A cushioning article comprises a first and a second polymeric sheet bonded to one another and enclosing an interior cavity. The polymeric sheets retain a gas in the interior cavity. A tensile component disposed in the interior cavity includes a first tensile layer, a second tensile layer, and a plurality of tethers spanning the interior cavity and connecting the first tensile layer to the second tensile layer. An inwardly-protruding bond joins the first polymeric sheet to the first tensile layer, protrudes inward from the first polymeric sheet toward the second polymeric sheet, and partially traverses the plurality of tethers. The first polymeric sheet is displaced from the first tensile layer adjacent to the inwardly-protruding bond by the gas. A method of manufacturing a cushioning article is disclosed.

Disclosed herein are methods, apparatus and computer program products for use in manufacturing an anatomical protective item for one or more users. Embodiments of anatomical protective items may comprise a single layer of energy controlling cells. Input data associated with one or more users is obtained. The obtained input data is processed to identify one or more energy controlling criteria for the anatomical protective item. A packing process is employed to generate each energy controlling cell in the single layer. Each energy controlling cell comprises one or more walls which extend from an upper surface of the single layer to a lower surface of the single layer. The packing process is performed at least on the basis of the identified one or more energy controlling criteria. The anatomical protective item comprising the single layer of energy controlling cells is manufactured.

An orthotic footwear system including a removable outsole, a removable reinforced hollow midsole attached to the top of the outsole, and a removable insole attached to the top of the midsole. A removable metatarsal pad can be attached to the top of the insole, and removable support inserts can be attached around the insole for additional support of problematic areas. Support inserts can be used to support the arch area, the heel area, or both. Each of the removable parts can be interchanged with parts of the same type having different ergonomic characteristics. The user can change the parts of the orthotic to suit their needs. Further, the support inserts can be used apart from the rest of the system, with any insole configured to receive them.

Ground-engaging components for articles of footwear include: (a) an outer perimeter boundary rim that at least partially defines an outer perimeter of the ground-engaging component, wherein the outer perimeter boundary rim defines an open space at least at a forefoot support area of the ground-engaging component; and (b) a matrix structure extending at least partially across the open space at least at the forefoot support area to define an open cellular construction with plural open cells in the open space at least at the forefoot support area. A plurality of these open cells of the open cellular construction have openings with curved perimeters and no distinct corners. Additional aspects of this invention relate to ground-engaging components that are very lightweight yet very stiff, particularly in the forefoot support area. Two or more sizes of the ground-engaging components may be provided with substantially constant forefoot stiffness (optionally substantially constant over a size run).

Provided are footbeds having multiple points of contact and varying compression rates for use in articles of footwear. In one embodiment, a footbed may include apertures (for example, ovals) arranged in a varying grid density. In another embodiment, a footbed may include a lattice having edges that define polygons arranged in a constant grid density. In another embodiment, a footbed may include a lattice having edges that define polygons arranged in a constant grid density and having protruding structures within each polygon.

A sole structure for an article of footwear comprises a midsole system with a plurality of cushioning units, each having multiple cushioning layers configured to work together as a system to absorb a compressive load, such as a dynamic compressive load due to impact with the ground, in stages of progressive cushioning according to the relative stiffness values of the layers. Various midsole systems disclosed include isolated cushioning units, linked cushioning units, sole layers having stanchions interfacing with the midsole system, midsole systems with sole layers having keyed and unkeyed portions overlying a bladder, and midsole systems with vertically-stacked cushioning units disposed in inverted relationship to one another.

A sole structure for an article of footwear comprises a midsole coupled to an outsole. The midsole comprises a plurality of sipes on a first side and a plurality of sipes on a second side opposite the first side. The sipes partition portions of the midsole body into impact attenuation cells on the first and second sides of the midsole. The second side of the midsole further comprises a plurality of grooves and a plurality of protruding members separated by the grooves. The protruding members extend from a midsole body towards the outsole when the midsole is coupled to the outsole, spacing the midsole body apart from the outsole. When coupled together, the midsole and the outsole form voids at the grooves. The grooves, protruding members, and sipes provide increased flexibility to the midsole even when the midsole is coupled to the outsole.

A breathable shoe, including an outsole arranged below a structural insert that is at least partially breathable, and below an upper. The outsole is at least partially breathable, including at least one sheet-like breathable element defined by a plurality of granules made of expanded material and having a uniform size, arranged in a substantially ordered manner and between which there are voids that form one or more channels through the breathable element that are permeable to air and/or vapor.

A three-dimensional structure according to the present invention is a three-dimensional structure defined by X, Y, and Z directions, including: a body portion in which a plurality of through holes extending in the X direction are disposed in alignment in at least one of the Y and Z directions; and a partition portion that is provided in at least one of the through holes and that partitions the through hole in at least one location in an axial direction of the through hole, wherein the three-dimensional structure is formed by a rubber composition.

Improved soles and insoles for shoes, in particular sports shoes, are described. In an aspect, a sole for a shoe, in particular a sports shoe, with at least a first and a second surface region is provided. The first surface region comprises expanded thermoplastic polyurethane (TPU). The second surface region is free from expanded TPU.