, and/or the lateral side 116 discussed herein.
Still referring to FIGS. 2 and 3 , the medial side 118 begins at the distal, toc end 140 and bows outward along an inner side of the article of footwear 100 along the forefoot region 108 toward the midfoot region 110. The medial side 118 reaches the first line 144, at which point the medial side 118 bows inward, toward the central, longitudinal axis 120. The medial side 118 extends from the first line 144, i.e., the widest portion 142, toward the second line 150, i.e., the thinnest portion 148, at which point the medial side 118 enters into the midfoot region 110, i.e., upon crossing the first line 144. Once reaching the second line 150, the medial side 118 bows outward, away from the longitudinal, central axis 120, at which point the medial side 118 extends into the heel region 112, i.e., upon crossing the second line 150. The medial side 118 then bows outward and then inward toward the heel end 146, and terminates at a point where the medial side 118 meets the longitudinal, central axis 120.
The lateral side 116 also begins at the distal, toe end 140 and bows outward along an outer side of the article of footwear 100 along the forefoot region 108 toward the midfoot region 110. The lateral side 116 reaches the first line 144, at which point the lateral side 116 bows inward, toward the longitudinal, central axis 120. The lateral side 116 extends from the first line 144, i.e., the widest portion 142, toward the second line 150, i.e., the thinnest portion 148, at which point the lateral side 116 enters into the midfoot region 110, i.e., upon crossing the first line 144. Once reaching the second line 150, the lateral side 116 bows outward, away from the longitudinal, central axis 120, at which point the lateral side 116 extends into the heel region 112, i.e., upon crossing the second line 150. The lateral side 116 then bows outward and then inward toward the heel end 146, and terminates at a point where the lateral side 116 meets the longitudinal, central axis 120.
Still referring to FIGS. 2 and 3 , the upper 102 extends along the lateral side 116 and the medial side 118, and across the forefoot region 108, the midfoot region 110, and the heel region 112 to house and enclose a foot of a user. When fully assembled, the upper 102 also includes an interior surface 162 and an exterior surface 164. The interior surface 162 faces inward and generally defines the interior cavity 106, and the exterior surface 164 of the upper 102 faces outward and generally defines an outer perimeter or boundary of the upper 102. The upper 102 also includes an opening 166 that is at least partially located in the heel region 112 of the article of footwear 100, which provides access to the interior cavity 106 and through which a foot may be inserted and removed. In some embodiments, the upper 102 may also include an instep region 168 that extends from the opening 166 in the heel region 112 over an area corresponding to an instep of a foot to an area proximate the forefoot region 108. The instep region 168 may comprise an area similar to where a tongue 170 of the present embodiment is disposed. In some embodiments, the upper 102 does not include the tongue 170, i.e., the upper 102 is tongueless.
In the illustrated embodiment, the sole structure 104 includes a midsole 172 and an outsole 174. The outsole 174 may define a bottom end or bottom surface 176 of the sole structure 104 across the heel region 112, the midfoot region 110, and the forefoot region 108. Further, the outsole 174 may be a ground-engaging portion or include a ground-engaging surface of the sole structure 104 and may be opposite of the insole thereof. As illustrated in FIG. 1 , the bottom surface 176 of the outsole 174 may include a tread pattern 178 that can include a variety of shapes and configurations. The outsole 174 may be formed from one or more materials to impart durability, wear-resistance, abrasion resistance, or traction to the sole structure 104. In some embodiments, the outsole 174 may be formed from any kind of elastomer material, e.g., rubber, including thermoset elastomers or thermoplastic elastomers, or a thermoplastic material, e.g., thermoplastic polyurethane (TPU). In some embodiments, the outsole 174 may define a shore A hardness up to 95. In addition, the outsole 174 may be manufactured by a process involving injection molding, vulcanization, printing layer by layer, i.e., additive manufacturing systems or methods, and the like.
Still referring to FIG. 1 , the midsole 172 may be individually constructed from a thermoplastic material, such as polyurethane (PU), for example, and/or an ethylene-vinyl acetate (EVA), copolymers thereof, or a similar type of material. In other embodiments, the midsole 172 may be an EVA-Solid-Sponge (“ESS”) material, an EVA foam (e.g., PUMA® ProFoam Lite™, IGNITE Foam), polyurethane, polyether, an olefin block copolymer, organosheets, a thermoplastic material (e.g., a thermoplastic polyurethane, a thermoplastic elastomer, a thermoplastic polyolefin, etc.), or a supercritical foam. The midsole 172 may be a single polymeric material or may be a blend of materials, such as an EVA copolymer, a thermoplastic polyurethane, a polyether block amide (PEBA) copolymer, and/or an olefin block copolymer. One example of a PEBA material is PEBAX®. In some embodiments, the midsole 172 is manufactured by a process involving injection molding, vulcanization, printing layer by layer, i.e., additive manufacturing systems or methods, and the like.
In embodiments where the midsole 172 is formed from a supercritical foaming process, the supercritical foam may comprise micropore foams or particle foams, such as a TPU, EVA, PEBAX®, or mixtures thereof, manufactured using a process that is performed within an autoclave, an injection molding apparatus, or any sufficiently heated/pressurized container that can process the mixing of a supercritical fluid (e.g., CO₂, N₂, or mixtures thereof) with a material (e.g., TPU, EVA, polyolefin elastomer, or mixtures thereof) that is preferably molten. During an exemplary process, a solution of supercritical fluid and molten material is pumped into a pressurized container, after which the pressure within the container is released, such that the molecules of the supercritical fluid rapidly convert to gas to form small pockets within the material and cause the material to expand into a foam. In further embodiments, the midsole 172 may be formed using alternative methods known in the art, including the use of an expansion press, an injection machine, a pellet expansion process, a cold foaming process, a compression molding technique, die cutting, or any combination thereof. For example, the midsole 172 may be formed using a process that involves an initial foaming step in which supercritical gas is used to foam a material and then compression molded or die cut to a particular shape.
Referring to FIG. 4 , another embodiment of an article of footwear 200 is depicted with an upper 202 and a sole structure 204 that includes a forefoot cushion 206 that is disposed in a forefoot region 208, a heel cushion 210 that is disposed in a heel region 212, a lateral cushion pod 214 that is disposed adjacent a lateral side 216, and a medial cushion pod 218 (see FIG. 5 ) that is disposed adjacent a medial side 220. Together, the forefoot cushion 206 and the heel cushion 210 are spaced apart in the longitudinal direction (i.e., toe-to-heel) by an upper gap or an intermediate gap 222 to provide a bifurcated midsole structure 224. Put another way, the intermediate gap 222 is formed in the midfoot region 226 between the heel cushion 210 and the forefoot cushion 206, such that the heel cushion 210 and the forefoot cushion 206 are linked or connected by a bridge portion 228 that extends across the intermediate gap 222. The sole structure 204 includes a plurality of plates 230 that are arranged in a multi-plate system to provide cushioning, stability, propulsion, reduced weight, and other performance advantages, which will be further described in detail herein. The sole structure 204 further includes a forward outsole portion 232 coupled to the plurality of plates 230 and a rearward outsole portion 234 that is coupled to the heel cushion 210. In the illustrated embodiment, when the article of footwear 200 is unworn, i.e., no foot is inserted, and rested on a planar surface P, the forward outsole portion 232 contacts the planar surface P while the rearward outsole portion 234 is elevated a distance D1 above the planar surface P. This is, in part, due to a center of mass (CM) point 235 of the article of footwear 200 being disposed toward, i.e., closer to a toc end 236, of a midplane MP (see FIG. 7 ) that bisects the article of footwear 200 between the toe end 236 and a heel end 238. The midplane MP extends perpendicular to a longitudinal axis LA (see FIG. 6 ) and intersects the sole structure 204 in the midfoot region 226. Accordingly, the CM point 235 is located between the midplane MP (see FIG. 7 ) and the toe end 236, such that footwear 200 is weighted toward the toe end 236 to enhance or emphasize aspects of the plurality of plates 230 and bifurcated midsole structure 224, as will be further described herein. By locating the CM point 235 toward of the midplane MP, the article of footwear 200 is toc-weighted and, thus, pre-loaded to provide efficient impact response with the ground (e.g., planar surface P) when jogging or running. In other words, the mass distribution of the article of footwear 200 is intentionally imbalanced and programmed to promote efficient running and impact. For instance, a user running on the ball of the foot or MTP is afforded leverage that assists with propulsion. Further, locating the CM point 235 toewardly of the midplane MP also promotes efficient travel of the user's foot through a gait cycle, since the forefoot region has a greater proportion of mass than the heel region and is weighted more heavily, which exerts a greater downward force on the forefoot of the user as compared to a downward force on the heel of the user. As a result, the downward force on the forefoot assists with positioning or angling the user's foot for subsequent impact with the ground surface to further aid with leverage and propulsion. In this way, the sole structure reduces wasted energy and effort involved in counteracting a conventional balanced or heel-weighted shoe.
Still referring to FIGS. 4 , the upper 202 of the article of footwear 200 includes an ankle opening 240 that is at least partially located in the heel region 212 of the article of footwear 200, that provides access to the interior cavity (not shown) and through which a foot may be inserted and removed. In the illustrated embodiment, the ankle opening 240 is formed by an ankle cuff 242 that is configured to elastically expand and contract during entry and exit of a user's foot. Accordingly, the ankle cuff 242 is biased to a contracted position, as illustrated in FIG. 4 , and is configured to be expanded by the user pulling on at least one of a first strap 244 and a second strap 246 when inserting the foot through the ankle opening 240. Together, the ankle cuff 242, the first strap 244, and the second strap 246 form a closure system 250 of the article of footwear 200. In the illustrated embodiments, the first strap 244 is formed as a loop with opposing ends attached to a portion of the ankle cuff 242 of the upper 202 toewardly, i.e., closer to the toe end 236, of the ankle opening 240. The first strap 244 extends over the ankle opening 240 to be intuitively and easily pulled by the user before inserting the foot through the ankle opening 240. The second strap 246 is formed as a loop with opposing ends attached to the upper 202 rearwardly, i.e., closer to the heel end 238, of the ankle opening 240. The second strap 246 is arranged at the heel end 238 of the upper 202 to be opposite the first strap 244 relative to the ankle opening 240, such that the user can intuitively and easily pull the first strap 244 and the second strap 246 away from one another to cause the ankle cuff 242 to expand, thereby enlarging the ankle opening 240 to receive the user's foot. Once the user's foot is inserted through the ankle opening 240, the first strap 244 and second strap 246 can be released to allow the ankle cuff 242 to contract and tighten around the user's ankle, thereby securing the foot within the footwear 200. Further, the upper 202 is formed of a material that fits tightly or snugly around a user's foot, thereby distributing compressive forces along the entire foot to secure the foot within the footwear 200.
In some embodiments, the closure system 250 includes a lace (not shown) that extends through a plurality of eyelets (not shown). In some aspects, the closure system 250 includes bands, strips, segments, or regions of elastic material that is biased to compress and conform to a user's inserted foot. The closure system 250 may allow a user to modify dimensions of the upper 202, e.g., to tighten or loosen portions of the upper 202, around a foot as desired by the wearer. In some aspects, the closure system 250 also includes a band (not shown) that runs along a center of the upper 202 and includes one or more loops through which the lace is guided. In other aspects, the closure system 250 is a hook-and-loop fastening system, such as Velcro®. For example, in some aspects, the closure system 250 includes one or more hook-and-loop fastening straps. In further aspects, the closure system 250 is another laceless fastening system known in the art. In some aspects, the closure system 250 includes a rotary closure device or an automatic lacing system, such as the lacing systems described in U.S. patent application Ser. No. 15/780,368, filed on May 31, 2018, and U.S. patent application Ser. No. 16/392,470, filed on Apr. 23, 2019, each of which is hereby incorporated by reference in its entirety.
With reference to FIG. 4 , the article of footwear 200 includes the ankle pad 248 in the heel region 212 which extends along the lateral side 216 of the upper 202 to follow the curvature of the ankle cuff 242. The ankle pad 248 of the illustrated embodiment is curved and widens or thickens moving toward the heel end 238. In some embodiments, the ankle pad 248 wraps or extends around the heel end 238 of the upper 202 to the medial side 220 to be substantially symmetrical in size and shape across the lateral side 216 and the medial side 220. The ankle pad 248 is configured to provide cushion and support to a user's ankle by thickening the portion of the upper 202 adjacent the ankle cuff 242 to accommodate ranges of anatomical sizes of ankles. In other words, the ankle pad 248 provides a cushion for both comfort and adjustment to improve the fit of the shoe for a range of sizes and types of users.
Turning to FIG. 5 , an exploded view of the sole structure 204 of the footwear 200 depicts the plurality of plates 230 and the bifurcated midsole structure 224 in relation to one another. In the illustrated embodiment, the plurality of plates 230 includes a shank 252, an upper plate 254, an intermediate plate 256, and a lower plate 258. It will be appreciated that the shank 252 may be referenced herein as a top plate and any of the upper plate 254, the intermediate plate 256, or the lower plate 258 may be referenced herein as a middle plate or a bottom plate. It will also be appreciated that any of the plurality of plates 230 may be referenced herein as a first plate, a second plate, a third plate, or a fourth plate. A liner or insole 260 is configured to rest atop and extend along the shank 252. The lateral cushion pod 214 and the medial cushion pod 218 are configured to be disposed among the plurality of plates 230. In the illustrated embodiment, the lateral cushion pod 214 and the medial cushion pod 218 are disposed between the shank 252 and the lower plate 258. As illustrated in FIG. 5 , each of the lateral cushion pod 214 and the medial cushion pod 218 are in contact with and arranged between the upper plate 254 and the intermediate plate 256.
The shank 252 includes a shank anterior end 262 that is opposite a shank posterior end 264. The upper plate 254 includes an upper anterior end 266 that is opposite an upper posterior end 268, the intermediate plate 256 includes an intermediate anterior end 270 that is opposite an intermediate posterior end 272, and the lower plate 258 includes a lower anterior end 274 that is opposite a lower posterior end 276. Any of the anterior ends 262, 266, 270, 274 may be referenced herein as a first anterior end, a second anterior end, a third anterior end, or a fourth anterior end. Similarly, any of the posterior ends 264, 268, 272, 276 may be referenced herein as a first posterior end, a second posterior end, a third posterior end, or a fourth posterior end. The forefoot cushion 206 includes a forefoot cushion anterior end 278 and a forefoot cushion posterior end 280, while the heel cushion 210 includes a heel cushion anterior end 282 and a heel cushion posterior end 284. As illustrated, the shank 252 extends continuously from the shank posterior end 264 to the shank anterior end 262. Alternatively, in some embodiments, the shank 252 may be discontinuous such that the shank 252 includes interconnected segments (e.g., seams, hinges, or interlocking structures), decoupled or discrete portions, or apertures or cutouts between the shank posterior end 264 to the shank anterior end 262. The upper plate 254 includes an upper cutout 286 that is positioned between the upper anterior end 266 and the upper posterior end 268, the intermediate plate 256 includes an intermediate cutout 288 that is positioned between the intermediate anterior end 270 and the intermediate posterior end 272, and the lower plate 258 includes a lower cutout 290 that is positioned between the lower anterior end 274 and the lower posterior end 276.
With continued reference to FIG. 5 , the forward outsole portion 232 includes an outsole cutout 292 between a forward outsole anterior end 294 and a forward outsole posterior end 296. Furthermore, the forward outsole portion 232 may include a plurality of slots 298 and a plurality of apertures 300 that are disposed around the outsole cutout 292. In some embodiments, the size of the cutouts 286, 288, 290, 292 can be different from each other. For example, the size of the cutouts can change gradually along the thickness of the plurality of plates 230. In some embodiments, the size of the cutouts 286, 288, 290, 292 can be identical to each other. In some embodiments, the cutouts 286, 288, 290, 292 are axially aligned with one other to be collinear or coaxial along a vertical direction that is perpendicular to the longitudinal axis LA. In some embodiments, the cutouts 286, 288, 290, 292 are stacked to form a pyramid like structure, such that edges of cutouts form an incrementally expanding or narrowing profile or periphery. In some embodiments, the cutouts 286, 288, 290, 292 each define a geometric center (not shown) that is aligned with one another to be collinear or coaxial in the vertical direction. In some embodiments, the geometric center of the cutouts 286, 288, 290, 292 can be unaligned (e.g., offset) from one another. In some embodiments, at least one of the cutouts 286, 288, 290, 292 is identical in size and shape to at least one other of the cutouts 286, 288, 290, 292.
The upper plate 254 of FIG. 5 includes an upper plate top surface 302 that is opposite an upper bottom surface 304, intermediate plate 256 includes an intermediate top surface 306 opposite of an intermediate bottom surface 308, and the lower plate 258 includes a lower plate top surface 310 that is opposite a lower bottom surface 312. The forward outsole portion 232 includes a forward outsole top surface 314 that is opposite a forward outsole bottom surface 316 and the rearward outsole portion 234 includes a rearward outsole top surface 318 that is opposite a rearward outsole bottom surface 320. The forward outsole bottom surface 316 and the rearward outsole bottom surface 320 are configured to engage the ground. The heel cushion 210 includes a heel cushion top surface 322 that is opposite a heel cushion bottom surface 324, and the forefoot cushion includes a forefoot top surface 326 that is opposite a forefoot bottom surface 328. The shank includes a shank top surface 330 that is opposite a shank bottom surface 332. The lateral cushion pod 214 includes a lateral cushion top surface 334 that is opposite a lateral cushion bottom surface 336, and the medial cushion pod 218 includes a medial cushion top surface 338 that is opposite a medial cushion bottom surface 340.
Referring to FIG. 6 , illustrates a bottom view of the sole structure 204 and shows various cross-sections are taken along a length of the footwear 200 between the toe end 236 and the heel end 238. A first cross-section (7-7) is taken along a central plane CP defined along the longitudinal axis LA of the footwear (see FIG. 8 ) and is illustrated in FIG. 7 , a second cross-section (8-8) is taken along a forefoot region 208 and is illustrated in FIG. 8 , a third cross-section (9-9) is taken between the forefoot region 208 and the midfoot region 226 and is illustrated in FIG. 9 , a fourth cross-section (10-10) is taken along the midfoot region 226 and is illustrated in FIG. 10 , and a fifth cross-section (11-11) is taken along the heel region 212 and is illustrated in FIG. 11 .
FIG. 6 depicts the forward outsole portion 232 extending from the toe end 236 in the forefoot region 208 to the midfoot region 226 and the rearward outsole portion 234 that is disposed in the heel region 212 extending from the heel end 238 toward the medial and lateral cushion pods 214, 218. The forward outsole portion 232 and the rearward outsole portion 234 are separate and distinct portions. In some embodiments, the forward outsole portion 232 and the rearward outsole portion 234 may include groove patterns to provide additional traction with a ground surface or terrain, which may be represented as, e.g., the planar surface P in FIG. 4 .
Still referring to FIG. 6 , the intermediate plate 256, the lower plate 258 and the forward outsole portion 232 are connected to form a lateral leg 342 and a medial leg 344, between which is an expansion zone 346. For instance, referring back to FIG. 5 , the lateral leg 342 and the medial leg 344 are formed at the intermediate posterior end 272 of the intermediate plate 256, the lower posterior end 276 of the lower plate 258, and the forward outsole posterior end 296 of the forward outsole portion 232. Referring again to FIG. 6 , in the illustrated example, the lateral leg 342 is disposed directly adjacent to the lateral cushion pod 214 and the medial leg 344 is disposed directly adjacent to the medial cushion pod 218. The expansion zone 346 is disposed between the lateral leg 342 and the medial leg 344 and allows the cushion pods 214, 218 to expand when the outsole (e.g., ground engaging surface) strikes or is compressed under loading against the ground or terrain, e.g., surface P. In some embodiments, the cushion pods 214, 218 that are disposed directly above the lateral and medial legs 342, 344 are spaced apart across the expansion zone 346. In some embodiments, the expansion zone 346 is bounded by the bridge portion 228. The lateral leg 342 includes a first distal end 348 and a first proximal end 350 that is opposite the first distal end 348. The first distal end 348 of the lateral leg 342 is disposed opposite the toe end 236 position along the lateral side 216 of the forward outsole portion 232. Similarly, the medial leg 344 includes a second distal end 352 and a second proximal end 354 that is disposed opposite the second distal end 352. The second distal end 352 of the medial leg 344 is disposed opposite the toe end 236 along the medial side 220 of the forward outsole portion 232. The first distal end, 348, the second distal end 352, and the expansion zone 346 disposed between the first and second proximal ends 350, 354 forms at least two inflexion points (e.g., a point where change in curvature occurs).
In some examples, the size of the expansion zone 346 may be different. For instance, the size of the expansion zone 346 gets smaller along the plurality of plates 230, as the plurality of plates 230 is closer to the shank 252. In some embodiments, the shank 252 may include a rib 359 that is disposed along the shank bottom surface 332 (e.g., underside of the upper plate). The rib 359 extends between the forefoot and the heel cushions 206, 210 and the rib 359 provides additional thickness to the shank 252 along the longitudinal axis LA for stability and/or propulsion. Referring back to FIG. 5 , in the illustrated example, the size of the expansion zone 346 is greatest at a location that is adjacent and coplanar with the forward outsole portion 232 (e.g., furthest from the shank) and is smallest at a location that is adjacent and coplanar with the upper plate 254 (e.g., closest to the shank). Alternatively, in some examples, size of the expansion zone 346 may be greater toward the planar surface.
Still referring to FIG. 6 , the rearward outsole portion 234 is provided with a lateral heel outsole section 360 and a medial heel outsole section 362 that are separate and distinct portions, which are arranged on opposing sides of the longitudinal axis LA. The lateral heel outsole section 360 and the medial heel outsole section 362 of the illustrated embodiment is separated by a recessed surface 364 that extends along the longitudinal axis LA of the heel cushion 210. In some embodiments, the recessed surface 364 may include grooves, barbs, cutouts, or a combination thereof. In some embodiments, the recessed surface 364 may be disposed between a channel. In some embodiments, the recessed surface 364 may include undulations or grooves. The recessed surface 364 is defined between a lateral arm 366 that extends along the lateral side 216 of the heel cushion 210, and a medial arm 368 that extends along the medial side 220 of the heel cushion 210. In the illustrated example, the lateral heel outsole section 360 is disposed directly beneath the lateral arm 366 of the heel cushion 210 and the medial heel outsole section 362 is disposed directly beneath the medial arm 368 of the heel cushion 210. The medial arm 368 and the lateral arm 366 of the heel cushion 210 forms part of the bridge portion 228 that connects to the medial leg 344 and the lateral leg 342 respectively. In the illustrated example, the bridge portion 228 can extend obliquely relative to the longitudinal axis LA. In some examples, the shape of the bridge portion 228 can be perpendicular to the longitudinal axis LA.
In some examples, the outsole cutout 292, the lower cutout 290, the intermediate cutout 288, and the upper cutout 286 can be stratified along a sole-to-upper direction that is perpendicular to the planar surface P (See FIG. 4 ). With reference to FIGS. 5 and 6 , the cutouts 286, 288, 290, 292 can define a cutout axis CA that is offset from the longitudinal axis LA by an offset angle OA1. In particular, the cutout axis CA extends from the toe end 236 toward the longitudinal axis LA between a lateral apex point 369A and a medial apex point 369B such that the lateral apex point 369A and the medial apex point 369B are equidistant from the cutout axis CA. Referring back to FIG. 5 , the upper plate 254 includes a first cutout axis CA1, the intermediate plate 256 includes a second cutout axis CA2, the lower plate 258 includes a third cutout axis CA3, and the forward outsole portion 234 includes a fourth cutout axis CA4. The first, second, third and fourth cutout axis CA1, CA2, CA3, CA4 are all aligned with each other at a predetermined offset angle OA1 relative to the longitudinal axis LA. Accordingly, as illustrated in FIG. 6 , the cutout axis CA is offset from the longitudinal axis by the offset angle OA1. However, in some embodiments, the cutout axes CA can be offset relative to each other such that the cutout axes are not aligned with each other. In the illustrated example, the shape of the cutouts 286, 288, 290, 292 can be an arrowhead shape. In some examples, the shape of the cutouts 286, 288, 290, 292 can be a polygon, ovular, circular, an irregular shape, or the like.
FIG. 7 illustrates a cross-sectional view of the footwear 200 along the longitudinal direction (e.g., 7-7). The toe end 236 of the sole structure 204 is arranged with the forward outsole anterior end 294 extending as a cover partially across the upper 202, the forefoot cushion anterior end 278, and the lower anterior end 274. Beneath the upper 202, the insole 260 extends along the shank 252 and has an insole anterior end 370 that is disposed between the shank anterior end 262 and disposed at a tip 371 of a forefoot cushion anterior lip 372 of the forefoot cushion anterior end 278 of the forefoot cushion 206. In some examples, the forefoot cushion anterior lip 372 described herein can extend from the forefoot cushion anterior end 278 to the forefoot cushion posterior end 280, forming a forefoot periphery 373 of a forefoot retaining region or a forefoot recess 374 (see FIG. 5 ). Similarly, an insole posterior end 375 is disposed between the shank posterior end 264 and a heel cushion posterior lip 376 that is disposed at the heel cushion posterior end 284 of the heel cushion 210. In some examples, the heel cushion posterior lip 376 described herein can extend from the heel cushion posterior end 284 to the heel cushion anterior end 282, forming a heel periphery 378 of a heel retaining region or a heel recess 380 (see FIG. 5 ). The forefoot recess 374 and the heel recess 380 can be configured to retain a portion of a neighboring structure (e.g., plates, cushions, and/or pods).
With continued reference to FIG. 7 , the shank 252 extends continuously from the shank anterior end 262 in the forefoot region 208, which is adjacent the toc end 236, through the midfoot region 226, to the shank posterior end 264 in the heel region 212, which is adjacent the heel end 238. The shank 252 includes a shank bridge portion 382 that spans between the forefoot cushion 206 and the heel cushion 210. In the illustrated embodiment, the rib 359 extends along at least a portion of the shank bridge portion 382 and is exposed through the intermediate gap 222 from a bottom view of the sole structure 204, as illustrated in FIG. 6 . The shank anterior end 262 of the shank 252 sits within the forefoot recess 374 that is formed in the forefoot cushion 206 and the shank posterior end 264 of the shank sits within the heel recess 380 that is formed in the heel cushion 210. In some examples, the heel recess 380 and the forefoot recess 374 together form a midsole bed 384 (see FIG. 8 ) in which the insole 260 and the shank 252 are disposed.
Still referring to FIG. 7 , the placement of the plurality of plates 230 to form a sole structure 204 is shown. In the illustrated example, three plates (e.g., upper, intermediate, and lower) are shown to form a divergent configuration 383 of the sole structure 204, which may be described as a structure having forked or divergent plates or members. In some embodiments, a first plate (e.g., shank 252) of the plurality of plates 230 may have a first anterior end (e.g., shank anterior end 262) that is disposed adjacent to the toe end 236 of the sole structure 204 and a first posterior end (e.g., shank posterior end 264) that is disposed within the heel region 212 of the sole structure 204. In other words, the first plate extends from the forefoot region 208 to the heel region 212. A second plate (e.g., upper plate 254) of the plurality of plates 230 may have a second anterior end (e.g., upper anterior end 266) that is disposed adjacent to the toe end 236 and a second posterior end (e.g., upper posterior end 268) that is disposed in the midfoot region 226 of the sole structure 204. In some examples, a first cushion (e.g., forefoot cushion 206) is disposed between the first and second plate to support the shank anterior end 262 in the forefoot region 208. Additionally, the heel cushion 210 is disposed opposite of the forefoot cushion 206 to support the shank posterior end 264. As described above, the bridge portion 228 is formed above the intermediate gap 222 to connect the heel cushion 210 to the forefoot cushion 206. A third plate (e.g., intermediate plate 256) of the plurality of plates 230 may have a third anterior end (e.g., intermediate anterior end 270) that is disposed adjacent the toe end 236 and a third posterior end (e.g., intermediate posterior end 272) that is disposed in the midfoot region 226. In some embodiments, the second and third plates are coplanar in the forefoot region 208, in that the second and third plate contact one another to define a contact surface area in two directions, e.g., a medial-lateral direction between the medial side 220 and lateral side 216 and a longitudinal direction along the longitudinal axis LA, and extend in parallel with one another along at least one of such directions, e.g., the longitudinal direction. The second plate and the third plate may be coplanar until the second plate diverges from the third plate to form the divergent configuration 383 at the diverging point DP in the forefoot region 208. A fourth plate (e.g., lower plate 258) may be coupled to the forward outsole portion 232, and the fourth plate can be sandwiched between the third plate and the outsole in the forefoot region 208.
Referring back to FIG. 5 , the upper plate 254 may include an upper recess 386 that is at least partially bounded by a lateral upper lip 424 and a medial upper lip 426, the intermediate plate 256 may include an intermediate recess 388 that is at least partially bounded by a lateral intermediate lip 398 and a medial intermediate lip 400, and the lower plate 258 may include a lower recess 390 that is at least partially bounded by a lateral intermediate lip 398 and a medial intermediate lip 400. Accordingly, the recesses 386, 388, 390 can be configured to receive a portion of the neighboring components. For instance, along a forefoot region 208, the upper plate 254 is nested within the intermediate recess 388, and the intermediate plate 256 is nested within the lower recess 390. Additionally, the forefoot cushion 206 can be nested within the upper recess 386. The nested configuration of the plates 254, 256, 258 within the recesses 386, 388, 390 provide various benefits. For example, the recesses 386, 388, 390 allows the plates to be contained in multiple directions providing a lock and key relationship. Furthermore, the recesses 386, 388, 390 may provide reduction of weight via reduction of material along the given cross-section of the article of footwear 200.
Referring now to FIG. 8 , the nested plurality of plates 230 are arranged within and along the forefoot region 208. As described above, the forefoot recess 374 retains the insole 260 and the shank 252. In the illustrated example, a width W1 between the lateral side 216 of the upper 202 and the medial side 220 of the upper 202 can be greater than a width W2 of the insole 260. In some examples, the width W1 of the upper 202 may vary (e.g., get narrower toward the ankle opening 240) as the upper 202 extends away from the insole 260 and the sole structure 204. Furthermore, the width W1 of the upper 202 can be greater than both the width W2 of the insole 260 and a width W3 of the shank 252. The width W2 of the insole 260 can be greater than the width W3 of the shank 252. The forefoot cushion anterior lip 372 of the forefoot cushion 206 retains the shank 252 between a lateral forefoot recess wall 392 and a medial forefoot recess wall 394 disposed within the forefoot recess 374. Additionally, the forefoot cushion anterior lip 372 of the forefoot cushion 206 retains the insole anterior end 370. In some examples, the width W2 of the insole 260 is equivalent to the distance between the lateral forefoot recess wall 392 and the medial forefoot recess wall 394. A width W4 of the forefoot cushion 206 increases gradually from the forefoot cushion anterior lip 372 toward the forefoot bottom surface 328. In the illustrated example, the forefoot cushion 206 includes plurality of ridges 396 formed along the lateral side 216 and the medial side 220 of the forefoot region 208.
With continued reference to FIG. 8 , the intermediate plate 256 includes a lateral intermediate lip 398 and a medial intermediate lip 400 that is configured to retain the forefoot bottom surface 328 of the forefoot cushion 206. In the illustrated example, a bottommost ridge 397 of the plurality of ridges 396 of the forefoot cushion 206 is disposed directly adjacent to the lateral intermediate lip 398 and the medial intermediate lip 400. In some examples, the bottommost ridge 397 of the plurality of ridges 396 may be flush with the lateral intermediate lip 398 and the medial intermediate lip 400. The intermediate recess 388 includes a lateral intermediate recess wall 402 and a medial intermediate recess wall 404 that are configured to retain the upper plate 254. A width W5 defined between the intermediate lips 398, 400 is greater than a width W6 defined between the intermediate recess walls 402, 404. In some examples, the width of the intermediate recess walls 402, 404 may be identical to a width of the upper plate 254. The intermediate plate 256 further includes a rim 405 that protrudes beyond the lower bottom surface 312 of the intermediate plate 256 between the intermediate cutout 288. The lower plate 258 includes a lateral lower lip 406 and a medial lower lip 408 (See FIG. 10 ) that is configured to retain a portion the intermediate bottom surface 308. In the illustrated embodiment, the width W5 between the lateral intermediate lip 398 and the medial intermediate lip 400 is substantially similar to a width W7 defined by lateral lower lip 406 and the medial lower lip 408. The forward outsole top surface 314 of the forward outsole portion 232 is disposed directly adjacent to the lower bottom surface 312 of the lower plate 258. The widths W1, W2, W3, W4, W5, W6, W7 of the sole structure 204 may vary between the toe end 236 and the heel end 238 of the article of footwear 200.
Still referring to FIG. 8 , the cutouts 286, 288, 290, 292 (e.g., upper cutout, intermediate cutout, lower cutout, outsole cutout) are located between the medial side 220 and the lateral side 216 of the footwear 200. In some embodiments, the cutouts 286, 288, 290, 292 are disposed partially along the longitudinal axis LA and intersected by the central plane CP that is defined along the longitudinal axis LA. In some embodiments, one or more of the cutouts 286, 288, 290, 292 can be disposed offset from the central plane CP of the longitudinal axis LA.
Referring now to FIG. 9 , a cross-sectional view of the footwear 200 between the forefoot region 208 and the midfoot region 226 is shown. In some embodiments, the lateral arm 366 of the forefoot cushion 206 along the lateral side 216 extends a greater distance from the toc end 236 than a distance that the medial arm 368 of the forefoot cushion 206 extends from the toc end 236 along the medial side 220. Alternatively, in some embodiments, the lateral arm 366 of the forefoot cushion 206 along the lateral side 216 extends a shorter distance than a distance that the medial arm 368 of the forefoot cushion 206 extends along the medial side 220. In some embodiments, both the lateral arm 366 and the medial arm 368 of the forefoot cushion 206 may extend the same distance to be coextensive relative to the toe end 236. The upper plate 254 and the intermediate plate 256 are spaced apart by the intermediate gap 222 in order to form the divergent configuration 383. Referring back to FIGS. 5 and 7 , the upper plate 254 curves upwardly toward the shank 252, while the intermediate plate 256 extends downwardly away from the upper plate 254. More specifically, the upper plate 254 curves concavely relative to the forefoot cushion 206 from the upper anterior end 266 to a transition point UT1 that is spaced toewardly from the upper posterior end 268, and the upper plate 254 further curves convexly relative to the forefoot cushion 206 and the heel cushion 210 from the transition point UT1 to the upper posterior end 268. The intermediate plate 256 curves concavely relative to the forefoot cushion 206 from the intermediate anterior end 270 to the intermediate posterior end 272, and the lower plate 258 curves concavely relative to the forefoot cushion 206 from the lower anterior end 274 to the lower posterior end 276. The upper plate 254, the intermediate plate 256, and the lower plate 258 have a relatively similar and/or constant radius of curvature extending from the toe end 236 to a divergent point DP at which the upper plate 254 begins to diverge from, e.g., curves along a different radius of curvature in comparison to, the intermediate plate 256 and the lower plate 258 moving in the heelward direction from the divergent point DP toward the upper posterior end 268 in the midfoot region 226. Put another way, the divergent point DP is a location where the upper plate 254 and the intermediate plate 256 begin to diverge or extend in opposite directions to form the divergent configuration 383. In some embodiments, the upper plate 254 may curve from an anterior-most point 410 toward the divergent point DP that is positioned toeward, e.g., closer to the toe end 236, of a metatarsophalangeal (MTP) point of the sole structure 204. In the illustrated embodiment, the transition point UT1 is positioned heelward, e.g., closer to the heel end 238, of the divergent point DP and the MTP Ipoint, although other configurations are contemplated.
FIG. 10 shows a gap disposed between the heel cushion 210 and the cushion pods 214, 218. Referring back to FIG. 4 and as described above, the upper plate 254 curves away from the intermediate plate 256 forming the bifurcating midsole structure 224. The cushion pods 214, 218 are disposed between the upper posterior end 268 and the intermediate posterior end 272. In some examples, along the lateral cushion top surface 334, the lateral cushion pod 214 engages with the upper plate 254 along the lateral side 216, and along the medial cushion top surface 338, the medial cushion pod 218 engages along the medial side 220 of the upper plate 254. Further, along the lateral cushion bottom surface 336, the lateral cushion pod 214 engages with the intermediate plate 256 along the lateral side 216, and along the medial cushion bottom surface 340, the medial cushion pod 218 engages along the medial side 220 of the intermediate plate 256. In some examples, the rear wall 416 of the cushion pods 214, 218 extends obliquely between the upper plate 254 and the intermediate plate 256. In some examples, the cushion pods 214, 218 are arranged to be collinear with the CM point 235 of the footwear 200.
Further, referring to FIG. 4 , an overall length or total length OL of the footwear 200 measured between a toe plane TP and a heel plane HP is shown. The upper plate 254 extends away from the toe plane TP toward the heel end 238 a first distance 418 and the intermediate plate 256 extends away from the toe plane TP toward the heel end 238 a second distance 419. In the illustrated embodiment, the second distance 419 is greater than the first distance 418. The lower plate 258 extends away from the toc plane TP toward the heel end 238 a third distance 420, which is equal to the second distance 419 and, thus, is represented by the same illustrative arrows in FIG. 4 as the second distance 419. In some embodiments, the third distance 420 and the second distance 419 can be different (e.g., one can be greater than the other). Furthermore, the CM point 235 is disposed at a fourth distance 421 away from the toe plane TP. In some examples, the fourth distance 421 may be smaller than the second distance 419, or the third distance 420, or both. In some examples, the fourth distance 421 may be smaller than each of the first, second, and third distances 418, 419, 420.
Referring now to FIG. 11 , the heel cushion 210 surrounding the upper 202, the shank 252, and the insole 260 is shown. Similar to the forefoot cushion 206, the heel cushion includes the heel recess 380 that is configured to receive the shank 252 and the insole 260. In the illustrated example, the recessed surface 364 is disposed opposite of the heel recess 380 in a form of a channel.
FIG. 12 illustrates a medial arm nub 422 of the medial cushion pod 218 abutting the upper plate 254 along a cross-section. In some embodiments, the medial arm nub 422 of the medial arm 368 rests freely on the upper top surface of the upper plate 254. In some embodiments, the medial arm nub 422 of the medial arm 368 is secured or attached to the upper top surface of the upper plate 254, such as, e.g., using adhesives, fasteners, or welding, or another suitable technique. The medial cushion pod 218 is disposed between the upper plate 254 and the intermediate plate 256 such that the medial cushion top surface 338 of the medial cushion pod 218 is partially retained within a medial upper lip 426 and the medial cushion bottom surface 340 that is partially retained within the medial intermediate lip 400. Similarly, referring to FIG. 4 , a lateral arm nub 432 of the heel cushion 210 is partially retained within a lateral upper lip 424. In other words, the upper posterior end 268 of the upper plate 254 abuts the medial arm nub 422 of the medial arm 368 (e.g., opposite of the lateral arm nub) and the lateral arm nub 432 of the lateral arm 366 along the midfoot region 226 of the sole structure 204. Further, the intermediate gap 222 is formed between the shank 252 and the upper plate 254 between the forefoot cushion posterior end 280 and the nubs 422, 432 along the heel cushion anterior end 282. A lower forward gap 442 is formed between the front wall 414 of the cushion pods 214, 218 and the diverging point DP and a lower rear gap 444 is formed between the rear wall of the cushion pods 214, 218 and the heel cushion 210.
The cushion top surfaces 334, 338 of the cushion pods 214, 218 are attached to the upper bottom surface 304 of the upper plate 254 by an adhesive, fasteners, welding, or other suitable techniques. Referring to FIG. 5 , in some embodiments, the cushion top surfaces 334, 338 at the top of the cushion pods 214, 218 includes an upper lateral pod retaining region 446 and an upper medial pod retaining region 447 to establish a connection between upper posterior end of the upper plate 254 and the cushion pods 214, 218. In the illustrated embodiment, the upper lateral pod retaining region 446 and the upper medial pod retaining region 447 are disposed along the cushion top surfaces 334, 338 at the top of the cushion pods 214, 218 in a form of a groove. Similarly, the cushion bottom surfaces 336, 340 of the cushion pods 214, 218 and the intermediate top surface 306 of the intermediate plate 256 can be connected by adhesives. In some embodiments, the intermediate top surface 306 directly beneath the cushion pods 214, 218 may include a lower lateral pod retaining region 448 and a lower medial pod retaining region 449 to establish a connection between the intermediate plate 256 and the cushion pods 214, 218. The cushion pods 214, 218 can be adhered within the upper and lower pod retaining regions 446, 447 448, 449 by an adhesive or a fastener.
Referring now to FIG. 10 , a medial outer side wall 450 of the medial cushion pod 218 protrudes beyond the medial side 220 of the heel cushion 210 and the medial intermediate lip 400. However, a lateral outer side wall 452 of the lateral cushion pod 214 protrudes beyond the lateral intermediate lip 398 but does not protrude beyond the lateral side 216 of the heel cushion 210. Further a medial inner side wall 454 protrudes beyond the intermediate cutout 288 by a first dimension 455, and a lateral inner side wall 456 protrudes beyond the intermediate cutout 288 by a second dimension 457, the first dimension 455 being less than the second dimension 457. In other words, additional material is disposed toward the direction of the medial side 220 of the footwear in order to provide stability when the footwear 200 strikes the ground surface.
Referring now to FIG. 13 , illustrates a cross-section of the heel cushion 210 including one or more ridges (e.g., undulated surface) along an outer heel surface 460 of the heel cushion 210. Further the shank 252 can be exposed between along the bridge portion 228. As illustrated in FIGS. 6 and 7 , a portion of the shank 252 is revealed between the lower posterior end 276 of the lower plate 258 and the heel cushion anterior end 282 of the heel cushion 210. Referring to FIG. 7 , a thickness t1 of the shank 252 may vary between the toe end 236 and the heel end 238. In some examples, the thickness t1 of the shank 252 may be uniform between the toe end 236 and the heel end 238. In some examples, a thickness t2 of the insole 260 may be uniform between the toe end 236 and the heel end 238. In some examples, the thickness t2 of the insole 260 may vary between the toe end 236 and the heel end 238. In some examples, a thickness t3 of the forefoot cushion 206 and the heel cushion 210 may vary between opposing ends along the longitudinal direction. In some examples, the thickness t3 of the forefoot cushion 206 and the heel cushion 210 may be uniform between the opposing ends along the longitudinal direction. In some examples, a thickness t4 of the plurality of plates 230 may vary between opposing ends along the longitudinal direction. In some examples, the thickness t4 of the plurality of plates 230 may be uniform between opposing ends along the longitudinal direction. In some examples, a thickness t5 of the forward outsole portion 232 and the rearward outsole portion 234 may vary between opposing ends along the longitudinal direction. In some examples, the thickness t5 of the forward outsole portion 232 and the rearward outsole portion 234 may vary between opposing ends along the longitudinal direction.
Referring now to FIG. 14 , the heel end 238 of the heel cushion 210 is shown. In the illustrated example, the lateral heel outsole section 360 and the medial heel outsole section 362 wraps partially around the heel cushion 210 adjacent to the heel cushion bottom surface 324. Between the lateral heel outsole section 360 and the medial heel outsole section 362, a channel 464 is formed between the heel cushion anterior end 282 and the heel cushion posterior end 284. As described above, the outer heel surface 460 of the heel cushion 210 may include one or more of the plurality of ridges 396 that extends along the lateral side 216 and the medial side 220 of the heel cushion 210. In some embodiments, the one or more of the plurality of ridges 396 along the lateral side 216 may be symmetrical with the one or more of the plurality of ridges 396 along the medial side 220 of the heel cushion about the central plane CP that extends along the longitudinal axis LA. In some embodiments, the one or more of the plurality of ridges 396 along the lateral side 216 may be asymmetrical with the medial side 220 of the heel cushion 210 about the central plane CP.
Similarly, referring back to FIGS. 8 and 9 , the plurality of ridges 396 disposed on the lateral side 216 of an outmost surface 470 of the forefoot cushion 206 can be symmetrical with the plurality of ridges 396 disposed on the medial side 220 of the outmost surface 470 of the forefoot cushion 206. Alternatively, referring to FIG. 9 , the plurality of ridges 396 disposed on the lateral side 216 of an outmost surface 470 of the forefoot cushion 206 can be asymmetrical with the plurality of ridges 396 disposed on the medial side 220 of the outmost surface 470 of the forefoot cushion 206. In some embodiments, the plurality of ridges 396 may extend along an inner most surface 472 of the forefoot cushion that is opposite of the outmost surface 470.
The plurality of plates 230 described above can be formed from a thermoplastic material, such as a thermoplastic polyurethane, a thermoplastic elastomer, a thermoplastic olefin, or the like. In particular aspects, however, the plurality of plates 230 may be formed from a composite or one or more layers of fibers, such as carbon fibers, aramid fibers, boron fibers, glass fibers, natural fibers, and polymer fibers, or a combination thereof. In some examples, the fibers may be affixed or bonded to a substrate or a thermoplastic material, e.g., a thermoplastic polyurethane, a thermoplastic polyolefin, or a thermoplastic elastomer, by stitching or an adhesive. In other examples, the plurality of plates 230 may be formed from a unidirectional tape that includes carbon fibers, aramid fibers, boron fibers, glass fibers, polymer fibers, or the like. In yet other examples, plurality of plates 230 may be formed from densified wood or densified wood panels formed from chemically treating natural wood to remove lignin or hemicellulose therefrom, or compressing natural wood.
In some aspects, one or more materials of the plurality of plates 230 have a stiffness (e.g., a tensile strength) defined by a Young's modulus. For example, the one or more materials forming the plurality of plates 230 may have a Young's modulus of at least about 25 gigapascals (GPa), at least about 40 GPa, or at least about 70 GPa, or at least about 85 GPa, or at least about 200 GPa. In other examples, the one or more materials forming the plurality of plates 230 may have a Young's modulus between about 25 GPa and about 200 GPa, or between about 25 GPa and about 80 GPa, or between about 25 GPa and about 70 GPa, or between about 50 GPa and about 75 GPa. In some aspects, the plurality of plates 230, and the stiffness thereof, may be selected and designed for a particular user. For example, a stiffness of the plurality of plates 230 may be selected based on the particular muscle strength, tendon flexibility, or joint flexibility of a user. In some aspects, the stiffness of the plurality of plates 230 may vary, such that a portion of the plurality of plates 230 is stiffer compared to another portion of the plurality of plates 230.
As disclosed herein, the article of footwear 200 includes the multi-plate, toc-weighted, bifurcated sole structure 204 comprising the forefoot cushion 206, the heel cushion 210, the shank 252, the upper plate 254, the intermediate plate 256, the lower plate 258, the insole 260, the lateral cushion pod 214, and the medial cushion pod 218. Each of the upper plate 254, the intermediate plate 256, and the lower plate 258 has portion that contacts the forefoot cushion 206. The upper plate 254 varies in curvature in the longitudinal direction between the upper anterior end 266 and the upper posterior end 268, such that the upper plate 254 defines at least two different radii of curvatures therealong and includes the upper transition point UT1 between the concave portion and the convex portion. The upper plate 254 diverges in curvature from the intermediate plate 256 at the divergent point DP to form the divergent configuration 383 that accommodates the lateral cushion pod 214 and the medial cushion pod 218 being disposed between the upper plate 254 and the intermediate plate 256. The shank 252 also includes the shank bridge portion 382 in the form a thickened area that spans the intermediate gap 222 in the midfoot region 226 to connect the heel cushion 210 to the forefoot cushion 206.
As a result of the location, size, and materials of the forefoot cushion 206 and the plurality of plates 230, including the upper plate 254, the intermediate plate 256, and the lower plate 258, as well as the location, size, and materials of the lateral cushion pod 214 and the medial cushion pod 218, the article of footwear 200 is arranged to distribute mass so that the CM point 235 is positioned in the midfoot region 226 and closer to the toe end 236 than to the heel end 238 of the sole structure 204, which affords the article of footwear 200 the ability rest to only on the forward outsole portion 232 so that the rearward outsole portion 234 is cantilevered and elevated the distance D1 above the planar surface P.
In some embodiments, the forefoot cushion 206 and heel cushion 210 provide different cushioning properties, such as, e.g., stiffness, density, abrasion resistance, puncture resistance, and the like. In some embodiments, the forefoot cushion 206 and the heel cushion 210 are formed of different materials from one another to provide the different cushioning properties. It will be appreciated that the sole structure 204 and/or the plurality of plates 230 may be fabricated using various manufacturing techniques, including additive manufacturing, e.g., continuous fiber fabrication (CFF), binder jetting, direct energy deposition, selective laser melting (SLM), fused deposition modeling (FDM), electron beam melting, laser powered bed fusion (LPBF), ultrasonic additive manufacturing, material extrusion, material jetting, Joule printing, electrochemical deposition, cold spray metal printing, DLP metal printing, Ultrasonic Consolidation or Ultrasonic Additive Manufacturing (UAM), LENS laser-based printing, vat photopolymerization, sheet lamination, or electron beam freeform fabrication (EBF3). Further, the sole structure 204 and/or the plurality of plates 230 may be fabricated by injection molding, vulcanization, or any other suitable methods used in the industry.
Referring now to FIGS. 15-27 , an exemplary embodiment of another article of footwear 500 is shown, including an upper 504 and a sole structure 508. As will be further discussed herein, the upper 504 is attached to the sole structure 508 and together with the sole structure 508 defines an interior cavity (not shown) into which a foot of a user may be inserted. For reference, the article of footwear 500 includes a forefoot region 512, a midfoot region 516, and a heel region 520. The forefoot region 512 generally corresponds with portions of the article of footwear 500 that encase portions of the foot that include the toes, the ball of the foot, and joints connecting the metatarsals with the toes or phalanges. The midfoot region 516 is proximate and adjoining the forefoot region 512 and generally corresponds with portions of the article of footwear 500 that encase the arch of the foot, along with the bridge of a foot. The heel region 520 is proximate and adjoining the midfoot region 516 and generally corresponds with portions of the article of footwear 500 that encase rear portions of the foot, including the heel or calcaneus bone, the ankle, or the Achilles tendon. The regions defined above (i.e., forefoot region 512, midfoot region 516, and heel region 520), are not strictly limited to the article of footwear 500, meaning that they may also be applied to individual components of the sole structure 508.
While only a single shoe 500 is depicted, i.e., a shoe that is worn on a left foot of a user, it should be appreciated that the concepts disclosed herein are applicable to a pair of shoes (not shown), which includes a left shoe and a right shoe that may be sized and shaped to receive a left foot and a right foot of a user, respectively. For ease of disclosure, however, a single shoe will be referenced to describe aspects of the disclosure, but the disclosure below with reference to the article of footwear 500 is applicable to both a left shoe and a right shoe. However, in some aspects there may be differences between a left shoe and a right shoe other than the left/right configuration. Further, in some aspects, a left shoe may include one or more additional elements that a right shoe does not include, or vice versa.
Referring now to FIG. 15 , the sole structure 508 also defines a lateral side 524 and a medial side 528. When a user is wearing the article of footwear 500, the lateral side 524 corresponds with an outside-facing portion of the article of footwear, while the medial side 528 corresponds with an inside-facing portion of the article of footwear 500. As such, a left shoe and a right shoe have opposing lateral sides and medial sides, such that the medial sides are closest to one another when a user is wearing the shoes, while the lateral sides are defined as the sides that are farthest from one another while the shoes are being worn.
Further, the medial side 528 and the lateral side 524 adjoin one another at opposing, distal ends of the sole structure 508 along a longitudinal central plane or axis LA (see FIG. 18 ) of the article of footwear 500, where a longitudinal direction is parallel with the longitudinal axis LA. As will be further discussed herein, the longitudinal axis LA demarcates a central, intermediate axis between the medial side 528 and the lateral side 524 of the article of footwear 500. Put differently, the longitudinal axis LA extends between a toe end 532 of the sole structure 508 located in the forefoot region 512 and a heel end 536 of the sole structure 508 located in the heel region 520 and continuously defines a middle of an insole, the upper 504, and/or the sole structure 508 of the article of footwear 500. The toe end 532 is located at a distal end of the forefoot region 512. The heel end 536 is located at a distal end of the heel region 520. Further, a midplane or axis MP (see FIG. 17 ) extends vertically through the article of footwear 500 in a direction that is perpendicular to the longitudinal axis LA and/or with respect to a ground surface. Put another way, the midplane MP extends vertically through the sole structure 508 to bisect the article of footwear between the heel end 536 and the toe end 532, thereby demarcating a center of the article of footwear 500.
Still referring to FIG. 15 , the forefoot region 512, the midfoot region 516, the heel region 520, the medial side 528, and the lateral side 524 are intended to define boundaries or areas of the article of footwear 500. To that end, the forefoot region 512, the midfoot region 516, the heel region 520, the medial side 528, and the lateral side 524 generally characterize sections of the article of footwear 500. Certain aspects of the disclosure may refer to portions or elements that are coextensive with one or more of the forefoot region 512, the midfoot region 516, the heel region 520, the medial side 528, or the lateral side 524. Further, both the upper 504 and the sole structure 508 may be characterized as having portions within the forefoot region 512, the midfoot region 516, the heel region 520, or along the medial side 528 or the lateral side 524. Therefore, the upper 504 and the sole structure 508, or individual portions of the upper 104 and the sole structure 508, may include portions thereof that are disposed within the forefoot region 512, the midfoot region 516, the heel region 520, or along the medial side 528 or the lateral side 524. Further, the distal end of the article of footwear 500 in the forefoot region 512 defines a toe end 532 of the sole structure 508, and the distal end of the article of footwear 500 in the heel region 520 defines a heel end 536 of the sole structure 508.
It should be understood that numerous modifications may be apparent to those skilled in the art in view of the foregoing description, and individual components thereof, may be incorporated into numerous articles of footwear. Accordingly, aspects of the article of footwear 500 and components thereof, may be described with reference to general areas or portions of the article of footwear 500, with an understanding the boundaries of the forefoot region 512, the midfoot region 516, the heel region 520, the medial side 528, or the lateral side 524 as described herein may vary between articles of footwear. However, aspects of the article of footwear 500 and individual components thereof, may also be described with reference to exact areas or portions of the article of footwear 500 and the scope of the appended claims herein may incorporate the limitations associated with these boundaries of the forefoot region 512, the midfoot region 516, the heel region 520, the medial side 528, or the lateral side 524 discussed herein.
Still referring to FIG. 15 , the sole structure 508 may include one or more components, which may include a midsole 534 comprising an upper midsole cushion 540, a sole plate or plate 544 (see FIG. 16 ), an intermediate midsole cushion 548, a lower midsole cushion 552, and an outsole 556. For example, in some embodiments, the sole structure 508 may include an outsole 556 that provides structural integrity to the sole structure 508, along with providing traction for the user. The upper midsole cushion 540, intermediate midsole cushion 548, and the lower midsole cushion 552, which may be referred to collectively as the midsole 534, provide a cushioning system for absorbing impacts and forces felt under a load of a user's foot. Further, the plate 544 cooperates with the midsole and the outsole 566 and provides additional durability, stability, and propulsion. As will be further discussed herein, the sole structure 508 of the present embodiment includes one or more components that provide the sole structure 508 with preferable spring and damping properties.
FIG. 16 is an exploded view of the sole structure 508 and illustrates the various layers of the sole structure. The sole structure 508 includes the midsole 534 comprising the upper (e.g., top) midsole cushion 540, the plate 544, the intermediate midsole cushion 548, and the lower (e.g., bottom) midsole cushion 552. Thus, it will be understood that aspects discussed herein related to the midsole 534 are also applicable to the upper midsole cushion 540, the intermediate midsole cushion 548, or the lower midsole cushion 552. The outsole 556, the midsole 534, and the plate 544, or any components thereof, may include portions within the forefoot region 512, the midfoot region 516, and/or the heel region 520. Further, the outsole 556, the midsole 534, and the plate 544, or any components thereof, may include portions on the lateral side 524 or the medial side 528.
With reference to FIG. 16 , the intermediate midsole cushion 548 includes a forefoot cushion 560 and a heel cushion 564. The forefoot cushion 560 further comprises a lateral cushion pod 568 and a medial cushion pod 572 that are distinct and separate. The heel cushion 564 further comprises a lateral arm 576 and a medial arm 580 that define the channel 584 positioned centrally therebetween. The forefoot cushion 560 and the heel cushion 564 are spaced apart in the longitudinal direction (i.e., toe-to-heel) by an intermediate gap 588. The outsole 556, the midsole 534, and any other portions of the sole structure 508 may be attached to one another via, e.g., adhesive, cement, stitching, welding, fastening members, etc. The outsole 556 of the sole structure 508 comprises a forward outsole portion 592 disposed in the forefoot region 512 and a rearward outsole portion 596 disposed in the heel region 520. The sole structure 508 further includes the plate 544 that includes a top plate or upper segment 600 and a bottom plate or lower segment 604. The top plate 600 is integrally connected to the bottom plate 604 in the forefoot region 512 at a hinge portion 608 to provide stability, propulsion, energy return, and durability while also reducing a mass and number of components of the sole structure 508 in comparison with other sole structures having a plurality of plates. In the illustrated embodiment, the top plate 600 and the bottom plate 604 of the plate 544 are integrally formed of a common material. It is within the scope of the present disclosure that the plate 544 can comprise multiple components, e.g., plates or segments, that are permanently coupled together and formed of a common material, removably coupled together and formed of a common material, permanently coupled together and formed of entirely different materials, removably coupled together and formed of entirely different materials, permanently coupled together and formed entirely of the same material, or integrally formed as portions or segment made of different materials.
With continued reference to FIG. 16 , the upper midsole cushion 540 has an upper surface 612 opposite a lower surface 616. The top plate 600 has an upper surface 620 opposite a lower surface 624. The forefoot cushion 560 has an upper surface 628 opposite a lower surface 632. The heel cushion 564 has an upper surface 636 opposite a lower surface 640. The bottom plate 604 has an upper surface 644 opposite a lower surface 648. The lower midsole cushion 552 has an upper surface 652 opposite a lower surface 656. The forward outsole portion 592 has an upper surface 660 opposite a lower surface 664. The rearward outsole portion 596 has an upper surface 668 opposite a lower surface 672. The upper midsole cushion 540 is directly coupled to and disposed above the top plate 600, such that the lower surface 616 of the upper midsole 540 is in contact with the upper surface 620 of the top plate 600. The top plate 600 is directly coupled to and disposed atop the forefoot cushion 560 and the heel cushion 564, such that the lower surface 624 of the top plate 600 is in contact with both the upper surface 628 of the forefoot cushion 560 and the upper surface 636 of the heel cushion 564. In some embodiments, portions of the forefoot cushion 560 are not in direct contact with the top plate 600. The forefoot cushion 560 is directly coupled to and disposed above the bottom plate 604, such that the lower surface 632 of the forefoot cushion 560 is directly in contact with the upper surface 644 of the bottom plate 604. The bottom plate 604 is directly coupled to and disposed above the lower midsole cushion 552, such that the lower surface 648 of the bottom plate 604 is directly in contact with the upper surface 652 of the lower midsole cushion 552. The lower midsole cushion 552 is directly coupled to and disposed above the forward outsole portion 592, such that the lower surface 656 of the lower midsole cushion 552 is directly in contact with the upper surface 660 of the forward outsole portion 592. The rearward outsole portion 596 is directly coupled to and disposed below the heel cushion 564, such that the lower surface 640 of the heel cushion 564 is directly in contact with the upper surface 668 of the rearward outsole portion 596.
With reference to FIG. 17 , the outsole 556 is defined as a portion of the sole structure 508 that at least partially contacts an exterior surface (e.g., ground), when the article of footwear 500 is worn. In the illustrated embodiment, when the article of footwear is unworn (i.e., no foot inserted), and rested on a planar surface P, the forward outsole portion 592 contacts the planar surface P while the rearward outsole portion 596 is elevated a distance D1 above the planar surface (see FIG. 15 ). This is in part due to a center of mass (CM) being disposed toewardly (i.e., closer to a toc end 532), of a midplane MP (see FIG. 17 ) that bisects the sole structure between the toc end 532 and the heel end 536. By locating the CM point toeward of the midplane MP, the article of footwear is pre-loaded to provide efficient impact response with a ground surface (e.g., planar surface or reference plane P) when jogging or running. In other words, the mass distribution of the article of footwear 500 is intentionally imbalanced and programmed to promote efficient running and impact. For instance, a user running on the ball of the foot or MTP is afforded leverage that assists with propulsion. Further, locating the CM point toeward of the midplane MP also promotes efficient travel of the user's foot through a gait cycle, since the forefoot region has a greater proportion of mass than the heel region and is weighted more heavily, which exerts a greater downward force on the forefoot of the user as compared to a downward force on the heel of the user. As a result, the downward force on the forefoot assists with positioning or angling the user's foot for subsequent impact with the ground surface to further aid with leverage and propulsion. In this way, the sole structure 508 reduces wasted energy and effort involved in counteracting a conventional balanced or heel-weighted shoe.
Referencing FIG. 16 , the outsole 556 defines a bottom end or bottom surface of the sole structure 508 across the forefoot region 512 and the heel region 520. Put another way, the outsole 556 is a ground-engaging portion or defines a ground-engaging surface of the sole structure 508 that is generally opposite of the upper 504 (see FIG. 15 ). The bottom surface 664 of the outsole 556 includes treads thereon, which helps the outsole 556 to provide structural integrity to the sole structure 508 and traction for a user. Further, in some aspects, the outsole 556 is formed from one or more materials to impart durability, wear-resistance, abrasion resistance, or traction to the sole structure 508. For example, the outsole 556 may be fabricated from an injection molded polyurethane (PU) plastic, thermoplastic, rubber or rubberized material, (e.g., thermoplastic polyurethane (TPU), EVA, polyolefin elastomer, or mixtures thereof), which can resist wear resulting from contact with the ground in addition to increasing traction. However, it is contemplated that other thermoplastic elastomers consisting of block copolymers may also be used to form the outsole 556, including carbon fiber or high-density wood. In some aspects, the outsole 556 has a uniform thickness, or the outsole 556 has a variable thickness.
With continued reference to FIG. 16 , the midsole 534 provides a cushioning system for the article of footwear 500. The midsole 534 extends from the outsole 556 toward the upper 504 (see FIG. 15 ) or otherwise extends between and connects the outsole 556 with the upper 504. Further, the midsole 534 is configured as a cushioning member to reduce stress or increase the strength of portions, e.g., the forefoot region 512, the midfoot region 516, and/or the heel region 520. In some aspects, the midsole 534, which includes each of the upper midsole cushion 540, intermediate midsole cushion 548, and lower midsole cushion 552, is individually constructed from a thermoplastic material, such as PU, for example, and/or an ethylene-vinyl acetate (EVA), copolymers thereof, or a similar type of material. For example, any part of the midsole 534 may be an EVA-Solid-Sponge (“ESS”) material or an EVA foam, (e.g., PUMA® ProFoam Lite™, IGNITE Foam). Alternatively, any part of the midsole 534 may be polyurethane, polyether, an olefin block copolymer, a supercritical foam, or a thermoplastic material, e.g., a thermoplastic polyurethane, a thermoplastic elastomer, a thermoplastic polyolefin, etc. Any part of the midsole 534 may be a single polymeric material or may be a blend of materials, such as an EVA copolymer, a thermoplastic polyurethane, a polyether block amide (PEBA) copolymer, and/or an olefin block copolymer. One example of a PEBA material is PEBAX®.
In examples where the midsole 534 is partially or entirely formed from a supercritical foaming process, the supercritical foam may comprise micropore foams or particle foams such as a TPU and EVA mixture or pure PEBAX. The supercritical foam can be manufactured using a process that is performed within an autoclave, an injection molding apparatus, or any sufficiently heated/pressurized container and involves saturating a molten material. The material may include thermoplastic polyurethane, polyolefin elastomers, ethylene-vinyl acetate, or mixtures thereof, with a supercritical fluid that may include supercritical carbon dioxide, supercritical nitrogen, e.g., nitrogen gas, or mixtures thereof. During the process, the solution of supercritical fluid and molten material is pumped into a pressurized container, after which the pressure within the container is released, such that the molecules of the supercritical fluid rapidly convert to gas. This rapid conversion forms small pockets within the molten material and causes the material to expand into a foam, which may be used for the midsole cushion 534. In further examples, the midsole 534 is formed using alternative methods known in the art, including the use of an expansion press, an injection machine, a pellet expansion process, a cold foaming process, a compression molding technique, die cutting, or any combination thereof. For example, the midsole 534 may be formed using a process that involves an initial foaming step in which supercritical gas is used to foam a material and then compression molded or die cut to a particular shape.
Further, it is contemplated that the midsole 534 may be constructed from a single material or combination of materials, or the upper midsole cushion 540, intermediate midsole cushion 548, and the lower midsole cushion 552 are constructed of different materials. For example, the upper midsole cushion 540 defines a first hardness that is less than a second hardness defined by the lower midsole cushion 552, meaning that the lower midsole cushion 552 is harder than the upper midsole cushion 540. In some embodiments, the first hardness of the upper midsole cushion 540 is greater than or equal to the second hardness of the lower midsole cushion 552. The hardness ratings between the upper midsole cushion 540, the intermediate midsole cushion 548, and the lower midsole cushion 552, may vary to provide differentiated support and comfort across regions of the article of footwear 500. In one embodiment, the upper midsole cushion 540 exhibits a lower minimum compressive strength than the lower midsole cushion 552. In alternate embodiments, the upper midsole cushion 540 exhibits a higher minimum compressive strength than the lower midsole cushion 552. Additionally, the intermediate midsole cushion 548 may have a minimum compressive strength that is lower than both the upper midsole cushion 540 and the lower midsole cushion 552. The lower minimum compressive strength facilitates controlled compression and deformation of the plate 544 during loading, allowing the plate 544 to flex inward or outward in response to ground contact forces. The reduced hardness of the intermediate midsole cushion 548 enhances the dynamic responsiveness of the plate 544, enabling it to function as a mechanical lever or energy return system while maintaining comfort and stability. In some examples, the upper, intermediate, and lower midsole cushions 540, 548, 552 have a hardness between about 4 Shore A to about 75 Shore A, or between about 30 Shore A to about 60 Shore A, or between about 40 Shore A to about 55 Shore A. In some examples, splitting the midsole 534 into distinct layers, e.g., the upper midsole cushion 540, the intermediate midsole cushion 548, and the lower midsole cushion 552, increases a lever resistance of the plate 544, which in turn leads to decreased energy loss when the midsole 534 is under load. As a result, the midsole 534 conserves energy during a push-off phase of a gait cycle, thereby leading to faster propulsion off of the ground.
Still referring to FIG. 16 , the lower midsole cushion 552 is positioned above the forward outsole portion 592 and below the bottom plate 604 in the sole structure 508. In some aspects, the lower midsole cushion 552 extends from the toe end 532 to the midfoot region 516 and defines, in part, the lateral side 524 and the medial side 528 of the sole structure 508. As illustrated in the non-limiting example in FIG. 16 , the lower midsole top surface 652 defines an upper recessed portion 676 of the lower midsole cushion 552. The upper recessed portion 676 of the lower midsole cushion 552 corresponds in shape to an outer periphery of the bottom plate 604. Specifically, the upper recessed portion 676 is configured to receive the bottom plate 604 such that at least a portion of the bottom plate 604 is flush with the lower midsole top surface 652 when the sole structure 508 is assembled (see, e.g., FIG. 19 ). In other words, the bottom plate 604 is at least partially recessed into the lower midsole top surface 652. Further, the upper midsole cushion 540 contacts the lower midsole cushion 552 proximate the toe end 532 and does not contact the intermediate midsole cushion 548.
Still referring to FIG. 16 , the upper midsole cushion 540 is positioned above the top plate 600. In some embodiments, the top plate 600 is at least partially recessed into the upper midsole bottom surface 616. Because of this, the upper midsole cushion 540 includes a plurality of pockets 682 (see FIG. 20 ) corresponding with a plurality of plate ridges 680 within at least the forefoot region 512 and the heel region 520. In some embodiments, the upper midsole cushion 540 extends from the toe end 532 to the heel end 536 beyond the top plate 600 of the sole structure 508 and defines, in part, the lateral side 524 and the medial side 528 of the sole structure 508. In other words, the upper midsole cushion 540 extends continuously from the forefoot region 512 to the heel region 520 and from the lateral side 524 to the medial side 528. The lateral side 524 and the medial side 528 of the upper midsole cushion 540 may include a plurality of ribs 684 in the form of protruding contours, undulations, or ridges, which may vary in size, shape, pattern, and texture between the lateral side 524 and medial side 528. In other words, the lateral side 524 and the medial side 528 may not be perfect mirror images of each other. Further, in some embodiments, the plurality of ribs 684 do not extend along an entire length of the upper midsole cushion 540. Additionally, the upper midsole cushion 540 has an inner wall 688 that surrounds part of the upper 504 and provides a structural interface for the attachment of the sole structure 508 to the upper 504, such as by adhesive, stitching, fusion, welding, or combinations thereof. When viewed from the side (see FIG. 17 ), the upper midsole cushion 540 has an elongated W-shape. In other words, when viewed from the side, the upper midsole cushion 540 is convexly curved in the forefoot and heel regions 512, 520 relative to the plane P, with a concavely curved bridge or arch portion 690 in the midfoot region 516 that connects the forefoot region 512 to the heel region 520.
Referring to FIG. 16 , the plate 544 is positioned above the lower midsole cushion 552 and below the upper midsole cushion 540 in the sole structure 508. In some aspects, the plate 544 is directly coupled to the upper and lower midsoles 540, 552, as discussed below. The plate 544 is defined as a portion of the sole structure 508 that provides additional durability, stability, and propulsion characteristics to the sole structure 508. In some embodiments, the plate 544 is formed from a thermoplastic material, such as a thermoplastic polyurethane, a thermoplastic elastomer, a thermoplastic olefin, or the like. In particular aspects, however, the plate 544 may be formed from a composite or one or more layers of fibers, such as carbon fibers, aramid fibers, boron fibers, glass fibers, natural fibers, and polymer fibers, or a combination thereof. In some examples, the layers of the composite material are positioned at various angles such that the plate 544 has additional reinforcement and is less likely to fail under the same load. In some examples, the fibers may be affixed or bonded to a substrate or a thermoplastic material, e.g., a thermoplastic polyurethane, a thermoplastic polyolefin, or a thermoplastic elastomer, by stitching or an adhesive. In other examples, the plate 544 may be formed from a unidirectional tape that includes carbon fibers, aramid fibers, boron fibers, glass fibers, polymer fibers, or the like. In yet other examples, the plate 544 may be formed from densified wood or densified wood panels formed from chemically treating natural wood to remove lignin or hemicellulose therefrom, or compressing natural wood.
In the illustrated embodiment, the top plate 600 is integrally joined to the bottom plate 604 at the hinge 608. The top plate 600 includes a first anterior end 692 that is located in the forefoot region 512 and disposed adjacent the toe end 532 (see FIG. 15 ). The first anterior end 692 is opposite a first posterior end 696 that is located in the heel region 520. The bottom plate 604 includes a second anterior end 700 that is located in the forefoot region 512 and disposed adjacent the toe end 532 (see FIG. 15 ). The second anterior end 700 is opposite a second posterior end 704 that is located in the midfoot region 516. The top plate 600 includes a V-shaped slot 708 that extends from the midfoot region 516 through the first posterior end 696. In the illustrated embodiment, the slot 708 extends continuously from the midfoot region 516 to the heel region 520, although other configurations are within the scope of the present disclosure. The top plate 600 includes a lateral posterior leg 712 and a medial posterior leg 716 that are separated by the slot 708. This feature allows the lateral posterior leg 712 and medial posterior leg 716 to move (e.g., bend, flex, deflect, or rotate) independently of one another. This independent movement allows for a more responsive shoe with more dynamic movement under various forces or terrains. In addition to independent movement, the slot 708 reduces the overall weight of the plate 544 and, thus, the sole structure 508.
Referring to FIG. 16 , the plurality of plate ridges 680 (i.e., ridges) are integrally formed on the plate 544 and extend along the top plate 600 from the forefoot region 512 toward the heel region 520. The plurality of ridges 680 provide reinforcement of the plate 544 to increase durability, bending and flexure resistance, torsional rigidity, and propulsion. The plurality of plate ridges 680 comprise an arcuate shape while the thickness of the top plate 600 remains uniform across the ridges 680. In other words, while the ridges 680 cause the top plate 600 to protrude in certain regions, the addition of the ridges 680 adds no mass. This allows for the plate 544 to have increased rigidity without increasing the overall mass of the sole structure 508. The plurality of plate ridges 680 extend longitudinally along the top plate 600 from the forefoot region 512 to the midfoot region 516 and/or the heel region 520. In the illustrated embodiment, the plurality of plate ridges 680 extends vertically upward, although it is contemplated that the plurality of plate ridges 680 extends radially downward. In the illustrated embodiment, the top plate 600 includes a first plate ridge 720, a second plate ridge 724, and a third plate ridge 728. The first plate ridge 720, the second plate ridge 724, and the third plate ridge 728 may be referred to as the lateral plate ridge, the medial plate ridge, and the central plate ridge respectively. In some embodiments, the top plate 600 has more or fewer ridges than shown. In some embodiments, the plate ridges 680 are different in length or shape, the plate ridges 680 are placed differently, or the plate ridges 680 are sized differently. The plurality of plate ridges 680 define varying protrusion heights relative to the top plate 600. For example, the plurality of plate ridges 680 protrude greater distances from the top plate 600 in the forefoot region 512 than in the heel region 520. In the illustrated embodiment, the first plate ridge 720 extends from the forefoot region 512 through the heel region 520 on the lateral posterior leg 712, and tapers in protrusion height from the forefoot region 512 to the heel region 520, with the greatest protrusion height being in the forefoot region 512. The second plate ridge 724 extends from the forefoot region 512 through the heel region 520 on the medial posterior leg 716, and tapers in protrusion height from the forefoot region 512 to the heel region 520, with the greatest protrusion height being in the forefoot region 512. The third plate ridge 728 extends from the forefoot region 512 to the midfoot region 516.
With continued reference to FIG. 16 , the heel region 520 of the top plate 600 is configured to cup the user's heel, such that the top plate 600 curves upwards behind the user's heel to better secure the foot within the article of footwear 500. In other words, the top plate 600 curves convexly relative to the planar surface P from the midfoot region 516 to the first posterior end 696 to conform anatomically to the shape of the user's foot (see FIG. 17 ). This concavity provides additional stability when walking, jogging, and/or running. The lateral posterior leg 712 has a first internal edge 732 and a first external edge 736 in the heel region 520. The medial posterior leg 716 has a second internal edge 740 and a second external edge 744 in the heel region 520. The lateral posterior leg and medial posterior leg 712, 716, curve convexly from external edge 736, 744 to internal edge 732, 740 relative to the planar surface P (see FIG. 17 ). This concavity further provides the user with additional stability. In some embodiments, the top plate 600 includes a convex portion in each of the heel region 520 and the forefoot region 512
The shape of the top plate 600, including the shape and positions of the plate ridges 680, enhances the stability and propulsion characteristics of the sole structure 508. For example, the shape of the top plate 600 helps to guide a user's foot to strike the ground, which in turn enhances user comfort during impact and ensures that stress is better distributed across the sole structure 508. In this way, the plate 544 enhances user comfort by promoting stability within the article of footwear 500. In addition, the plate 544 increases the structural integrity of the sole structure 508. Specifically, stress during impact is concentrated on the plate ridges 680 because the plate ridges 680 extend radially upward from the plate 544 (see FIG. 30 ). In some examples, the plate ridges 680 correspond to anatomical structures of a user's foot, e.g., the metatarsals and/or phalanges, that provide stability and propulsion as the user moves through a gait cycle. Specifically, the plate ridges 680 may be located directly below such structures, thus allowing the plate ridges 680 to guide the energy exerted by anatomical structures of a user's foot. Thus, the plate ridges 680 provide the sole structure 508 with a more predictable response to stress during impact, leading to improved longevity and energy return characteristics of the sole structure 508. Moreover, focusing stress at particular points within the sole structure 508, e.g., along plate ridges 680, allows excess material to be removed from inactive areas of components of the sole structure 508, e.g., the midsole cushion 534 and the plate 544, that experience negligible strain during impact. This in turn reduces the weight of the sole structure 508, which further improves the energy return and propulsion characteristics of the article of footwear 500.
With continued reference to FIG. 16 , the bottom plate 604 is shorter in the direction parallel to the planar surface P than the top plate 600. The second posterior end 704 is located in the midfoot region 516. The distance between the lateral side 524 and the medial side 528 defines a width W of the bottom plate 604, and is largest in the forefoot region 512. The width W is greater in the forefoot region 512 than in the midfoot region 516. The distance between the lateral side 524 and the medial side 528 of the bottom plate 604 tapers to a point moving rearwardly to the midfoot region 516, where the lateral side 524 and the medial side 528 meet at the bottom plate posterior end 704, located in the midfoot region 516. The concavity of the bottom plate 604 mirrors that of the top plate 600. In other words, the bottom plate 604 has a curved portion extending between the lateral side 524 and the medial side 528, where the curved portion is convexly curved relative to the top plate 600.
As shown in FIG. 16 , the intermediate midsole cushion 548 comprises a forefoot cushion 560 disposed in the forefoot region 512 and the heel cushion 564 disposed in the heel region 520. The forefoot cushion 560 further comprises a lateral cushion pod 568 disposed on the lateral side 524 of the sole structure 508, and a medial cushion pod 572 disposed on the medial side 528 of the sole structure 508. The cushion pods 568, 572 may be the same size and shape as one another, or may vary in size in shape from one another. In the illustrated embodiment, the medial cushion pod 572 has a smaller volume than the lateral cushion pod 568. The cushion pods 568, 572 may gradually taper in height along its length such that it may be the same height as a gap 748 between the top plate 600 and the bottom plate 604. The forefoot cushion 560 is disposed at least partially within the gap 748 between the top plate 600 and the bottom plate 604 of the plate 544. In the illustrated embodiment, the cushion pods 568, 572 are separate and distinct components from one another. The cushion pods 568, 572 are spaced apart by an expansion zone 752 that allows for the cushion pods 568, 572 to expand during loading (e.g., compression) to support and cushion the plate 544 as the top plate 600 and bottom plate 604 move about the hinge 608. The cushion pods 568, 572 may include a plurality of protrusions 756 in the form of undulations, ridges, or contours along the lateral side 524 and medial side 528 of the cushion pods. The plurality of protrusions 756 may act as flexion zones that allow the medial and lateral cushion pods 568, 572 to compress more efficiently in response to vertical and lateral forces, thereby enhancing shock absorption, improving energy return, and contributing to the overall flexibility of the plate 544 during dynamic foot motion. The lateral cushion pod 568 and the medial cushion pod 572 may be in contact with both the top plate 600 and the bottom plate 604.
Still referring to FIG. 16 , the heel cushion 564 is coupled to and disposed directly beneath the top plate bottom surface 624. The heel cushion 564 has a forwardmost point 760 spaced rearwardly of the forefoot cushion 560. The heel cushion 564 includes a lateral arm 576 disposed on the lateral side 524 of the sole structure 508 and a medial arm 580 disposed on the medial side 528 of the sole structure 508. The lateral arm 576 and the medial arm 580 of the heel cushion 564 may be connected via the channel 584 that corresponds with the slot 708 of the top plate 600, or the arms 576, 580 may be separate and distinct.
Now, with reference to FIG. 17 , the top plate 600 and the bottom plate 604 are joined or connected to one another at the hinge 608 (e.g., bending fulcrum), giving the plate 544 a tweezer-like configuration. The hinge 608 is integrally formed by a thickened region proximate the toe end 532 of the sole structure 508. The hinge 608 has a rear-facing wall 764 that is curved between the top plate 600 and the bottom plate 604. When viewed from the midplane, the rear-facing wall 764 is concavely curved relative to the midplane MP. The hinge 608 further defines a flex axis FA extending in a lateral-medial direction that is perpendicular to the planar surface P. The gap 748 extends from the hinge 608 toward the first posterior end 696. A vertical distance of the gap 748 is measured between the top plate 600 and the bottom plate 604. The gap 748 has a minimum distance located proximate the toe end 532, closest to the rear-facing wall 764 of the hinge 608. The gap 748 has a maximum distance located rearwardly of the hinge 608 and proximate the second posterior end 704 of the bottom plate 604. During loading, the gap 748 decreases and, correspondingly, potential energy is stored in the plate 544 to assist with propulsion later on in the gait cycle. The tweezer-like configuration of the plate 544 enables the top plate 600 and bottom plate 604 to be biased away from one another, such that the top plate 600 and the bottom plate 604 diverge from one another in a rest configuration. The shape and geometry of the top plate 600, bottom plate 604, and hinge 608 are tuned to provide useful energy absorption during some portions of the gait cycle and to energy return during other portions of the gait cycle.
As shown in FIG. 17 , the plate 544 is positioned between the upper midsole cushion 540 and the lower midsole cushion 552, with the intermediate midsole cushion 548 positioned between the top plate 600 and the bottom plate 604. In some examples, the plate 544 is not visible from the side, such as when it is embedded in the respective midsole portions. Further, the upper midsole cushion 540 has an upper midsole height D2 that is defined by a distance between the top and bottom sides 612, 616 of the upper midsole cushion 540, and the lower midsole cushion 552 has a lower midsole height D3 that is defined by a distance between the top and bottom sides 652, 656 of the lower midsole cushion 552. The upper midsole height D2 is measured along a straight line that extends through a point in the upper midsole top surface 612 and a point in the upper midsole bottom surface 616 in a direction that is perpendicular with respect to a tangent line (not shown) running adjacent the upper midsole top surface 612. Similarly, the lower midsole height D3 is measured along a straight line that extends through a point in the lower midsole top surface 652 and a point on the lower midsole bottom surface 656 in a direction that is perpendicular to a tangent line (not shown) running adjacent the lower midsole top surface 652. Thus, it will be understood that the upper and lower midsole heights D2, D3 change along lengths of the upper and lower midsoles 540, 552, respectively. In the illustrated non-limiting example, the upper midsole height D2 increases from the toe end 532 to where the ball of a user's foot would be received, i.e., an area corresponding to the metatarsophalangeal (MTP) point of a user's foot located within the forefoot region 512 and/or the midfoot region 516, and then decreases from the MTP point to the heel region 520. Thus, in some examples, the upper midsole height D2 is largest beneath the MTP point. In some aspects, the upper midsole height D2 further increases from where a center of a user's heel would be received, i.e., a heel point, to the heel end 536. In some examples, the lower midsole height D3 changes inversely with respect to the upper midsole height D2. That is, the lower midsole height D3 decreases from the toe end 532 to the MTP point, increases from the MTP point to the heel point, and decreases from the heel point to the heel end 536. In this way, an interface between the upper midsole 540 and the top plate 600 defines a sinusoidal profile, which enhances the aesthetic appeal and cushioning characteristics of the article of footwear 500.
FIG. 18 depicts a bottom view of the sole structure 508. Here, it is shown that the forward outsole portion 592 extends from the toc end 532 in the forefoot region 512 to the midfoot region 516. The forward outsole portion 592 is coupled to and disposed directly beneath the lower midsole cushion 552. The rearward outsole portion 596 is disposed in the heel region 520. The forward outsole portion 592 and the rearward outsole portion 596 are separate and distinct portions. The forward outsole portion 592 and the rearward outsole portion 596 may comprise any suitable material, such as, e.g., a rubber or rubberized material. The rearward outsole portion 596 is provided with a lateral rearward outsole portion 768 located on the lateral portion 524 of the sole structure 508 and a medial rearward outsole portion 772 located on the medial portion 528 of the sole structure 508. The rearward outsole portions 768, 772 are separate and distinct from one another, and are arranged on opposite sides of the longitudinal axis LA. In some embodiments, the sole structure 508 includes just the medial rearward outsole portion 772 or just the lateral rearward outsole portion 768, or both the medial and lateral rearward outsole portions 768, 772, or neither of the rearward outsole portions 768, 772. The rearward outsole portions 768, 772 are separated by the channel 584. The channel 584 is defined between a lateral arm 576 that extends along the lateral side 524 of the heel cushion 564 and a medial arm 580 that extends along the medial side 528 of the heel cushion 564. The lateral rearward outsole section 768 is disposed directly beneath the lateral arm 576 of the heel cushion 564 and the medial heel outsole section 772 is disposed directly beneath the medial arm 580 of the heel cushion 564. Additionally, the outsole 556 may include groove patterns or treads to provide traction with the ground, or planar surface P.
As illustrated in FIG. 18 , the lower midsole cushion 552 defines a length D4 measured from the toe end 532 to the second posterior end 704 in a direction that is parallel with respect to the longitudinal axis LA. In some examples, the length D4 of the lower midsole cushion 552 is between about 30% and about 80%, or between about 30% and about 75%, or between about 50% and about 70%, or about 65% of a total length D5 of the sole structure 508. It is generally accepted that the length D4 of the lower midsole cushion 552 is substantially similar to the length of the bottom plate 604.
With reference to FIG. 19 , the forward outsole portion is shown along a lowermost portion of the sole structure 508. The lower midsole cushion 552 is shown coupled to the outsole 556, the bottom plate 604 is shown nested in the lower midsole cushion 552, and the top plate 600 is shown nested in the upper midsole cushion 540. The top plate 600 and the bottom plate 604 are spaced apart by the gap 748 and form a divergent configuration. The plurality of ribs 684 can be seen on both the lateral side 524 and the medial side 528 of the upper midsole cushion 540.
Now referring to FIG. 20 , another cross-sectional view along the forefoot region 512 of the sole structure 508 is shown. The lateral cushion pod 568 is disposed along the lateral side 524 of the sole structure 508, and the medial cushion pod 572 is disposed on the medial side 528 of the sole structure 508 opposite the lateral side 524. Both forefoot cushion pods 568, 572 engage with both the top plate 600 and the bottom plate 604. FIG. 20 also depicts the expansion zone 752 located between the lateral cushion pod 568 and the medial cushion pod 572. This expansion zone 752 allows for the cushion pods 568, 572 to expand when the outsole 556 strikes or is compressed under loading against the ground surface or planar surface P. The size of the expansion zone 752 may vary along the length D5 of the sole structure 508 (see FIG. 18 ). There is also a plurality of protrusions 756 along the external surfaces of the lateral cushion pod 568 and the medial cushion pod 572. It can be seen that the thickness of the top plate 600 does not increase or decrease at the location of the first ridge 720 and the second ridge 724. The plurality of ridges 680 correspond with the plurality of pockets 682 in the upper midsole cushion 540.
With reference to FIG. 21 , a cross-sectional view is illustrated of the sole structure 508 taken through line 21-21 of FIG. 18 , i.e., between the forefoot region 512 and the midfoot region 516. The bottom plate 604 is no longer nested into the lower midsole cushion 552 as it was in FIG. 19 . It can also be appreciated from the view of FIG. 21 that a portion of the upper surface 628 of each of the cushion pods 568, 572 is distanced from and not in contact with the top plate 600. This partial spacing between the upper surfaces 628 of the cushion pods 568, 572 and the top plate 600, in combination with the predisposition of the top plate 600 relative to the bottom plate 604 due to the hinge 608 and the elevated distance D1 from the planar surface P, enables the plate 544 to freely deflect and/or compress an initial amount without obstruction or resistance from the cushion pods 568, 572 or the heel cushion 564 (see FIG. 17 ) against the planar surface P. Subsequent loading and compression beyond the initial amount causes the plate 544 to compress so that the top plate 600 contacts the upper surfaces 628 of the cushion pods 568, 572 and the heel cushion 564 contacts the planar surface P. In other words, the top plate 600 can at least partially, initially deflect or rotate toward the bottom plate 604 about the hinge 608 without resistance provided by the cushion pods 568, 572 or heel cushion 564, and then further deflection or rotation of the top plate 600 toward the bottom plate 604 experiences resistance by the cushion pods 568, 572 and heel cushion 564. The degree of resistance offered by the cushion pods 568, 572 and heel cushion 564 is influenced by their size, shape, and material properties. In this way, smoother compression, cushioning, and reduced energy return or spring-back is afforded by the sole structure 508 during light loads (e.g., walking or shifting weight while standing). Additionally, such free deflection or compression enables an increased amount of potential energy to be quickly stored during initial deflection under heavier loading (e.g., jumping or running), thereby creating a greater propulsive or spring-back force later on in the gait cycle to propel the user upward or forward. Additionally, the medial cushion pod 572 appears larger in size than the lateral cushion pod 568. This is because, during the gait cycle, the user does not perfectly distribute their weight evenly across the width W of the sole structure. To account for this discrepancy, the medial cushion pod 572 is placed farther from the toe end 532 than the lateral cushion pod 568 to provide more cushioning where needed, and less cushioning where it is not needed to reduce overall weight of the sole structure 508.
With reference to FIG. 22 , a cross-sectional view is illustrated of the sole structure 508 taken through line 22-22 of FIG. 18 , i.e., across a portion of the midfoot region 516 of the article of footwear 500. In particular, line 22-22 is taken partially along a portion of the sole structure 508 that corresponds to the arch of the user's foot and is behind the point of divergence of the top plate 600. The concavity of the lateral posterior leg 712 and the medial posterior leg 716 are clearly shown in this Figure, with both plate legs 712, 716 being convex, relative to the planar surface P.
With reference to FIG. 23 , a cross-sectional view is illustrated of the sole structure 508 taken through line 23-23 of FIG. 18 , i.e., across a portion of the heel region 520 of the article of footwear 500. As previously described, the heel cushion 564 comprises the lateral arm 576 disposed on the lateral side 524 of the sole structure 508 and the medial arm 580 disposed on the medial side 528 of the sole structure 508. In this embodiment, the lateral arm 576 and the medial arm 580 of the heel cushion 564 are connected via the channel 584 that corresponds with the slot 708 of the top plate 600. The heel cushion is disposed directly beneath and is coupled to the top plate 600.
With reference to FIG. 24 , a cross-sectional view is illustrated of the sole structure 508 taken through line 24-24 of FIG. 18 . This cross-sectional view only shows the medial side of the heel portion, where the medial nub of the medial arm 580 of the heel cushion 564 abuts the top plate 600. The rearward outsole portion 596 can be coupled to and disposed beneath the heel cushion 564.
With reference to FIG. 25 , a cross-sectional view is illustrated of the sole structure 508 taken through line 25-25 of FIG. 18 , which is parallel to the longitudinal axis LA but not exactly through the middle of the sole structure 508. It can be seen that the forward outsole portion 592 extends to the toe end 532 of the sole structure 508 to encase the aft portion of the upper midsole cushion 540, which can be seen in further detail in FIG. 26 . From this view, it is clear that the cushion pods 568, 572 are not uniform in shape, and vary in height along the longitudinal axis LA. The plurality of protrusions 756 also vary from medial cushion pod 572 to lateral cushion pod 568 to better account for uneven weight distribution during use.
Now referring to FIG. 28 , the gait cycle is shown as a four phase process. The first phase can be referred to as heel strike or initial contact. This is the very first moment the heel of the foot touches the ground. The second phase is known as loading response or flat foot. After initial contact, the entire foot makes contact with the ground. The foot begins to pronate, or roll inward, to help with stability and load the leg. The third phase is referred to as the terminal stance or heel off. During this phase, the heel lifts off the ground, but the toes are still in contact. The foot begins to supinate, or turn outward, to prepare to push off the ground. The last and fourth phase is the pre-swing or toe off phase. During this phase, the toes are the last part of the foot to leave the ground, which in turn propels the user forward.
Now turning to FIG. 29 , a top view of the plate 544 is shown. The first phase distance D6 corresponds with the portion of the plate 544 bearing the load from the user during the first phase of the gait cycle. The first phase distance D6 may be about 30% of the total length of the plate 544. The second phase distance D7 corresponds with the portion of the plate 544 bearing the load from the user during the second phase of the gait cycle. The second phase distance D7 may be about 100% of the total length of the plate 544. The third phase distance D8 corresponds with the portion of the plate 544 bearing the load from the user during the third phase of the gait cycle. The third phase distance D8 may be about 52% of the total length of the plate 544. The fourth phase distance D9 corresponds with the portion of the plate 544 bearing the load from the user during the fourth phase of the gait cycle. The fourth phase distance D9 may be about 20% of the total length of the plate 544. The greatest load is applied to the plate 544 during the second phase of the gait cycle when comparing all four phases of the gait cycle.
Now referring to FIG. 30 , the plate 544 is shown as a maximum stress simulation, specifically during the second phase of the gait cycle. It can be seen that the regions of highest stress are in the midfoot region 516 corresponding to the area of the top plate 600 under the arch of the users foot, along the first plate ridge 720 and second plate ridge 724, and at the second posterior end 704. However, out of all these locations, the location of maximum stress during the second phase of the gait cycle is the midfoot region 516 of the top plate 600. The maximum stress value of the plate 544 may be between about 1500 MPa and about 3000 MPa, or between about 2000 MPa and about 2500 MPa, or between about 2200 MPa and about 2500 MPa, or about 2300 MPa. The plate 544 may be manufactured in such a way that additional reinforcements are added at the locations of high stress to enhance support and reduce stress.
The article of footwear 500 may be adapted to an unloaded state, such that the ground contact surface area is less than the total surface area of a bottom surface of the sole structure 508. The unloaded state may exist when the internal space, i.e., a void or cavity, which is created by interior sides of the upper 504 and sole structure 508, does not receive a foot of a user. The top plate 600 and the bottom plate 604 are configured to be disposed in a first position in an unloaded state. The article of footwear 500 may also be adapted to a loaded state, such that the ground contact surface area is greater than the ground contact surface area of the unloaded state. The loaded state may exist when the internal space, i.e., a void or cavity, which is created by interior sides of the upper 504 and sole structure 508, receives a foot of a user, such that a downward force is applied onto the sole structure 508. The load varies according to the weight of the user and the motion of the user, e.g., standing, walking, running, jogging, jumping, leaning, pivoting, or other maneuvers. The top plate 600 and the bottom plate 604 are configured to be disposed in a second position in a loaded state. The downward force creates a loaded, or compressed state, which decreases the height of the sole structure 508 while simultaneously increasing the ground contact surface area of the bottom surface of the sole structure 508. As a result, the sole structure 508 transitions from a low-contact, curved profile to a more stable, high-contact configuration that enhances traction and energy absorption. In other words, the top plate 600 and the bottom plate 604 are configured to rotate toward one another about the flex axis when a load is applied, and the hinge 608 is configured to return the top plate 600 and the bottom plate 604 to the first position when the load is removed. In other words, when the article of footwear 500 is in an unloaded state, the outsole is cantilevered above a ground surface.
In other aspects, other configurations are possible. For example, certain features and combinations of features that are presented with respect to particular aspects in the discussion above can be utilized in other aspects and in other combinations, as appropriate. Further, any of the aspects described herein may be modified to include any of the structures or methodologies disclosed in connection with other aspects. Additionally, the present disclosure is not limited to articles of footwear of the type specifically shown. Still further, aspects of the articles of footwear of any of the aspects disclosed herein may be modified to work with any type of footwear, apparel, or other athletic equipment.
As noted previously, it will be appreciated by those skilled in the art that while the invention has been described above in connection with particular aspects and examples, the invention is not necessarily so limited, and that numerous other aspects, examples, uses, modifications and departures from the aspects, examples and uses are intended to be encompassed by the claims attached hereto. The entire disclosure of each patent and publication cited herein is incorporated by reference, as if each such patent or publication were individually incorporated by reference herein. Various features and advantages of the invention are set forth in the following claims.

INDUSTRIAL APPLICABILITY

Numerous modifications to the present invention will be apparent to those skilled in the art in view of the foregoing description. Accordingly, this description is to be construed as illustrative only and is presented for the purpose of enabling those skilled in the art to make and use the invention. The exclusive rights to all modifications which come within the scope of the appended claims are reserved.

Claims

We claim:

1. An article of footwear, comprising:

an upper attached to a sole structure;

a forefoot region, a midfoot region, and a heel region;

a longitudinal axis that intersects a toe end located in the forefoot region and a heel end located in the heel region, wherein a longitudinal direction is parallel with the longitudinal axis;

a plate comprising a top plate that is integrally joined to a bottom plate at a hinge, wherein the top plate has a first anterior end disposed adjacent a toe end of the sole structure and a first posterior end disposed within the heel region, wherein the bottom plate has a second anterior end disposed adjacent the toe end and a second posterior end disposed in the midfoot region; and

a gap that is defined between the top plate and the bottom plate, the gap extending from the hinge toward the first posterior end of the top plate, wherein a vertical distance of the gap is measured between the top plate and the bottom plate, and

wherein the top plate includes a convex portion in each of the heel region and the forefoot region.

2. The article of footwear of claim 1, wherein the hinge has a rear-facing wall that is curved between the top plate and the bottom plate.

3. The article of footwear of claim 1, wherein the vertical distance is greatest proximate the second posterior end of the bottom plate.

4. The article of footwear of claim 1, wherein the top plate includes a slot that extends continuously from the midfoot region through the first posterior end to define a lateral posterior leg and a medial posterior leg.

5. The article of footwear of claim 4, wherein the top plate includes a plurality of ridges extending from the forefoot region toward the heel region.

6. The article of footwear of claim 1, wherein the bottom plate defines a width between a lateral edge and a medial edge, and wherein the width is greater in the forefoot region than in the midfoot region.

7. The article of footwear of claim 1, wherein a midplane bisects the article of footwear between the heel end and the toe end, and wherein a center of mass point of the article of footwear is located between the toe end and the midplane.

8. The article of footwear of claim 1, wherein hinge defines a flex axis extending in a lateral-medial direction that is perpendicular to the longitudinal direction, and wherein the top plate and the bottom plate are configured to be disposed in a first position in an unloaded state.

9. The article of footwear of claim 8, wherein the top plate and the bottom plate are configured to rotate toward one another about the flex axis to a second position of the hinge when a load is applied, and wherein the hinge is configured to return the top plate and the bottom plate to the first position when the load is removed.

10. An article of footwear, comprising:

an upper attached to a sole structure;

a forefoot region including a toe end at a distal end of the forefoot region, a midfoot region, and a heel region including a heel end at a distal end of the heel region;

a plate having a top plate, a bottom plate, and a hinge located at a toe end of the plate, wherein the top plate and bottom plate diverge relative to one another to define a gap therebetween;

a midsole having an upper midsole cushion, an intermediate midsole cushion, and a lower midsole cushion having a top surface that is attached to the bottom plate, wherein the upper midsole cushion extends continuously from the forefoot region to the heel region, and wherein the intermediate midsole cushion includes a forefoot cushion and a heel cushion that has a forwardmost point spaced rearwardly of the forefoot cushion; and

an outsole attached to a bottom surface of the lower midsole cushion,

wherein the forefoot cushion includes a medial cushion pod and a lateral cushion pod that are arranged between the top plate and the bottom plate.

11. The article of footwear of claim 10, wherein a portion of an upper surface of each of the medial cushion pod and the lateral cushion pod is distanced from and not in contact with the top plate.

12. The article of footwear of claim 10, wherein an expansion zone is formed between the medial cushion pod and the lateral cushion pod, and wherein both the lateral cushion pod and the medial cushion pod are arranged to be collinear with a center of mass point of the article of footwear.

13. The article of footwear of claim 10, wherein the forefoot cushion is directly in contact with the top plate and the bottom plate.

14. The article of footwear of claim 10, wherein the bottom plate is at least partially recessed into the top surface of the lower midsole cushion.

15. The article of footwear of claim 14, wherein the bottom plate has a curved portion extending between a lateral edge and a medial edge, wherein the curved portion is convexly curved relative to the top plate.

16. The article of footwear of claim 10, wherein the top plate is at least partially recessed into a bottom surface of the upper midsole cushion.

17. An article of footwear, comprising:

an upper attached to a sole structure;

a plate including a top plate, a bottom plate, and a hinge located at a distal end of the plate in the forefoot region, wherein the top plate and bottom plate are integrally formed of a common material, and wherein the top plate includes a lateral ridge extending from the forefoot region to the heel region, a medial ridge extending from the forefoot region to the heel region, and a central ridge extending from the forefoot region to the midfoot region;

a gap that extends between the top plate and the bottom plate;

an upper midsole cushion that continuously extends from the forefoot region to the heel region and is positioned adjacent to and above the top plate;

an intermediate midsole cushion comprising a forefoot cushion and a heel cushion, wherein the forefoot cushion is disposed within the gap between the top plate and the bottom plate;

a lower midsole cushion that continuously extends from the forefoot region to the midfoot region, wherein the lower midsole cushion includes a top surface that contacts a bottom surface of the bottom plate; and

an outsole attached to a bottom surface of the heel cushion.

18. The article of footwear of claim 17, wherein the upper midsole cushion contacts the lower midsole cushion proximate the toe end and does not contact the intermediate midsole cushion.

19. The article of footwear of claim 17, wherein the upper midsole cushion includes a plurality of pockets arranged within at least the forefoot region and the heel region.

20. The article of footwear of claim 17, wherein, when the article of footwear is resting on a flat ground surface in an unloaded state, the outsole is cantilevered above the ground surface.