US20220125160A1 - Sole structure having an outsole with integrated traction elements - Google Patents

Abstract

A sole structure including an outsole and a midsole disposed over the outsole. The outsole includes an outsole plate and a plurality of traction elements molded to the outsole plate. Each of the plurality of traction elements includes a plurality of overhangs. Each of the plurality of overhangs is cantilevered from the outsole plate. The midsole includes a plurality of discrete pods. Each of the plurality of discrete pods includes a midsole fluid-filled bladder. The midsole fluid-filled bladder defines an interior cavity and includes a first polymeric layer, a second polymeric layer, and a plurality of midsole tethers interconnecting the first polymeric layer and the second polymeric layer. Each of the plurality of midsole tethers is disposed in the interior cavity of the midsole fluid-filled bladder. Each of the plurality of discrete pods is disposed over and aligned with one of the plurality of traction elements.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS
• This application claims priority to, and the benefit of, U.S. Provisional Patent Application 63/104,617, filed on Oct. 23, 2020, the entire disclosure of which is hereby incorporated by reference.
TECHNICAL FIELD
• The present teachings generally relate to a sole structure for an article of footwear and, more particularly, to a footwear sole structure having an outsole with integrated traction elements.
BACKGROUND
• This section provides background information related to the present disclosure which is not necessarily prior art.
• Articles of footwear include an upper and a sole structure. The upper may be formed from any suitable material(s) to receive, secure, and support a foot on the sole structure. The upper may cooperate with laces, straps, or other fasteners to adjust the fit of the upper around the foot. A bottom portion of the upper, proximate to a bottom surface of the foot, attaches to the sole structure.
• Sole structures include a layered arrangement extending between a ground surface and the upper. One layer of the sole structure includes an outsole that provides abrasion-resistance and traction with the ground surface. The outsole may be formed from rubber or other materials that impart durability and wear-resistance, as well as enhancing traction with the ground surface. Another layer of the sole structure includes a midsole disposed between the outsole and the upper. The midsole provides cushioning for the foot and is at least partially formed from a polymer foam material that compresses resiliently under an applied load to cushion the foot by attenuating ground-reaction forces. The midsole may define a bottom surface on one side that opposes the outsole and a footbed on the opposite side that may be contoured to conform to a profile of the bottom surface of the foot. Sole structures may also include a comfort-enhancing insole or a sockliner located within a void proximate to the bottom portion of the upper.
• The metatarsophalangeal (MTP) joint of the foot is known to absorb energy as it flexes through dorsiflexion during running movements. As the foot does not move through plantarflexion until the foot is pushing off of a ground surface, the MTP joint returns little of the energy it absorbs to the running movement and, thus, is the source of an energy drain during running movements. Embedding flat and rigid plates having longitudinal stiffness within a sole structure increases the overall stiffness thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
• FIG. 1 is a schematic illustration in lateral side view of an article of footwear.
• FIG. 2 is a schematic illustration in exploded, rear view of the article of footwear shown inFIG. 1.
• FIG. 3 is a schematic illustration in an exploded, lateral view of the article of footwear ofFIG. 1, including an upper and a sole structure.
• FIG. 4 is a schematic illustration in perspective view of the sole structure of the article of footwear shown inFIG. 3, taken along section line4-4 ofFIG. 3.
• FIG. 5 is a schematic illustration in perspective, rear view of an outsole of the sole structure of the article of footwear ofFIG. 3.
• FIG. 6 is a schematic illustration in bottom view of the outsole of the sole structure of the article of footwear ofFIG. 1.
• FIG. 7 is a schematic illustration in rear view of the outsole of the sole structure ofFIG. 3.
• FIG. 8 is a schematic illustration in front view of the outsole of the sole structure ofFIG. 3.
• FIG. 9 is a schematic illustration in top view of the outsole of the sole structure ofFIG. 3.
• FIG. 10 is a schematic illustration in top view of a strobel board of the sole structure shown inFIG. 3.
• FIG. 11 is a schematic illustration in cross-sectional side view of the strobel board ofFIG. 10, taken along section line11-11 ofFIG. 10.
• FIG. 12 is a flowchart of the outsole of the sole structure shown inFIG. 3.
• FIG. 13 is a schematic illustration in cross-sectional view of a mold including a mold body, a mold cavity, and inserts inside the mold cavity.
DESCRIPTION
• The present disclosure describes an article of footwear. In an aspect of the present disclosure, the sole structure includes an outsole including an outsole plate and a plurality of traction elements molded to the outsole plate. Each of the plurality of traction elements includes a plurality of overhangs, each of the plurality of overhangs is cantilevered from the outsole plate. The sole structure further includes a midsole disposed over the outsole. The midsole includes a plurality of discrete pods. Each of the plurality of discrete pods includes a midsole fluid-filled bladder. The midsole fluid-filled bladder defines an interior cavity. The midsole fluid-filled bladder includes a first polymeric layer, a second polymeric layer, and a plurality of midsole tethers interconnecting the first polymeric layer and the second polymeric layer, each of the plurality of midsole tethers is disposed in the interior cavity of the midsole fluid-filled bladder. Each of the plurality of discrete pods is disposed over and aligned with one of the plurality of traction elements to maximize an energy efficiency of the sole structure.
• The outsole may be made of thermoplastic polyurethane. The thermoplastic polyurethane has a hardness measured in Shore A. The hardness of the thermoplastic polyurethane may be between 85 and 95 to promote flexion of the sole structure. The sole structure may further include a foam layer and a strobel disposed over the foam layer. The foam layer may be disposed between the strobel and the plurality of discrete pods. The strobel may include a strobel fluid-filled bladder, and the strobel fluid-filled bladder includes a first strobel layer, a second strobel layer, and a plurality of strobel tethers interconnecting the first strobel layer and the second strobel layer.
• The plurality of traction elements may include solely three traction elements. The outsole has a forefoot region, a heel region, and a midfoot region disposed between the forefoot region and the heel region. The plurality of traction elements may solely include a first forefoot traction element, a second forefoot traction element, and a heel traction element. The first forefoot traction element and the second forefoot traction element are disposed in the forefoot region of the outsole. The heel traction element is disposed in the heel region of the outsole. None of the plurality of traction elements is disposed in the midfoot region of the outsole.
• The heel traction element may cover a majority of the heel region of the outsole, and the heel traction element is larger than the first forefoot traction element and the second forefoot traction element. The adjacent overhangs of the plurality of overhangs of each of the plurality of traction elements may be spaced apart from one another by a void. The void between the adjacent overhangs may define an acute angle from one of the adjacent overhangs to another of the adjacent overhangs to facilitate flexion along predefined flex lines.
• In an aspect of the present disclosure, an article of footwear includes an upper and a sole structure coupled to the upper. The sole structure includes an outsole including an outsole plate and a plurality of traction elements molded to the outsole plate. Each of the plurality of traction elements includes a plurality of overhangs. Each of the plurality of overhangs is cantilevered from the outsole plate. The sole structure further includes a midsole disposed over the outsole. The midsole includes a plurality of discrete pods. Each of the plurality of discrete pods includes a midsole fluid-filled bladder. The midsole fluid-filled bladder defines an interior cavity. The midsole fluid-filled bladder includes a first polymeric layer and a second polymeric layer. The midsole includes a plurality of midsole tethers interconnecting the first polymeric layer and the second polymeric layer. Each of the plurality of midsole tethers is disposed in the interior cavity of the midsole fluid-filled bladder. Each of the plurality of discrete pods is disposed over and aligned with one of the plurality of traction elements to maximize the energy efficiency of the sole structure.
• The outsole may be made of thermoplastic polyurethane. The thermoplastic polyurethane has a hardness measured in Shore A. The hardness of the thermoplastic polyurethane is between 85 and 95 to promote flexion of the sole structure. The article of footwear may further include a foam layer and a strobel disposed over the foam layer. The foam layer is disposed between the strobel and the plurality of discrete pods.
• The strobel may include a strobel fluid-filled bladder. The strobel fluid-filled bladder may include a first strobel layer, a second strobel layer, and a plurality of strobel tethers interconnecting the first strobel layer and the second strobel layer.
• The article of footwear may further a string having a first string terminus and a second string terminus opposite the first string terminus. The first string terminus is directly coupled to the midsole, and the second string terminus is configured to be directly coupled to an upper.
• The plurality of traction elements may solely include three traction elements. The outsole has a forefoot region, a heel region, and a midfoot region disposed between the forefoot region and the heel region. The plurality of traction elements may solely include a first forefoot traction element, a second forefoot traction element, and a heel traction element. The first forefoot traction element and the second forefoot traction element are disposed in the forefoot region of the outsole. The heel traction element may be disposed in the heel region of the outsole. None of the plurality of traction elements is disposed in the midfoot region of the outsole.
• The heel traction element may cover a majority of the heel region of the outsole. The heel traction element is larger than the first forefoot traction element and the second forefoot traction element. Adjacent overhangs of the plurality of overhangs of each of the plurality of traction elements may be spaced apart from one another by a void. The void between the adjacent overhangs may define an acute angle from one of the adjacent overhangs to another of the adjacent overhangs to facilitate flexion along predefined flex lines.
• The present disclosure also describes a method of manufacturing an outsole. The method includes injecting a molten polymeric material into a mold cavity of a mold. The mold includes a mold body and a plurality of inserts detachably coupled to the mold body. The mold body defines the mold cavity. The mold cavity is shaped as the outsole. The plurality of inserts is shaped to form a plurality of gaps between an outsole plate of the outsole and each of a plurality of traction elements of the outsole. The method further includes cooling the polymeric material until the polymeric material solidifies and removing the plurality of inserts from the polymeric material after the polymeric material solidifies to form the plurality of gaps.
• Removing the plurality of inserts may include hand picking the inserts from the polymeric material after the polymeric material solidifies. Removing the plurality of inserts may include applying a magnetic field toward the plurality of inserts to withdraw the plurality of inserts from the polymeric material after the polymeric material solidifies.
• The present disclosure also describes a sole structure including an outsole. The outsole has a forefoot region, a heel region, and a midfoot region disposed between the forefoot region and the heel region. The outsole includes an outsole plate and a plurality of traction elements molded to the outsole plate. Each of the plurality of traction elements includes a plurality of overhangs. Each of the plurality of overhangs is cantilevered from the outsole plate. The plurality of traction elements may include at least a first forefoot traction element, a second forefoot traction element, and a heel traction element. The first forefoot traction element and the second forefoot traction element are disposed in the forefoot region of the outsole, and the heel traction element is disposed in the heel region of the outsole.
• The outsole may be made of thermoplastic polyurethane. The thermoplastic polyurethane has a hardness measured in Shore A, and the hardness of the thermoplastic polyurethane may be between 85 and 95 to promote flexion of the sole structure.
• Adjacent overhangs of the plurality of overhangs of each of the plurality of traction elements may be spaced apart from one another by a void. The void between the adjacent overhangs may define an acute angle from one of the adjacent overhangs to another of the adjacent overhangs to facilitate flexion along predefined flex lines. The heel traction element may cover the majority of the heel region of the outsole, and the heel traction element is larger than the first forefoot traction element and the second forefoot traction element. The outsole plate may extend through the forefoot region, the heel region, and the midfoot region of the outsole.
• The above features and advantages and other features and advantages of the present teachings are readily apparent from the following detailed description of the modes for carrying out the present teachings when taken in connection with the accompanying drawings.
• Example configurations will now be described more fully with reference to the accompanying drawings. Example configurations are provided so that this disclosure will be thorough, and will fully convey the scope of the disclosure to those of ordinary skill in the art. Specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of configurations of the present disclosure. It will be apparent to those of ordinary skill in the art that specific details need not be employed, that example configurations may be embodied in many different forms, and that the specific details and the example configurations should not be construed to limit the scope of the disclosure.
• To assist and clarify the description of various embodiments, various terms are defined herein. Unless otherwise indicated, the following definitions apply throughout this specification (including the claims). Additionally, all references referred to are incorporated herein in their entirety.
• An “article of footwear”, a “footwear article of manufacture”, and “footwear” may be considered to be both a machine and a manufacture. Assembled, ready to wear footwear articles (e.g., shoes, sandals, boots, etc.), as well as discrete components of footwear articles (such as a midsole, an outsole, an upper component, etc.) prior to final assembly into ready to wear footwear articles, are considered and alternatively referred to herein in either the singular or plural as “article(s) of footwear” or “footwear”.
• “A”, “an”, “the”, “at least one”, and “one or more” are used interchangeably to indicate that at least one of the items is present. A plurality of such items may be present unless the context clearly indicates otherwise. All numerical values of parameters (e.g., of quantities or conditions) in this specification, unless otherwise indicated expressly or clearly in view of the context, including the appended claims, are to be understood as being modified in all instances by the term “about” whether or not “about” actually appears before the numerical value. “About” indicates that the stated numerical value allows some slight imprecision (with some approach to exactness in the value; approximately or reasonably close to the value; nearly). If the imprecision provided by “about” is not otherwise understood in the art with this ordinary meaning, then “about” as used herein indicates at least variations that may arise from ordinary methods of measuring and using such parameters. As used in the description and the accompanying claims, unless stated otherwise, a value is considered to be “approximately” equal to a stated value if it is neither more than 5 percent greater than nor more than 5 percent less than the stated value. In addition, a disclosure of a range is to be understood as specifically disclosing all values and further divided ranges within the range.
• The terms “comprising”, “including”, and “having” are inclusive and therefore specify the presence of stated features, steps, operations, elements, or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, or components. Orders of steps, processes, and operations may be altered when possible, and additional or alternative steps may be employed. As used in this specification, the term “or” includes any one and all combinations of the associated listed items. The term “any of” is understood to include any possible combination of referenced items, including “any one of” the referenced items. The term “any of” is understood to include any possible combination of referenced claims of the appended claims, including “any one of” the referenced claims.
• For consistency and convenience, directional adjectives may be employed throughout this detailed description corresponding to the illustrated embodiments. Those having ordinary skill in the art will recognize that terms such as “above”, “below”, “upward”, “downward”, “top”, “bottom”, etc., may be used descriptively relative to the figures, without representing limitations on the scope of the invention, as defined by the claims.
• The term “longitudinal” refers to a direction extending along a length of a component. For example, a longitudinal direction of an article of footwear extends between a forefoot region and a heel region of the article of footwear. The term “forward” or “anterior” is used to refer to the general direction from a heel region toward a forefoot region, and the term “rearward” or “posterior” is used to refer to the opposite direction, i.e., the direction from the forefoot region toward the heel region. In some cases, a component may be identified with a longitudinal axis as well as a forward and rearward longitudinal direction along that axis. The longitudinal direction or axis may also be referred to as an anterior-posterior direction or axis.
• The term “transverse” refers to a direction extending along a width of a component. For example, a transverse direction of an article of footwear extends between a lateral side and a medial side of the article of footwear. The transverse direction or axis may also be referred to as a lateral direction or axis or a mediolateral direction or axis.
• The term “vertical” refers to a direction generally perpendicular to both the lateral and longitudinal directions. For example, in cases where a sole structure is planted flat on a ground surface, the vertical direction may extend from the ground surface upward. It will be understood that each of these directional adjectives may be applied to individual components of a sole structure. The term “upward” or “upwards” refers to the vertical direction pointing towards a top of the component, which may include an instep, a fastening region, and/or a throat of an upper. The term “downward” or “downwards” refers to the vertical direction pointing opposite the upwards direction, toward the bottom of a component and may generally point towards the bottom of a sole structure of an article of footwear.
• The “interior” of an article of footwear, such as a shoe, refers to portions at the space that is occupied by a wearer's foot when the article of footwear is worn. The “inner side” of a component refers to the side or surface of the component that is (or will be) oriented toward the interior of the component or article of footwear in an assembled article of footwear. The “outer side” or “exterior” of a component refers to the side or surface of the component that is (or will be) oriented away from the interior of the article of footwear in an assembled article of footwear. In some cases, other components may be between the inner side of a component and the interior in the assembled article of footwear. Similarly, other components may be between an outer side of a component and the space external to the assembled article of footwear. Further, the terms “inward” and “inwardly” refer to the direction toward the interior of the component or article of footwear, such as a shoe, and the terms “outward” and “outwardly” refer to the direction toward the exterior of the component or article of footwear, such as the shoe. In addition, the term “proximal” refers to a direction that is nearer a center of a footwear component, or is closer toward a foot when the foot is inserted in the article of footwear as it is worn by a user. Likewise, the term “distal” refers to a relative position that is further away from a center of the footwear component or is further from a foot when the foot is inserted in the article of footwear as it is worn by a user. Thus, the terms proximal and distal may be understood to provide generally opposing terms to describe relative spatial positions.
• The terminology used herein is for the purpose of describing particular exemplary configurations only and is not intended to be limiting. As used herein, the singular articles “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of features, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and/or groups thereof. The method, steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. Additional or alternative steps may be employed.
• When an element or layer is referred to as being “on,” “engaged to,” “connected to,” “attached to,” or “coupled to” another element or layer, it may be directly on, engaged, connected, attached, or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” “directly attached to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.
• 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.
• Referring toFIGS. 1-3, an article offootwear100 may be a golf shoe and includes an upper102 and asole structure200, which is partially formed by the upper102. The article of footwear100 (and its components, such as the upper102 and the sole structure200) may be divided into one or more portions. The portions may include aforefoot portion12, amidfoot portion14, and aheel portion16. Theforefoot portion12 may correspond with toes and joints connecting metatarsal bones with phalanx bones of a foot during use of thefootwear100. Theforefoot portion12 may correspond with the metatarsophalangeal (MTP) joint of the foot. Themidfoot portion14 may correspond with an arch area of the foot, and theheel portion16 may correspond with rear portions of the foot, including a calcaneus bone, during use of the article offootwear100. Thefootwear100 may include lateral andmedial sides18,20, respectively, corresponding with opposite sides of thefootwear100 and extending through theportions12,14,16.
• The upper102 includes interior surfaces that define an interior void103 (FIG. 2) that receives and secures a foot for support on thesole structure200, during use of the article offootwear100. Anankle opening104 in theheel portion16 may provide access to theinterior void103. For example, theankle opening104 may receive a foot to secure the foot within theinterior void103 and facilitate entry and removal of the foot to and from theinterior void103. In some examples, one ormore fasteners106 extend along the upper102 to adjust a fit of theinterior void103 around the foot while concurrently accommodating entry and removal of the foot therefrom. The upper102 may include apertures such as eyelets and/or other engagement features such as fabric or mesh loops that receive thefasteners106. Thefasteners106 may include laces, straps, cords, hook-and-loop, or any other suitable type of fastener. For example, thefasteners106 include flexible laces, and the upper102 further includes a retainingtube107 coupled to the fasteners106 (e.g., laces). During use, the wearer of the article offootwear100 can pull the retainingtube107 to adjust and tighten thefasteners106.
• The upper102 may also include aheel cup115 at theheel portion16 to support the heel of the footwear user. The upper102 may include atongue portion110 that extends between theinterior void103 and thefasteners106. The upper102 may be formed from one or more materials (i.e., the upper material) that are stitched or adhesively bonded together to form theinterior void103. Suitable materials of the upper may include, but are not limited, textiles, fabrics, foam, leather, and synthetic leather. The materials may be selected and located to impart properties of durability, air-permeability, wear-resistance, flexibility, and comfort. For example, the upper102 may be wholly or partially made of a waterproof knitted textile to protect the wearer's foot from moisture.
• Thesole structure200 is secured to the upper102 and is spaced apart from the upper102 along a vertical direction VT. Thesole structure200 may include amidsole202 for providing cushioning to the footwear user. To this end, themidsole202 may be made of a polymeric material, such as rubber or foam. As a non-limiting example, themidsole202 may be wholly or partially made of an ethylene-vinyl acetate (EVA) foam to enhance cushioning of thesole structure200. Themidsole202 may continuously extend along theforefoot portion12, themidfoot portion14, and theheel portion16 to provide cushioning to the entire foot of the footwear wearer.
• As a non-limiting example, themidsole202 may include afoam layer204 extending through theforefoot portion12, themidfoot portion14, and theheel portion16 to provide cushioning to the entire foot of the footwear wearer. Thefoam layer204 may be wholly or partly made of a foam to provide cushioning to the footwear wearer. For example, thefoam layer204 may be wholly or partly made of EVA foam. Themidsole202 may define one ormore midsole openings206 extending through the part or the entire thickness of thefoam layer204. Each of themidsole openings206 may be configured as thru-holes or recesses. Regardless of the specific configuration, each of themidsole openings206 is configured, shaped, and sized to receive at least onediscrete pod208, which are described in detail below.
• As discussed above, one or more of themidsole openings206 may be a thru-hole to enhance the energy efficiency of themidsole202. Further, themidsole openings206 may have a hexagonal shape or a substantially hexagonal shape to tightly accommodate eachdiscrete pod208, thereby preventing thediscrete pods208 from moving lateral or longitudinally relative to the upper102. By limiting the lateral and longitudinal movement of thediscrete pods208 relative to the upper102, the energy efficiency of thediscrete pods208 can be enhanced.
• In order to simplify manufacturing, themidsole202 may solely include threemidsole openings206, namely: a first midsole opening206a, a second midsole opening206b, and athird midsole opening206c. The first midsole opening206aand the second midsole opening206bare entirely located in theforefoot portion12, whereas thethird midsole opening206cis entirely located inheel portion16. Thethird midsole opening206cis spaced apart from the first midsole opening206aand the second midsole opening206balong a longitudinal direction LG. The first midsole opening206ais spaced apart from the second midsole opening206balong the longitudinal direction LG and the lateral direction LT. The lateral direction LT is perpendicular to the longitudinal direction LG and the vertical direction VT. Each of the first midsole opening206a, the second midsole opening206b, and thethird midsole opening206chas a respective opening center, namely: thefirst opening center207a, thesecond opening center207b, and thethird opening center207c. A first central axis209aintersects thefirst opening center207aof the first midsole opening206a. A secondcentral axis209bintersects thesecond opening center207bof the second midsole opening206b. A thirdcentral axis209cintersects thethird opening center207cof thethird midsole opening206c. Each of the first central axis209a, the secondcentral axis209b, and the thirdcentral axis209cis parallel with the vertical direction VT. Because each of themidsole openings206 receives one of thediscrete pods208, the location of themidsole openings206 as described above assist in enhancing the energy efficiency of thesole structure200 during the heel strike and the toe-off of the gait cycle. Nomidsole opening206 ordiscrete pod208 is located in themidfoot portion14 of thesole structure200 to minimize costs and facilitate manufacturing of the article offootwear100.
• In order to simplify manufacturing, themidsole202 may include solely threediscrete pods208, namely: a firstdiscrete pod208a, a seconddiscrete pod208b, and a thirddiscrete pod208c. It is contemplated, however, that themidsole202 may include more or fewerdiscrete pods208. The firstdiscrete pod208aand the seconddiscrete pod208bare entirely located in theforefoot portion12, whereas the thirddiscrete pod208cis entirely located inheel portion16. The thirddiscrete pod208cis spaced apart from the firstdiscrete pod208aand the seconddiscrete pod208balong the longitudinal direction LG. The firstdiscrete pod208ais spaced apart from the seconddiscrete pod208balong the longitudinal direction LG and the lateral direction LT. Each of the firstdiscrete pod208a, the seconddiscrete pod208b, and the thirddiscrete pod208chas a respective pod center, namely: thefirst pod center212a, thesecond pod center212b, and thethird pod center212c. The first central axis209aintersects thefirst opening center207aof the first midsole opening206aand thefirst pod center212aof the firstdiscrete pod208ato tightly fit the firstdiscrete pod208ain the first midsole opening206a. The secondcentral axis209bintersects thesecond opening center207bof the second midsole opening206band thesecond pod center212bof the seconddiscrete pod208bto tightly fit the seconddiscrete pod208bin the second midsole opening206b. The thirdcentral axis209cintersects thethird opening center207cof thethird midsole opening206cand thethird pod center212cof the thirddiscrete pod208cto tightly fit the thirddiscrete pod208cin thethird midsole opening206c. Each of the first central axis209a, the secondcentral axis209b, and the thirdcentral axis209cis parallel with the vertical direction VT as discussed above. Because each of themidsole openings206 receives one of thediscrete pods208, the location of themidsole openings206 as described above assist in enhancing the energy efficiency of thesole structure200 during the heel strike and the toe-off of the gait cycle. Nodiscrete pod208 is located in themidfoot portion14 of thesole structure200 to minimize costs and facilitate manufacturing of the article offootwear100. It is envisioned, however, that one or morediscrete pods208 may be located in themidfoot portion14 of thesole structure200. Further, thediscrete pods208 are not necessarily encased. Moreover, thediscrete pods208 may be exposed. As such, thediscrete pods208 may be visible from the bottom of thesole structure200.
• The article offootwear100 may further include one ormore strings108 interconnected between the upper102 and themidsole202 to enhance the connection between the upper102 and themidsole202. As a non-limiting example, the article offootwear100 includes a plurality ofstrings108 each directly connected to the upper102 and directly connected to themidsole202 to enhance the structure integrity of the connection between the upper102 and themidsole202. For example, each of thestrings108 has a first string terminus108aand asecond string terminus108bopposite the first string terminus108a. The first string terminus108ais directly coupled to themidsole202, and thesecond string terminus108bis directly coupled to the upper102. Further, one or more of thestrings108 are in tension between the upper102 and themidsole202 to enhance the structural integrity of the article offootwear100. Thesole structure200 further includes anoutsole214 below (and directly connected to the midsole202).
• Thesole structure200 further includes astrobel board210 disposed between themidsole202 and the upper102. Thus, thestrobel board210 is disposed between thefoam layer204 and the upper102. Accordingly, the upper102 is spaced apart from thestrobel board210 along the vertical direction VT, and themidsole202 is spaced apart from thestrobel board210 along the vertical direction VT. Thefoam layer204 is disposed between thestrobel board210 and thediscrete pods208 to provide cushioning to the footwear wearer while maximizing the energy efficiency of thesole structure200. As described in detail below, thestrobel board210 enhances the energy efficiency of thesole structure200 and may extend through theforefoot portion12, themidfoot portion14, and theheel portion16 of thesole structure200 to provide such enhanced energy efficiency throughout thesole structure200.
• With reference toFIG. 4, each of thediscrete pods208 includes a midsole fluid-filledbladder230 to provide cushioning to thesole structure200. The fluid-filledbladder230 of each of thediscrete pods208 is sealed, thereby preventing fluid from escaping the fluid-filledbladder230. By maintaining the fluid inside the fluid-filledchamber230, the cushioning properties of themidsole202 are preserved. The fluid-filledchamber230 defines aninterior cavity234. Further, the fluid-filledchamber230 of eachdiscrete pod208 includes afirst polymeric layer236 and asecond polymeric layer238 surrounding theinterior cavity234. Thefirst polymeric layer236 includes a firstperipheral edge240, and thesecond polymeric layer238 includes a secondperipheral edge242. The firstperipheral edge240 is directly connected, through for example thermal bonding, to the secondperipheral edge242 sealed a fluid inside theinterior cavity234 of the fluid-filledbladder230. The fluid-filledbladder230 may further include one ormore midsole tethers244 interconnecting thefirst polymeric layer236 and thesecond polymeric layer238 to maintain thefirst polymeric layer236 and thesecond polymeric layer238 spaced apart from one another when no load is applied to thediscrete pod208, thereby maximizing the energy efficiency of thesole structure200. As a non-limiting example, each of the midsole tethers244 are tensioned and directly connected to thefirst polymeric layer236 and directly to thesecond polymeric layer238 to maximize the energy efficiency of thesole structure200.
• With reference toFIGS. 5-9, theoutsole214 has anoutsole plate216 and a plurality oftraction elements218 integrally coupled to theoutsole plate216. As such, theoutsole plate216 and thetraction elements218 form a one-piece structure to enhance the structural integrity of theoutsole214. Theoutsole214 has aforefoot region220, aheel region222, and amidfoot region224 disposed between theforefoot region220 and theheel region222. Theoutsole214 has alateral side226 and amedial side228 opposite thelateral side226. Thelateral side226 is spaced apart from themedial side228 along the lateral direction LT. Theoutsole214 includestreads231 disposed alongforefoot region220, themidfoot region224 and theheel region222 of theoutsole plate216 to enhance traction when thesole structure200 contacts a ground surface. Each of thetreads231 extends from thelateral side226 to themedial side228 of theoutsole plate216 and can be configured as curved ridges and grooves.
• As discussed above, theoutsole214 includes alip245 extending upwardly from theforefoot region220 of theoutsole plate216 to protect the footwear wearer's toes from impacts. In addition to thelip245, theoutsole214 includes one ormore traction elements218 as discussed above. Regardless of the specific quantity, each of thetraction elements218 is integrally coupled to theoutsole plate216. As such, thetraction elements218 and theoutsole plate216 form a one-piece structure, thereby maximizing the structural integrity of theoutsole214. As a non-limiting example, each of thetraction elements218 is molded to theoutsole plate216. In present disclosure, the term “molded” means that two or more parts are integrally coupled to one another, by a molding process, such that the two or more parts form a one-piece structure. To facilitate traction with a ground surface, theoutsole214 may be wholly or partly made of a thermoplastic polyurethane. The thermoplastic polyurethane may have a hardness (measured in the Shore A scale) that is between 84 and 95 to promote flexion of thesole structure200.
• As a non-limiting example, theoutsole214 may include solely threetraction elements218 to minimize costs and facilitate manufacturing, namely: a firstforefoot traction element218a, a secondforefoot traction element218b, and aheel traction element218c. It is envisioned, however, that theoutsole214 may include more orfewer traction elements218. The firstforefoot traction element218aand the secondforefoot traction element218bare entirely located in theforefoot portion12, whereas theheel traction element218cis entirely located inheel portion16. Theheel traction element218cis spaced apart from the firstforefoot traction element218aand the secondforefoot traction element218balong the longitudinal direction LG. The firstforefoot traction element218ais spaced apart from the secondforefoot traction element218balong the longitudinal direction LG and the lateral direction LT. Each of the firstforefoot traction element218a, the secondforefoot traction element218b, and theheel traction element218chas a respective pod center, namely: thefirst traction center246a, thesecond traction center246b, and thethird traction center246c. Each of thediscrete pods208 is disposed over and aligned with one of thetraction elements218 to maximize the energy efficiency of thesole structure200. For example, the first central axis209amay intersect thefirst opening center207aof the first midsole opening206a, thefirst pod center212aof the firstdiscrete pod208a, and thefirst traction center246 of the firstforefoot traction element218ato maximize the energy efficiency of thesole structure200. The secondcentral axis209bmay intersect thesecond opening center207bof the second midsole opening206b, thesecond pod center212bof the seconddiscrete pod208b, and thesecond traction center246bof the secondforefoot traction element218bto maximize the energy efficiency of thesole structure200. The thirdcentral axis209cmay intersect thethird opening center207cof thethird midsole opening206c, thethird pod center212cof the thirddiscrete pod208c, and thethird traction center246cof theheel traction element218cto maximize the energy efficiency of thesole structure200. Notraction element218 is located in themidfoot portion14 of thesole structure200 to minimize costs and facilitate manufacturing of the article offootwear100.
• Theheel traction element218ccovers the majority of theheel region222 of theoutsole214 and is larger than the firstforefoot traction element218aand the secondforefoot traction element218bto maintain the footwear wearer's foot to stationary during the backswing and downswing of a golf swing. Each of thefirst traction element218aand the secondforefoot traction element218bare smaller than theheel traction element218cand solely cover less than half of theforefoot region220 of theoutsole214 to maintain the footwear wearer's foot stationary during the backswing and downswing of a golf swing, while allowing rotation of the footwear's foot during the follow-thru state of the golf swing.
• Each of thetraction elements218 includes a plurality ofoverhangs248 integrally coupled to theoutsole plate216. As such, theoverhangs248 and theoutsole plate216 form a one-piece structure to enhance the structural integrity of theoutsole214. Theoverhangs248 may be referred to as flanges, and each of theoverhangs248 is cantilevered from theoutsole plate216 to enhance the energy efficiency of thesole structure200. The plurality ofoverhangs248 includes a plurality of adjacent overhangs248p. The adjacent overhangs248pmay be a pair to minimize costs. Eachtraction element218 may include solely three pairs of adjacent overhangs248pto maximize flexion of thesole structure200, while facilitating manufacturing of thesole structure200. It is contemplated, however, that thetraction elements218 may include more orfewer overhangs248. Each pair of adjacent overhangs248pis spaced apart from another pair of adjacent overhangs248pby a void250 to enhance the flexion of thesole structure200. The void250 between the pairs of adjacent overhangs248pmay define an acute angle AA to facilitate flexion along predefined flexion lines FL. The acute angle AA is defined from one pair of adjacent overhangs248pto another pair of adjacent overhangs248p. All the predefined flexion lines FL intersect a corresponding center of the traction elements218 (i.e., thefirst traction center246a, thesecond traction center246b, and thethird traction center246c) to maximize flexion of thesole structure200.
• As shown inFIGS. 4 and 9, each of theoverhangs248 is obliquely angled relative tooutsole plate216 to formgaps217 between theoutsole plate216 and theoverhangs248 to enhance the energy efficiency of theoutsole214. For instance, an oblique angle OA (e.g., acute angle) is defined from theoutsole plate216 to theoverhang248 to enhance the energy efficiency of theoutsole214. Theoutsole plate216 has afirst plate surface252 and asecond plate surface254 opposite thefirst plate surface252. Thefirst plate surface252 is in direct contact with themidsole202 to enhance the structural integrity of thesole structure200, whereas thesecond plate surface254 is directly connected to each of thetraction elements218 to enhance the structural integrity of theoutsole214.
• With reference toFIGS. 10 and 11, thestrobel board210 includes one or more strobel fluid-filledbladders316 wholly or partly made of a polymeric material to enhance the energy efficiency of thesole structure200. The strobel fluid-filledbladder316 defines a strobel interior cavity318 (FIG. 11) and is configured to retain a fluid in the strobelinterior cavity318. The strobel fluid-filledbladder316 has aperipheral flange320 extending around at least a portion of aperimeter321 of theinterior cavity318. In the embodiment shown, theperipheral flange320 extends around the entire perimeter321 (e.g., outwardly surrounding the strobel interior cavity318) generally in an X-Y plane (defined by the X direction and the Y direction) of the strobel fluid-filledbladder316, where the Z plane (defined by the Z direction) is the height of the strobel fluid-filledbladder316 from aproximal surface324 of the strobel fluid-filledbladder316 to adistal surface326 of the strobel fluid-filledbladder316. Theperipheral flange320 extends around astrobel forefoot region325, astrobel midfoot region327, and astrobel heel region329 of the strobel fluid-filledbladder316.
• Theperipheral flange320 defines agroove322 extending along theperipheral flange320. As further discussed herein, thegroove322 serves as a guide path for an operator or for a machine, including a robotic machine. In some of the embodiments shown and described herein, thestrobel board210 is secured to the upper102 by stitching that extends through theperipheral flange320. When thestrobel board210 is secured to the upper102, thestrobel board210 and the upper102 together defineinterior void103. Dynamic compressive loading of thesole structure200 by a foot in theinterior void103 may cause tension in thestrobel board210 around theperipheral flange320 in an outward direction, creating a trampoline like effect as the tension is subsequently relieved and strobel tethers360 of thestrobel board210 return to their tensioned state.
• The strobel fluid-filledbladder316 includes afirst strobel layer328 and asecond strobel layer330. Each of thefirst strobel layer328 and thesecond strobel layer330 may be partly or wholly made of a polymeric material. Thefirst strobel layer328 is secured to thesecond strobel layer330 at theperipheral flange320 to enclose theinterior cavity318. Stated differently, when thefirst strobel layer328 and thesecond strobel layer330 are secured together at theperipheral flange320 and the strobel fluid-filledbladder316 is sealed, thefirst strobel layer328 and thesecond strobel layer330 retain a fluid in theinterior cavity318. As used herein, the term “fluid” means a gas, such as air, nitrogen, another gas, or a combination thereof.
• Thefirst strobel layer328 and thesecond strobel layer330 can be made a variety of polymeric materials that can resiliently retain a fluid such as nitrogen, air, or another gas. Examples of polymeric materials for thefirst strobel layer328 and thesecond strobel layer330 include thermoplastic urethane, polyurethane, polyester, polyester polyurethane, and polyether polyurethane. Moreover, thefirst strobel layer328 and thesecond strobel layer330 can each be formed of layers of different materials including polymeric materials. In one embodiment, each of thefirst strobel layer328 and thesecond strobel layer330 is formed from thin films having one or more thermoplastic polyurethane layers with one or more barrier layers of a copolymer of ethylene and vinyl alcohol (EVOH) that is impermeable to the pressurized fluid contained therein such as a flexible microlayer membrane that includes alternating layers of a gas barrier material and an elastomeric material. Alternatively, thefirst strobel layer328 and thesecond strobel layer330 may include ethylene-vinyl alcohol copolymer, thermoplastic polyurethane, and a regrind material of the ethylene-vinyl alcohol copolymer and thermoplastic polyurethane. Further suitable materials for thefirst strobel layer328 and thesecond strobel layer330 include thermoplastic films containing a crystalline material, and polyurethane including a polyester polyol. In selecting materials for thestrobel board210, engineering properties such as tensile strength, stretch properties, fatigue characteristics, dynamic modulus, and loss tangent can be considered. For example, the thicknesses of thefirst strobel layer328 and thesecond strobel layer330 used to form thestrobel board210 can be selected to provide these characteristics.
• As best shown inFIG. 11, atensile component350 is disposed in the strobelinterior cavity318. Thetensile component350 is secured to opposinginner surfaces352,354 of the strobel fluid-filledbladder316. Thetensile component350 includes a firsttensile layer356, a secondtensile layer358, and a plurality of strobel tethers360 spanning the strobelinterior cavity318 from the firsttensile layer356 to the secondtensile layer358. The strobel tethers360 connect the firsttensile layer356 to the secondtensile layer358. Therefore, thetethers360 interconnect thefirst strobel layer328 and thesecond strobel layer330. Only some of the strobel tethers360 are indicated with reference numbers inFIG. 11. The strobel tethers360 may also be referred to as fabric tensile members or threads and may be in the form of drop threads that connect the firsttensile layer356 and the secondtensile layer358. Thetensile component350 may be formed as a unitary, one-piece textile element having a spacer-knit textile.
• The firsttensile layer356 is bonded to theinner surface352 of thefirst strobel layer328, and the secondtensile layer358 is bonded to theinner surface354 of thesecond strobel layer330. More specifically, afirst surface bond362 joins theinner surface352 of thefirst strobel layer328 to theouter surface364 of the firsttensile layer356. Asecond surface bond366 joins theinner surface354 of thesecond strobel layer330 to theouter surface368 of the secondtensile layer358, opposite the firsttensile layer356. Entire interfacing portions of thesurfaces352,364 and of thesurfaces354,368 are bonded to one another.
• The strobel tethers360 restrain separation of thefirst strobel layer328 and thesecond strobel layer330 to the maximum separated positions shown inFIG. 11, which depicts the strobel fluid-filledbladder316 with the strobelinterior cavity318 inflated and sealed under a given inflation pressure of gas in theinterior cavity318, so that the strobel fluid-filledbladder316 is in an inflated state. The outward force on thefirst strobel layer328 and thesecond strobel layer330 due to the pressurized gas in the strobelinterior cavity318 places the strobel tethers360 in tension, and the strobel tethers360 prevent the first and secondtensile layers356,358 andfirst strobel layer328 and thesecond strobel layer330 from further outward movement away from one another. However, the strobel tethers360 do not present resistance to compression when under a compressive load. When pressure is exerted on the strobel fluid-filledbladder316 such as due to compressive forces of a dynamic load of a wearer when the article offootwear100 impacts the ground during running or other movements. Rather, upon exertion of compressive forces on the article offootwear100, the strobel fluid-filledbladder316 is compressed, and thefirst strobel layer328 and thesecond strobel layer330 move closer together as the strobel tethers360 collapse (e.g., go slack) in proportion to the load on thefirst strobel layer328 and thesecond strobel layer330 adjacent the particular strobel tethers360.
• One or more inwardly-protrudingbonds370 joins thefirst strobel layer328 to the firsttensile layer356 and protrudes inward from thefirst strobel layer328 toward thesecond strobel layer330 directly into a region of the strobelinterior cavity318 occupied by some of the strobel tethers360. The plurality of inwardly-protrudingbonds370 protrude inward from thefirst strobel layer328 only partially across the plurality of strobel tethers360 toward thesecond strobel layer330, and the strobel fluid-filledbladder316 is narrowed at the inwardly-protrudingbonds370. For example, the inwardly-protrudingbonds370 may be formed by a welding process, such as radio frequency or ultrasonic welding using tooling that results in thermal bonds in the strobel fluid-filledbladder316. The inwardly-protrudingbonds370 result indepressed grooves374 at theproximal surface324 of thefirst strobel layer328.
• Because the inwardly-protrudingbonds370 at least partially traverse the plurality of strobel tethers360 and the plurality of strobel tethers360 includes first strobel tethers360A aligned with one of the inwardly-protrudingbonds370, the second strobel tethers360B displaced each of the inwardly-protrudingbonds370. Only some of the first and second strobel tethers360A,360B are labelled inFIG. 11. The first strobel tethers360A that are aligned with an inwardly-protrudingbond370 are deformed by heat, by compression of the overlaying of material of the firsttensile layer356, and/or by the overlaying material of the firsttensile layer356 coating the first strobel tethers360A such that the first strobel tethers360A are shorter, thicker, or both shorter and thicker at the inwardly-protrudingbonds370 than elsewhere. The firsttensile layer356 is spaced apart from the secondtensile layer358 by a first distance D1 at the second strobel tethers360B adjacent to the inwardly-protrudingbond370, and the inwardly-protrudingbond370 is spaced apart from the secondtensile layer358 by a second distance D2, which may be the minimum distance between the inwardly-protrudingbond370 and the second tensile layer358 (i.e., the distance at the most narrowed portion of theinterior cavity318 under the inwardly-protruding bond370).
• With reference toFIGS. 12 and 13, the present disclosure also describes amethod400 of manufacturing anoutsole214. Themethod400 begins atblock402. Atblock402, a moltenpolymeric material410 is injected into amold cavity502 of a mold500. The mold500 includes amold body504 and a plurality ofinserts506 detachably coupled to themold body504. Themold body504 defines themold cavity502. Themold cavity502 is shaped as theoutsole214. Theinserts506 may be made of a metallic material and are shaped to formgaps217 between theoutsole plate216 of theoutsole214 and each of thetraction elements218. After injecting thepolymeric material410, themethod400 proceeds to block404. Atblock404, thepolymer material410 is cooled until thepolymeric material410 solidifies. Then, themethod400 proceeds to block406. Atblock406, theinserts506 are removed frompolymeric material410 after thepolymeric material410 solidifies to form thegaps217. To remove theinserts506, theinserts506 may be handpicked from thepolymeric material410 after thepolymeric material410 solidifies. Alternately or additionally, removing the plurality of inserts may include applying a magnetic field toward theinserts506 to withdraw theinserts506 from thepolymeric material410 after thepolymeric material410 has solidified.
• While various embodiments have been described, the description is intended to be exemplary, rather than limiting and it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible that are within the scope of the embodiments. Any feature of any embodiment may be used in combination with or substituted for any other feature or element in any other embodiment unless specifically restricted. Accordingly, the embodiments are not to be restricted except in light of the attached claims and their equivalents. Also, various modifications and changes may be made within the scope of the attached claims.
• While several modes for carrying out the many aspects of the present teachings have been described in detail, those familiar with the art to which these teachings relate will recognize various alternative aspects for practicing the present teachings that are within the scope of the appended claims. It is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and exemplary of the entire range of alternative embodiments that an ordinarily skilled artisan would recognize as implied by, structurally and/or functionally equivalent to, or otherwise rendered obvious based upon the included content, and not as limited solely to those explicitly depicted and/or described embodiments.

Claims (28)

What is claimed is:

1. A sole structure, comprising:

an outsole including an outsole plate and a plurality of traction elements molded to the outsole plate, each of the plurality of traction elements includes a plurality of overhangs, each of the plurality of overhangs is cantilevered from the outsole plate; and

a midsole disposed over the outsole, the midsole including a plurality of discrete pods, each of the plurality of discrete pods includes a midsole fluid-filled bladder, the midsole fluid-filled bladder defines an interior cavity, the midsole fluid-filled bladder includes a first polymeric layer, a second polymeric layer, and a plurality of midsole tethers interconnecting the first polymeric layer and the second polymeric layer, each of the plurality of midsole tethers is disposed in the interior cavity of the midsole fluid-filled bladder; and

wherein each of the plurality of discrete pods is disposed over and aligned with one of the plurality of traction elements to maximize an energy efficiency of the sole structure.

2. The sole structure ofclaim 1, wherein the outsole is made of thermoplastic polyurethane, the thermoplastic polyurethane has a hardness measured in Shore A, and the hardness of the thermoplastic polyurethane is between 85 and 95 to promote flexion of the sole structure.

3. The sole structure ofclaim 1, further comprising a foam layer and a strobel board, wherein the strobel board is disposed over the foam layer, and the foam layer is disposed between the strobel board and the plurality of discrete pods.

4. The sole structure ofclaim 3, wherein the strobel board includes a strobel fluid-filled bladder, and the strobel fluid-filled bladder includes a first strobel layer, a second strobel layer, and a plurality of strobel tethers interconnecting the first strobel layer and the second strobel layer.

5. The sole structure ofclaim 4, further comprising a string having a first string terminus and a second string terminus opposite the first string terminus, wherein the first string terminus is directly coupled to the midsole, and the second string terminus is configured to be directly coupled to an upper.

6. The sole structure ofclaim 1, wherein the plurality of traction elements includes solely three traction elements.

7. The sole structure ofclaim 1, wherein the outsole has a forefoot region, a heel region, and a midfoot region disposed between the forefoot region and the heel region, the plurality of traction elements solely includes a first forefoot traction element, a second forefoot traction element, and a heel traction element, the first forefoot traction element and the second forefoot traction element are disposed in the forefoot region of the outsole, and the heel traction element is disposed in the heel region of the outsole, and none of the plurality of traction elements is disposed in the midfoot region of the outsole.

8. The sole structure ofclaim 7, wherein the heel traction element covers a majority of the heel region of the outsole, and the heel traction element is larger than the first forefoot traction element and the second forefoot traction element.

9. The sole structure ofclaim 8, wherein adjacent overhangs of the plurality of overhangs of each of the plurality of traction elements are spaced apart from one another by a void.

10. The sole structure ofclaim 9, wherein the void between the adjacent overhangs defines an acute angle from one of the adjacent overhangs to another of the adjacent overhangs to facilitate flexion along predefined flex lines.

11. An article of footwear, comprising:

an upper;

a sole structure coupled to the upper, wherein the sole structure includes:

an outsole including an outsole plate and a plurality of traction elements molded to the outsole plate, each of the plurality of traction elements includes a plurality of overhangs, each of the plurality of overhangs is cantilevered from the outsole plate; and

a midsole disposed over the outsole, the midsole including a plurality of discrete pods, each of the plurality of discrete pods includes a midsole fluid-filled bladder, the midsole fluid-filled bladder defines an interior cavity, the midsole fluid-filled bladder includes a first polymeric layer and a second polymeric layer, and a plurality of midsole tethers interconnecting the first polymeric layer and the second polymeric layer, each of the plurality of midsole tethers is disposed in the interior cavity of the midsole fluid-filled bladder; and

wherein each of the plurality of discrete pods is disposed over and aligned with one of the plurality of traction elements to maximize an energy efficiency of the sole structure.

12. The article of footwear ofclaim 11, wherein the outsole is made of thermoplastic polyurethane, the thermoplastic polyurethane has a hardness measured in Shore A, and the hardness of the thermoplastic polyurethane is between 85 and 95 to promote flexion of the sole structure.

13. The article of footwear ofclaim 11, further comprising a foam layer and a strobel board disposed over the foam layer, wherein the foam layer is disposed between the strobel board and the plurality of discrete pods.

14. The article of footwear ofclaim 13, wherein the strobel board includes a strobel fluid-filled bladder, and the strobel fluid-filled bladder includes a first strobel layer, a second strobel layer, and a plurality of strobel tethers interconnecting the first strobel layer and the second strobel layer.

15. The article of footwear ofclaim 14, further comprising a string having a first string terminus and a second string terminus opposite the first string terminus, the first string terminus is directly coupled to the midsole, and the second string terminus is directly coupled to the upper.

16. The article of footwear ofclaim 11, wherein the plurality of traction elements includes solely three traction elements.

17. The article of footwear ofclaim 11, wherein the outsole has a forefoot region, a heel region, and a midfoot region disposed between the forefoot region and the heel region, the plurality of traction elements solely includes a first forefoot traction element, a second forefoot traction element, and a heel traction element, the first forefoot traction element and the second forefoot traction element are disposed in the forefoot region of the outsole, and the heel traction element is disposed in the heel region of the outsole, and none of the plurality of traction elements is disposed in the midfoot region of the outsole.

18. The article of footwear ofclaim 17, wherein the heel traction element covers a majority of the heel region of the outsole, and the heel traction element is larger than the first forefoot traction element and the second forefoot traction element.

19. The article of footwear ofclaim 18, wherein adjacent overhangs of the plurality of overhangs of each of the plurality of traction elements are spaced apart from one another by a void, and the void between the adjacent overhangs defines an acute angle from one of the adjacent overhangs to another of the adjacent overhangs to facilitate flexion along predefined flex lines.

20. A method of manufacturing an outsole, comprising:

injecting a molten polymeric material into a mold cavity of a mold, wherein the mold includes a mold body and a plurality of inserts detachably coupled to the mold body, the mold body defines the mold cavity, and the mold cavity is shaped as the outsole, wherein the plurality of inserts are shaped to form a plurality of gaps between an outsole plate of the outsole and each of a plurality of traction elements of the outsole;

cooling the polymeric material until the polymeric material solidifies; and

removing the plurality of inserts from the polymeric material after the polymeric material solidifies to form the plurality of gaps.

21. The method ofclaim 20, wherein the removing the plurality of inserts includes hand picking the inserts from the polymeric material after the polymeric material solidifies.

22. The method ofclaim 21, wherein removing the plurality of inserts includes applying a magnetic field toward the plurality of inserts to withdraw the plurality of inserts from the polymeric material after the polymeric material solidifies.

23. A sole structure, comprising:

an outsole having a forefoot region, a heel region, and a midfoot region disposed between the forefoot region and the heel region, wherein the outsole includes:

an outsole plate; and

a plurality of traction elements molded to the outsole plate, wherein each of the plurality of traction elements includes a plurality of overhangs, and each of the plurality of overhangs is cantilevered from the outsole plate, the plurality of traction elements includes a first forefoot traction element, a second forefoot traction element, and a heel traction element, the first forefoot traction element and the second forefoot traction element are disposed in the forefoot region of the outsole, the heel traction element is disposed in the heel region of the outsole.

24. The sole structure ofclaim 23, wherein the outsole is made of thermoplastic polyurethane, the thermoplastic polyurethane has a hardness measured in Shore A, and the hardness of the thermoplastic polyurethane is between 85 and 95 to promote flexion of the sole structure.

25. The sole structure ofclaim 23, wherein adjacent overhangs of the plurality of overhangs of each of the plurality of traction elements are spaced apart from one another by a void.

26. The sole structure ofclaim 25, wherein the void between the adjacent overhangs defines an acute angle from one of the adjacent overhangs to another of the adjacent overhangs to facilitate flexion along predefined flex lines.

27. The sole structure ofclaim 23, wherein the heel traction element covers a majority of the heel region of the outsole, and the heel traction element is larger than the first forefoot traction element and the second forefoot traction element.

28. The sole structure ofclaim 23, wherein the outsole plate extends through the forefoot region, the heel region, and the midfoot region of the outsole.

Images