Articles of footwear and sole structures with pressure-mapped midsole topographies and inlaid outsoles
11357285 · 2022-06-14
Assignee
Inventors
- Darryl Matthews (Portland, OR, US)
- Dov Michael Lashmore (Milwaukie, OR, US)
- Can Eldem (Portland, OR, US)
Cpc classification
A43B13/22
HUMAN NECESSITIES
International classification
A43B13/22
HUMAN NECESSITIES
A43B13/12
HUMAN NECESSITIES
Abstract
Presented are footwear sole structures with pressure-mapped midsole topographies and inlaid wear-mitigating outsoles, methods for making/using such sole structures, and footwear fabricated with such sole structures. An article of footwear includes an upper for receiving and attaching to a foot of a user, and a sole structure attached to the upper for supporting thereon the user's foot. The sole structure includes a midsole that is formed with a first material having a first hardness, and an outsole that is mounted to the midsole and formed with a second material that is harder than the first material. The midsole has a ground-facing surface with multiple cavities, multiple channels interspersed with the cavities, and ground-contacting land segments that separate the cavities from the channels. The outsole is disposed in the channels and positioned between the cavities such that a ground-contacting outsole surface is substantially flush with the midsole's ground-contacting land segments.
Claims
1. A sole structure for an article of footwear, the sole structure comprising: a midsole with a sidewall and a ground-facing surface adjoining the sidewall, the sidewall defining an outer perimeter of the sole structure, and the ground-facing surface having a plurality of cavities, a plurality of channels adjacent the cavities, and ground-contacting land segments separating the cavities from the channels, the plurality of channels including multiple sidewall channel segments extending from the ground-facing surface and onto the sidewall; and an outsole attached to the midsole, the outsole disposed in the channels and positioned between the cavities such that a ground-contacting outsole surface is substantially flush with the ground-contacting land segments of the midsole, the outsole including multiple outsole segments disposed in the sidewall channel segments of the midsole.
2. The sole structure of claim 1, further comprising a plurality of fasteners extending through the outsole segments and into the sidewall channel segments, the fasteners being interference fit with pockets in the sidewall of the midsole.
3. The sole structure of claim 1, wherein the plurality of channels includes a chain of elongated channel segments substantially parallel to each other and interconnected by multiple linking channel segments.
4. The sole structure of claim 3, wherein first and second ones of the linking channel segments are interposed between and substantially orthogonal to first and second ones of the elongated channel segments.
5. The sole structure of claim 1, wherein the plurality of channels includes multiple elongated channel segments substantially parallel to each other and obliquely angled with respect to a longitudinal centerline extending lengthwise through forefoot, hindfoot and midfoot regions of the midsole.
6. The sole structure of claim 1, wherein the plurality of channels includes first and second elongated channel segments extending from a medial side of the sole structure to a lateral side of the sole structure.
7. The sole structure of claim 1, wherein the plurality of channels includes a first elongated channel segment having a first length and a first plan-view profile, and a second elongated channel segment having a second length and a second plan-view profile distinct from the first length and the first plan-view profile, respectively, of the first elongated channel.
8. The sole structure of claim 7, wherein the first plan-view profile has a first width that varies along the first length of the first channel segment, and the second plan-view profile has a second width that varies along the second length of the second channel segment.
9. The sole structure of claim 1, wherein the plurality of channels includes first and second elongated channel segments substantially parallel to each other, and the plurality of cavities includes first and second elongated cavities substantially parallel to each other and interleaved with the first and second elongated channel segments.
10. The sole structure of claim 1, wherein the plurality of channels includes discrete forefoot and hindfoot channels located in forefoot and hindfoot regions, respectively, of the midsole, and wherein the outsole includes discrete forefoot and hindfoot outsole segments disposed in the forefoot and hindfoot channels, respectively, of the midsole.
11. The sole structure of claim 10, wherein the plurality of cavities includes midfoot cavities located in a midfoot region of the midsole between the forefoot and hindfoot regions, the midfoot region of the midsole being characterized by a lack of a ground-contacting outsole.
12. The sole structure of claim 10, wherein the plurality of cavities includes discrete forefoot and hindfoot cavities located in the forefoot and hindfoot regions, respectively, of the midsole and exposed through the forefoot and hindfoot outsole segments, respectively.
13. The sole structure of claim 1, wherein the plurality of cavities includes a first elongated cavity having a first length and a first plan-view profile, and a second elongated cavity having a second length and a second plan-view profile distinct from the first length and the first plan-view profile, respectively, of the first elongated cavity.
14. The sole structure of claim 13, wherein the first plan-view profile has a first width that varies along the first length of the first elongated cavity, and the second plan-view profile has a second width that varies along the second length of the second elongated cavity.
15. The sole structure of claim 1, wherein the plurality of cavities includes a first elongated cavity having a first undulating base with a first depth that varies along a first length of the first elongated cavity, and a second elongated cavity having a second undulating base with a second depth that varies along a second length of the second elongated cavity.
16. The sole structure of claim 1, wherein the midsole further includes multiple pockets, the sole structure further comprising multiple fasteners extending through the outsole and interference fitting with the pockets of the midsole, each of the fasteners including a ground-contacting head portion that protrudes from the ground-contacting outsole surface.
17. The sole structure of claim 16, wherein the plurality of channels includes a first elongated channel segment substantially parallel to a second elongated channel segment, the plurality of fasteners including a first rows of fasteners extending into the first elongated channel segment and a second rows of fasteners extending into the second elongated channel segment.
18. The sole structure of claim 1, wherein the midsole is molded as a single-piece structure from a polymer foam, and wherein the outsole is molded as a bipartite structure from a synthetic rubber.
19. The sole structure of claim 1, wherein the midsole is formed with a first material having a first hardness, and the outsole is formed with a second material having a second hardness distinct from the first hardness.
20. The sole structure of claim 1, wherein the plurality of channels includes multiple mutually parallel elongated channels, and the plurality of cavities includes multiple mutually parallel elongated cavities interleaved with and substantially parallel to the mutually parallel elongated channels.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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(6) The present disclosure is amenable to various modifications and alternative forms, and some representative embodiments are shown by way of example in the drawings and will be described in detail herein. It should be understood, however, that the novel aspects of this disclosure are not limited to the particular forms illustrated in the above-enumerated drawings. Rather, the disclosure is to cover all modifications, equivalents, combinations, subcombinations, permutations, groupings, and alternatives falling within the scope of this disclosure as encompassed by the appended claims.
DETAILED DESCRIPTION
(7) This disclosure is susceptible of embodiment in many different forms. Representative examples of the disclosure are shown in the drawings and will be described in detail herein with the understanding that these representative examples are provided as an exemplification of the disclosed principles, not limitations of the broad aspects of the disclosure. To that extent, elements and limitations that are described in the Abstract, Technical Field, Background, Summary, and Detailed Description sections, but not explicitly set forth in the claims, should not be incorporated into the claims, singly or collectively, by implication, inference or otherwise.
(8) For purposes of the present detailed description, unless specifically disclaimed: the singular includes the plural and vice versa; the words “and” and “or” shall be both conjunctive and disjunctive; the words “any” and “all” shall both mean “any and all”; and the words “including,” “comprising,” “having,” “containing,” and the like shall each mean “including without limitation.” Moreover, words of approximation, such as “about,” “almost,” “substantially,” “approximately,” and the like, may be used herein in the sense of “at, near, or nearly at,” or “within 0-5% of,” or “within acceptable manufacturing tolerances,” or any logical combination thereof, for example. Lastly, directional adjectives and adverbs, such as fore, aft, medial, lateral, proximal, distal, vertical, horizontal, front, back, left, right, etc., may be with respect to an article of footwear when worn on a user's foot and operatively oriented with a ground-engaging portion of the sole structure seated on a flat surface, for example.
(9) Referring now to the drawings, wherein like reference numbers refer to like features throughout the several views, there is shown in
(10) The representative article of footwear 10 is generally depicted in
(11) With reference again to
(12) The upper 12 portion of the footwear 10 may be fabricated from any one or combination of a variety of materials, such as textiles, engineered foams, polymers, natural and synthetic leathers, etc. Individual segments of the upper 12, once cut to shape and size, may be stitched, adhesively bonded, fastened, welded or otherwise joined together to form an interior void for comfortably receiving a foot. The individual material elements of the upper 12 may be selected and located with respect to the footwear 10 in order to impart desired properties of durability, air-permeability, wear-resistance, flexibility, appearance, and comfort, for example. An ankle opening 15 in the rear quarter 12C of the upper 12 provides access to the interior of the shoe 10. A shoelace 20, strap, buckle, or other conventional mechanism may be utilized to modify the girth of the upper 12 to more securely retain the foot within the interior of the shoe 10 as well as to facilitate entry and removal of the foot from the upper 12. Shoelace 20 may be threaded through a series of eyelets 16 in or attached to the upper 12; the tongue 18 may extend between the lace 20 and the interior void of the upper 12.
(13) Sole structure 14 is rigidly secured to the upper 12 such that the sole structure 14 extends between the upper 12 and a support surface upon which a user stands. In effect, the sole structure 14 functions as an intermediate support platform that separates and protects the user's foot from the ground. In addition to attenuating ground reaction forces and providing cushioning for the foot, sole structure 14 of
(14) With collective reference to
(15) To enhance underfoot comfort for a variety of discrete gate movements during use of the footwear 10, while concomitantly enhancing ground-reaction-force attenuation, increasing energy return, and minimizing shoe weight, the midsole's topography is provided with an engineered pattern of channels and cavities, the shapes, depths, locations, orientations and mean densities of which are designed to coincide with pressure zones identified through sensor-generated pressure map data. A normative population of individuals were provided with athletic shoes retrofit with a distributed array of sensors in the sock liner. These individuals underwent pressure-map testing throughout a full day of use to chart the points along the plantar region of the foot that experiences the largest and smallest magnitudes of pressure from walking, running, frequent lateral maneuvers, and the like. The aforementioned topology parameters of the midsole were then derived through algebraic tiles applied to the resultant pressure map data to create a patterned midsole that allocates polymer foam density according to pressure magnitude distribution.
(16) Outwardly facing surfaces of the midsole 24, including the laterally and rearwardly-facing surfaces of the midsole sidewall 28 and the ground-facing surface of the midsole base 30, are formed with an assortment of recessed cavities 32 intermixed with an assortment of open channels 34. Separating the cavities 32 and the channels 34 are ground-contacting land segments 36 of varying shape, size and orientation that are coterminous with the cavities 32 and channels 34. The cavities 32 are mapped to predetermined sections of sole structure 14 that coincide with reduced-magnitude pressure zones of the user's plantar region. To do so, however, may require each cavity 32 have a distinct shape from every other cavity 32. In the same vein, the channels 34 are mapped to predetermined sections of sole structure 14 that coincide with increased-magnitude pressure zones of the plantar region; this necessitates each channel 34 have a distinct shape from every other channel 34. As a result of the distinctly shaped cavities 32 and channels 34, each land segment 36 may have a distinct shape from every other land segment 36. For at least some implementations, the outsole 26 substantially fills the midsole channels 34; in so doing, segments of the outsole 26 will share the shape and dimensions of the corresponding midsole channel 34 in which they fill. The nuanced geometries of the midsole's surface features and the outsole's channel-filling elements will be described in further detail hereinbelow.
(17) In accord with the illustrated example, the midsole 24 may include one or more continuous chains of elongated channel segments. As seen in
(18) It is desirable, for at least some configurations, to allocate the largest concentrations of the midsole 24 and outsole 26 at regions of the sole structure 14 that have been determined to coincide with increased-magnitude pressure zones of the plantar region, while contemporaneously minimizing or eliminating the respective volumes of midsole 24 and outsole 26 at regions of the sole structure 14 that have been determined to coincide with decreased-magnitude pressure zones of the plantar region. In order to realize this structural configuration, each segment of the midsole's discrete channel series 34A, 34B may have a distinct shape, orientation and set of dimensions. Each plume segment 40 of the hindfoot channel series 34B of
(19) Similar to the geometries of the forefoot and hindfoot channel series 34A, 34B, the midsole's recessed cavities 32 may each have a respective irregular shape and corresponding set of dimensions that are distinct from the shapes and dimensions of all other cavities 32. Looking once again to
(20) A further option may include varying the configurations of the cavities 32 based on their placement with respect to the sole structure 14. In accord with the representative article of footwear 10, for example, the midsole 24 is fabricated with forefoot cavities 32A located in the forefoot region R.sub.FF of the sole structure 14, hindfoot cavities 32B located in the hindfoot region R.sub.HF of the sole structure 14, and midfoot cavities 32C located in the midfoot region R.sub.MF of the sole structure 14. Many of the forefoot cavities 32A of
(21) As indicated above, footwear 10 employs a midsole 24 that may be formed, in whole or in part, from a polymer foam composition that provides enhanced ground-reaction force attenuation while providing a softer feel with increased energy return. Such foam compositions, however, may result in a less-than-desirable durability with diminished resistance to normal wear and tear resulting from use of the footwear 10. To help improve the overall durability and resilience of the sole structure 14 without unduly increasing materials costs and shoe weight, the wear-resistant outsole 26 if fabricated as a bipartite structure with a forefoot outsole segment 26A that is longitudinally spaced from a hindfoot outsole segment 26B, each of which is disposed in and substantially fills a respective one of the forefoot and hindfoot channel series 34A, 34B. Each segment 26A and 26B of the outsole 26 is interspersed with a respective subset of the cavities 32A, 32B such that bottom-most, ground-contacting surfaces of the outsole 26 are substantially flush with the ground-contacting land segments 36 of the midsole 24, as seen in
(22) By substantially filling the forefoot and hindfoot channel series 34A, 34B of the midsole 24 with the forefoot and hindfoot segments 26A, 26B of the outsole 26, respectively, the outsole segments 26A, 26B take on the shapes and dimensions of their corresponding midsole channel series 34A, 34B. For instance, the forefoot outsole segment 26B of
(23) The sole structure 14 of
(24) Aspects of the present disclosure have been described in detail with reference to the illustrated embodiments; those skilled in the art will recognize, however, that many modifications may be made thereto without departing from the scope of the present disclosure. The present disclosure is not limited to the precise construction and compositions disclosed herein; any and all modifications, changes, and variations apparent from the foregoing descriptions are within the scope of the disclosure as defined by the appended claims. Moreover, the present concepts expressly include any and all combinations and subcombinations of the preceding elements and features.