US20230320461A1 - Article of footwear having a sole structure - Google Patents

Abstract

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

Description

CROSS-REFERENCE TO RELATED APPLICATION(S)
• This application is a continuation of U.S. application Ser. No. 18/178,342, filed on Mar. 3, 2023, which claims priority to U.S. Provisional Application No. 63/316,632, filed Mar. 4, 2022, each of which is incorporated by reference herein in its entirety.
FIELD
• The present disclosure relates generally to articles of footwear, and more particularly to a sole structure for an article of footwear.
BACKGROUND
• This section provides background information related to the present disclosure which is not necessarily prior art.
• Articles of footwear conventionally 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 generally 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 polymers 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, generally, 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 and/or a sockliner located within a void proximate to the bottom portion of the upper.
BRIEF DESCRIPTION OF THE DRAWINGS
• The drawings described herein are of selected embodiments for illustrative purposes only. Accordingly, the drawings do not include all possible implementations, and are not intended to limit the scope of the present disclosure.
• FIG.1 illustrates an exemplary article of footwear including a sole structure, according to an embodiment of the disclosure;
• FIG.2 illustrates an exploded view of the sole structure of the article of footwear ofFIG.1;
• FIG.3aillustrates a top-down view of an outsole plate of the sole structure of the article of footwear ofFIG.1;
• FIG.3billustrates a bottom view of a studded moderator plate of the sole structure of the article of footwear ofFIG.1;
• FIG.4 illustrates a partially exploded view of the sole structure of the article of footwear ofFIG.1;
• FIG.4aillustrates a top-down view of a forefoot cushioning element of the sole structure of the article of footwear ofFIG.1;
• FIG.4billustrates a cross-sectional view of the sole structure of the article of footwear ofFIG.4;
• FIG.4cillustrates a cross-sectional view taken along line A-A of a cushioning element of the sole structure of the article of footwear ofFIG.4;
• FIG.4dillustrates a cross-sectional view taken along line B-B of a cushioning element of the sole structure of the article of footwear ofFIG.4;
• FIG.5 illustrates a top-down view of a forefoot cushioning element disposed in an outsole plate of the sole structure of the article of footwear ofFIG.1,
• FIG.6 illustrates a perspective view of the sole structure of the article of footwear ofFIG.1;
• FIG.7 illustrates an exploded view of an alternative embodiment of the sole structure of the article of footwear;
• FIG.8 illustrates a top-down view of an alternative embodiment of a forefoot cushioning element of the sole structure of the article of footwear ofFIG.7;
• FIG.9 illustrates a perspective view of a moderator plate of the sole structure of the article of footwear ofFIG.7;
• FIG.10 illustrates a bottom view of a moderator plate and a gasket of the sole structure of the article of footwear ofFIG.7;
• FIG.11 illustrates a perspective view of a gasket of the sole structure of the article of footwear ofFIG.7;
• FIG.12 illustrates a perspective view of the sole structure of the article of footwear ofFIG.7;
• FIG.13 illustrates a bottom view of the sole structure of the article of footwear ofFIG.7;
• FIG.14 illustrates an exploded view of an alternative embodiment of the sole structure of the article of footwear;
• FIG.15 illustrates an exploded view of an alternative embodiment of the sole structure of the article of footwear;
• FIG.16 illustrates a cross-sectional view of the footwear ofFIG.15; and
• FIG.17 illustrates a bottom view of the sole structure ofFIG.15.
• Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.
DETAILED DESCRIPTION
• Example embodiments will now be described more fully with reference to the accompanying drawings. Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope of those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well known technologies are not described in detail.
• The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “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, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, 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. It is also to be understood that additional or alternative steps may be employed.
• When an element or layer is referred to as being “on,” “engaged to,” “connected to,” or “coupled to” another element or layer, it may be directly on, engaged, connected 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,” 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.
• Although 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 when used herein 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 embodiments.
• Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” may encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.
• In the discussion that follows, terms “about,” “approximately,” “substantially,” and the like, when used in describing a numerical value, denote a variation of +/−10% of that value, unless specified otherwise.
• Examples of the present disclosure relate to, among other things, articles of footwear having a sole structure. In one example, the articles of footwear may improve performance of a user. Each of the examples disclosed herein may include one or more of the features described in connection with any of the other disclosed examples. Examples of the present disclosure may incorporate cushioning elements into a sole structure while maintaining an overall height of an article of footwear relatively low/short.
Article of Footwear
• Referring toFIG.1, an article of footwear10 includes an upper100 and sole structure101 (shown inFIG.2). The article of footwear10 may be divided into one or more regions. The regions may include aforefoot region12, amid-foot region14, and aheel region16. Theforefoot region12 may be subdivided into atoe portion12T corresponding with phalanges, and aball portion12B associated with metatarsal bones of a foot. Themid-foot region14 may correspond with an arch area of the foot, and theheel region16 may correspond with rear portions of the foot, including a calcaneus bone. The footwear10 may further include ananterior end18 associated with a forward-most point of theforefoot region12 and aposterior end20 associated with a rearward-most point of theheel region16. A longitudinal axis of the footwear10 extends along a length of the footwear10 from theanterior end18 to theposterior end20, and generally divides the footwear10 into a medial side22 (shown inFIG.3B) and a lateral side24 (also shown inFIG.3B). Accordingly, themedial side22 and thelateral side24 respectively correspond with opposite sides of the footwear10 and extend through theregions12,14,16.
Upper
• Referring toFIG.1, the upper100 includes interior surfaces that define an interior void configured to receive and secure a foot for support on thesole structure101. The upper100 may be formed from one or more materials that are stitched or adhesively bonded together to form the interior void. Suitable materials of the upper100 may include, but are not limited to, mesh, textiles, foam, leather, and synthetic leather. The materials may be selected and located to impart properties of durability, air-permeability, wear-resistance, flexibility, and comfort. Anankle opening110 in theheel region16 may provide access to the interior void. For example, theankle opening110 may receive a foot to secure the foot within the void and to facilitate entry and removal of the foot to and from the interior void.
• In some examples, the upper100 includes a strobel having a bottom surface opposing thesole structure101 and an opposing top surface defining a footbed of the interior void. Stitching or adhesives may secure the strobel to the upper100. The footbed may be contoured to conform to a profile of the bottom surface (e.g., plantar) of the foot. Optionally, the upper100 may also incorporate additional layers such as an insole or sockliner that may be disposed upon the strobel and reside within the interior void of the upper100 to receive a plantar surface of the foot to enhance the comfort of the article of footwear10. The sockliner may include resilient materials thereby imparting a desired level of support and stiffness.
• In some examples, one ormore fasteners111 extend along the upper100 to adjust a fit of the interior void around the foot and to accommodate entry and removal of the foot therefrom. The upper100 may include apertures such as eyelets and/or other engagement features such as fabric or mesh loops that receive thefasteners111. Thefasteners111 may include laces, straps, cords, hook-and-loop, or any other suitable type of fastener. The upper100 may include a tongue portion that extends between the interior void and thefasteners111. Additionally or alternatively, the upper100 may be formed with a tensioning system including a series of cables routed through cable locking devices attached to the article of footwear.
Sole Structure
• With reference toFIGS.1 and2, thesole structure101 includes a chassis plate (chassis)102 extending between themedial side22 and thelateral side24 from theanterior end18 to theposterior end20. Thesole structure101 further includes aforefoot cushion103 disposed on an outsole plate (stud plate)104. Theoutsole plate104 andforefoot cushion103 may be coupled to thechassis plate102. The bottom surface ofoutsole plate104 may define a ground-engaging surface of the article of footwear10.
Chassis
• Referring toFIG.2, thechassis plate102 may extend continuously from theanterior end18 of thesole structure101 to theposterior end20, and may span a width of thesole structure101 from themedial side22 to thelateral side24. Thechassis plate102 may further comprise a top (upper)surface202 facing the bottom of the upper100, and a bottom (lower)surface204 formed on an opposite side of thechassis plate102 from thetop surface202, facing in the direction of a ground surface. A distance from thetop surface202 to the bottom surface may define a thickness of thechassis plate102. In the present embodiment, thetop surface202 of thechassis plate102 may be positioned against the strobel of the upper100 (shown inFIG.1) from theanterior end18 to theposterior end20. In some examples, the entiretop surface202 may be attached (e.g., directly attached) to the strobel of the upper100, such that theupper surface202 of thechassis plate102 may define a profile of the footbed.
• Thechassis plate102 may be formed of a material providing relatively high strength and stiffness, such as polymeric material and/or composite materials. In some examples, thechassis plate102 may be a composite material manufactured using fiber sheets or textiles, including pre-impregnated (i.e., “prepreg”) fiber sheets or textiles. Alternatively or additionally, thechassis plate102 may be manufactured by strands formed from multiple filaments of one or more types of fiber (e.g., fiber tows) by affixing the fiber tows to a substrate or to each other to produce a plate having the strands of fibers arranged predominately at predetermined angles or in predetermined positions. When using strands of fibers, the types of fibers included in the strand may include synthetic polymer fibers which may be melted and re-solidified to consolidate the other fibers present in the strand and, optionally, other components such as stitching thread or a substrate or both. Alternatively or additionally, the fibers of the strand and, optionally the other components such as stitching thread or a substrate or both, may be consolidated by applying a resin after affixing the strands of fibers to the substrate and/or to each other.
• In some configurations,chassis plate102 may be formed from one or more layers of tows of fibers and/or layers of fibers including at least one of carbon fibers, boron fibers, glass fibers, and polymeric fibers. In a particular configuration, the fibers include carbon fibers, or glass fibers, or a combination of both carbon fibers and glass fibers. The tows of fibers may be affixed to a substrate. The tows of fibers may be affixed by stitching or using an adhesive. Additionally or alternatively, the tows of fibers and/or layers of fibers may be consolidated with a thermoset polymer and/or a thermoplastic polymer. Accordingly, thechassis plate102 may have a tensile strength or flexural strength in a transverse direction substantially perpendicular to the longitudinal axis of the article of footwear (i.e., the axis extending from theanterior end18 to the posterior end20). The stiffness of thechassis plate102 may be selected for a particular wearer based on the wearer's tendon flexibility, calf muscle strength, and/or metatarsophalangeal (MTP) joint flexibility. Moreover, the stiffness of thechassis plate102 may also be tailored based upon a running motion of the athlete. In other configurations, thechassis plate102 may be formed from one or more layers/plies of unidirectional tape. In some examples, each layer in the stack includes a different orientation than the layer disposed underneath. The plate may be formed from unidirectional tape including at least one of carbon fibers, boron fibers, glass fibers, and polymeric fibers. In some examples, the one or more materials forming thechassis plate102 may result in thechassis plate102 having a Young's modulus of at least 70 gigapascals (GPa).
• In some embodiments, thechassis plate102 may have a substantially uniform thickness. In some examples, the thickness of thechassis plate102 may range from about 0.6 millimeters (mm) to about 3.0 mm. In an exemplary embodiment, the thickness of thechassis plate102 is equal to one 1.0 mm. In other implementations, the thickness of thechassis plate102 may be non-uniform such that thechassis plate102 may have a greater thickness in one ofregions12,14, and16 of thesole structure101 than the thicknesses in theother regions12,14, and16. In other words,chassis plate102 may have a variable thickness in each ofregions12,14, and16. In some embodiments,chassis plate102 may be replaced by a sockliner.
• In an alternative embodiment, described in further detail in the Alternative Embodiments section below, achassis board1402 may be disposed solely within theforefoot region12. Further, thechassis board1402 may be located within thetoe portion12T of theforefoot region12. It is contemplated that in other alternative embodiments, thechassis board1402 may be disposed in theforefoot region12 and a portion of themid-foot region14. It is further contemplated that in other alternative embodiments, thechassis board1402 may be disposed within any of theforefoot region12, themid-foot portion14, and theheel portion16 so as to provide a desired level of support, stability, and comfortability to the article of footwear10.
Outsole Plate
• With reference toFIGS.3A and3B, theoutsole plate104 may extend continuously from theanterior end18 of the article of footwear10 to theposterior end20 of the article of footwear. Theoutsole plate104 may further include anupper surface302 facing the upper100 and alower surface304 formed on an opposite side of theoutsole plate104 from theupper surface302. A sidewall306 (shown inFIG.2) may extend vertically upward from theupper surface302.Sidewall306 may further define an outer periphery of theoutsole plate104. Theupper surface302 of theoutsole plate104 may be attached to the bottom surface of thechassis102.
• Theupper surface302 may further include arecess308. Recess308 may be present in the forefoot of theoutsole plate104. Recess308 may form a depression in theoutsole plate104. Recess308 may extend outwardly from a center of the recess toward ananterior segment310, aposterior segment312, alateral segment314, and amedial segment316. A portion extending from the center toward theanterior segment310 may extend in a direction toward theanterior end18. A portion extending from the center toward theposterior segment312 may extend in a direction toward theposterior end20. A portion extending from the center toward thelateral segment314 may extend in a direction toward thelateral side24. A portion extending from the center toward themedial segment316 may extend in a direction toward themedial side22. Following a path along the exterior ofrecess308, each of segments310-316 may be interconnected by theupper surface302. Aportion317 of the path running in between segments310-316 may be incurved. In other words, therecess308 may be bounded at its exterior by theupper surface302, and the exterior of therecess308 bounded by theupper surface302 may follow a path between the segments310-316 that is concave when viewed from a radially exterior position. Each of theincurved portions317 of the path may be convex when viewed from a center ofrecess308, although other configurations are contemplated.
• Further, theoutsole plate104 may be divided into an anterior region and a posterior region by an axis A114 that may be perpendicular to a central longitudinal axis A104. Axis A114 may intersect the centrallongitudinal axis104 at a point that is a longitudinal center between the anterior most and posterior most portions of theoutsole plate104. Additionally, axis A114 may divide theoutsole plate104 into ananterior region322 and aposterior region324.Anterior region322 andposterior region324 may or may not have equal two-dimensional areas or area projections (when viewed from directly above). Theanterior region322 may include therecess308 disposed within. The area ofrecess308 may be less than about 80%, less than about 70%, less than about 60%, or less than about 50% of the total two-dimensional area of theanterior region322.
• Recess308 may be substantially symmetrical about the axis A104, although non-symmetrical configurations are contemplated.Lateral segment314 andmedial segment316 may be mirrors of one another.Anterior segment310 andposterior segment312 may be mirrors of one another. In an exemplary embodiment, each of segments310-316 may be substantial mirrors of one another. In other words,recess308 may form a substantially plus-sign or cross shape. It is contemplated thatrecess308 may be of a shape that is substantially ovular, diamond, or irregular in shape.
• Thelower surface304 of theoutsole plate104 may form the ground-engaging surface of the article of footwear10, and may include a plurality oftraction elements318.Lower surface304 may also include a correspondingopposite face320 of therecess308. The plurality oftraction elements318 may be integrally molded with thebottom surface304 of theoutsole plate104. Additionally, some of the plurality oftraction elements318 may be integrally molded with theopposite face320 of therecess308. InFIG.3B, twotraction elements318 are shown extending directly fromopposite face320, but it is contemplated that fewer (e.g., zero or one), ormore traction elements318 may extend directly fromopposite face320. The remainder of the plurality oftraction elements318 in theforefoot region12 may surround oppositeface320 in various patterns in order to provide a desired form of traction. In the embodiment shown, there are sixadditional traction elements318 inforefoot region312, but other numbers and patterns other than those shown inFIG.3B are contemplated. The plurality oftraction elements318 may all have the same size, or they may have different sizes to provide the desired traction, stability, and/or other properties. It is contemplated that thetraction elements318 may alternatively be attached to theoutsole plate104 by a snap fit, screw structure, or the like. Theopposite face320 may havefewer traction elements318 than the remainder of thebottom surface304 of theoutsole plate104. Thetraction elements318 may be disposed in theforefoot region12 and theheel region16. Thetraction elements318 may extend from theheel region16 toward themid-foot region14 and from theforefoot region12 to themid-foot region14. Portions of thetraction elements318 may partially extend into themid-foot region14. In some embodiments, themid-foot region14 may be substantially free oftraction elements318.
Forefoot Cushioning Element
• With reference toFIGS.4 and4A-4D, therecess308 of theoutsole plate104 may have disposed within it, aforefoot cushioning element103. Theforefoot cushioning element103 may be a fluid-filled bladder, for example, that may be inflated to provide a desired form of cushioning and support.Forefoot cushioning element103 may be formed from a pair of barrier layers, which when joined together may define an enclosed inner volume (or hollow interior) for receiving, for example, a pressurized fluid (e.g. a gas as set forth in further detail below). The barrier layers may be joined to each other at discrete locations to define an overall shape of theforefoot cushioning element103. In an exemplary embodiment, theforefoot cushioning element103 may include a first,upper barrier layer402 and a second,lower barrier layer404. Theupper barrier layer402 may be attached to thelower barrier layer404 by applying heat and pressure at a perimeter of theupper barrier layer402 and thelower barrier layer404 to define aperipheral seam406. Theperipheral seam406 may seal theforefoot cushioning element103 and may define the peripheral profile of theforefoot cushioning element103.
• As used herein, the term “barrier layer” (e.g., barrier layers402,404) may encompass both monolayer and multilayer films. In some embodiments, one or both of barrier layers402,404 may each be produced (e.g., thermoformed or blow molded) from a monolayer film (a single layer). In other embodiments, one or both of barrier layers402,404 may each be produced (e.g., thermoformed or blow molded) from a multilayer film (multiple sublayers). In either embodiment, each layer or sublayer can have a film thickness ranging from about 0.2 micrometers to about be about 1 millimeter. In further embodiments, the film thickness for each layer or sublayer can range from about 0.5 micrometers to about 500 micrometers. In yet further embodiments, the film thickness for each layer or sublayer can range from about 1 micrometer to about 100 micrometers. It is contemplated that theforefoot cushioning element103 may have a thickness ranging from 6 mm to 10 mm, although other suitable values are contemplated. In an exemplary embodiment,forefoot cushioning element103 may have a thickness of 8 mm.
• One or both of barrier layers402,404 may independently be transparent, translucent, and/or opaque. As used herein, the term “transparent” for a barrier layer and/or a fluid-filled chamber means that light passes through the barrier layer in substantially straight lines and a viewer can see through the barrier layer. In comparison, for an opaque barrier layer, light does not pass through the barrier layer and one cannot see clearly through the barrier layer at all. A translucent barrier layer falls between a transparent barrier layer and an opaque barrier layer, in that light passes through a translucent layer but some of the light is scattered so that a viewer cannot see clearly through the layer.
• The barrier layers402,404 may each be produced from an elastomeric material that includes one or more thermoplastic polymers and/or one or more cross-linkable polymers. In an embodiment, the elastomeric material can include one or more thermoplastic elastomeric materials, such as one or more thermoplastic polyurethane (TPU) copolymers, one or more ethylene-vinyl alcohol (EVOH) copolymers, and the like.
• Theforefoot cushioning103 may be produced from the barrier layers402,404 using any suitable technique, such as thermoforming (e.g. vacuum thermoforming), blow molding, extrusion, injection molding, vacuum molding, rotary molding, transfer molding, pressure forming, heat sealing, casting, low-pressure casting, spin casting, reaction injection molding, radio frequency (RF) welding, and the like. In an embodiment, the barrier layers402,404 can be produced by co-extrusion followed by vacuum thermoforming to produceforefoot cushioning element103, which can optionally include one or more valves (e.g., one way valves) that allowsforefoot cushioning element103 to be filled with a fluid (e.g., gas).
• Theforefoot cushioning element103 may be provided in a fluid-filled or in an unfilled state. Theforefoot cushioning element103 may be filled to include any suitable fluid, such as a gas or liquid. In an embodiment, the gas may include air, nitrogen (N₂), or any other suitable gas. In other embodiments, theforefoot cushioning element103 may alternatively include other media, such as pellets, beads, ground recycled material, and the like (e.g., foamed beads and/or rubber beads). The fluid provided to theforefoot cushioning element103 can result in theforefoot cushioning element103 being pressurized. In some examples, theforefoot cushioning element103 may have a pressure ranging from 15 psi (pounds per square inch) to 25 psi. In other examples, theforefoot cushioning element103 may have a pressure ranging from 20 psi to 25 psi. In some examples, theforefoot cushioning element103 may have a pressure of 20 psi. In other examples, theforefoot cushioning element103 may have a pressure of 25 psi. Alternatively, the fluid provided to theforefoot cushioning element103 may be at atmospheric pressure such that theforefoot cushioning element103 is not pressurized but, rather, simply contains a volume of fluid at atmospheric pressure.
• Theforefoot cushioning element103 desirably has a low gas transmission rate to preserve its retained gas pressure. In some embodiments,forefoot cushioning element103 may have a gas transmission rate for nitrogen gas that is at least about ten (10) times lower than a nitrogen gas transmission rate for a butyl rubber layer of substantially the same dimensions. In an embodiment,forefoot cushioning element103 may have a nitrogen gas transmission rate of 15 cubic-centimeter/square-meter·atmosphere·day (cm³/m²·atm·day) or less for an average film thickness of 500 micrometers (based on thicknesses of barrier layers402,404). In further embodiments, the transmission rate may be 10 cm³/m²·atm·day or less, 5 cm³/m²·atm·day or less, or 1 cm³/m²·atm·day or less.
• Theforefoot cushioning element103 may receive atensile element408 therein (or one or more tensile elements408). Eachtensile element408 may include a series of tensile strands extending between an upper tensile sheet (not shown) and a lower tensile sheet (not shown). The upper tensile sheet may be attached to theupper barrier layer402 while the lower tensile sheet may be attached to thelower barrier layer404. In this manner, when theforefoot cushioning element103 receives the pressurized fluid, the tensile strands of the tensile element are placed in tension. Because the upper tensile sheet is attached to theupper barrier layer402 and the lower tensile sheet is attached to thelower barrier layer404, the tensile strands retain a desired shape of theforefoot cushioning element103 when the pressurized fluid is injected into the chamber.
• In an alternative embodiment,forefoot cushioning element103 may include a polymer foam and/or particulate matter in one or more, or all, regions of theforefoot cushioning element103 corresponding to the enclosed inner volume of theforefoot cushioning element103. For example, theforefoot cushioning element103 may include a plurality of fluid-filled chambers arranged in the forefoot region, as described in greater detail below. Additionally or alternatively, theforefoot cushioning element103 may be replaced or supplemented with other cushioning elements. For example, the cushion may include a foam block that replaces or supplements the pressurized fluid. The foam block(s) may be received within theinner void408 defined by theupper barrier layer402 and thelower barrier layer404. Positioning the foam block(s) within theinner void408 defined by theupper barrier layer402 and thelower barrier layer404 may allow the barrier layers to restrict expansion of the foam blocks beyond a predetermined amount when subjected to a predetermined load. Accordingly, the overall shape and, thus, the performance of the foam blocks may be controlled by allowing the foam blocks to interact with the barrier layers402 and404 during loading. While the foam blocks are described as being received within theinner void408 of the barrier layers402 and404, the foam blocks may alternatively be positioned between thechassis plate102 and theoutsole plate104 absent the barrier layers402 and404. In such a configuration, the foam blocks may be directly attached to the bottom surface of thechassis plate102 and tooutsole plate104, respectively.
• Forefoot cushioning element103 may extend outwardly from its center toward ananterior segment410, aposterior segment412, alateral segment414, and amedial segment416. A portion extending from the center toward theanterior segment410 may extend in a direction toward theanterior end18. A portion extending from the center toward theposterior segment412 may extend in a direction toward theposterior end20. A portion extending from the center toward thelateral segment414 may extend in a direction toward thelateral side24. A portion extending from the center toward themedial segment416 may extend in a direction toward themedial side22. When viewing the exterior offorefoot cushioning element103 from above, there may be a path defining the outer bounds offorefoot cushioning element103. The exterior path may run between each of segments410-416, and may also include each of segments410-416. Aportion417 of the path running between the ends of the segments may be concave when viewed from a radially exterior position. Each of theincurved portions417 of the path may be convex when viewed from a center offorefoot cushioning element103, although other configurations are contemplated.
• Forefoot cushioning element103 may be substantially symmetrical about the axis A104, although non-symmetrical configurations are contemplated.Lateral segment414 andmedial segment416 may be mirrors of one another.Anterior segment410 andposterior segment412 may be mirrors of one another. In an exemplary embodiment, each of segments410-416 may be substantial mirrors of one another. In other words,recess308 may form a substantially plus-sign or cross shape. It is contemplated thatrecess308 may be of a shape that is substantially ovular, diamond, or irregular in shape.
• Referring toFIG.5, the recess308 (shown inFIG.3A) may receive theforefoot cushioning element103.Recess308 andforefoot cushioning element103 may have substantially corresponding geometries. Referring toFIGS.4B-4D,recess308 may receive all or a portion offorefoot cushioning element103. In an exemplary configuration, 100% of theforefoot cushioning element103 may be disposed within therecess308. When all of the forefoot cushioning element is disposed withinrecess308, a top surface of theforefoot cushioning element103 and a top surface of theoutsole plate104 may be substantially flush with each other, or the top surface offorefoot cushioning element103 may be below the top surface ofoutsole plate104. In other configurations, less than an entirety of the forefoot cushioning element (e.g., about 90% or less, about 75% or less, about 50% or less) may be disposed within therecess308 so that a top surface of theforefoot cushioning element103 rests slightly above a top surface of theoutsole plate104. The percentage offorefoot cushioning element103 contained byrecess308 may be varied to impart desired cushioning characteristics.
Assembled Configuration
• Referring toFIGS.4A-4D, when assembled, a top surface of theforefoot cushioning element103 may protrude slightly above theupper surface302 of theoutsole plate104. In other embodiments, the top surface of theforefoot cushioning element103 may rest substantially flush with theupper surface302 of theoutsole plate104 when theforefoot cushioning element103 is disposed within therecess308.
• Referring toFIG.6, the fully assembledsole structure101 may include thechassis plate102, theforefoot cushioning element103, and theoutsole plate104.Forefoot cushioning element103 may be disposed withinrecess308.Chassis plate102 may be disposed along a substantial portion of theoutsole plate104.Chassis plate102 may be disposed on theforefoot cushioning element103. In other words,chassis plate102 may span a majority (or substantial entirety) of the length of theoutsole plate104 and may cover theforefoot cushioning element103 in the forefoot. Thesole structure101 may be adhered by stock fit, cementing, or any other suitable method for adhering elements of a sole structure made of varying materials.
• When the top surface of theforefoot cushioning element103 protrudes slightly above theupper surface302, there may be substantially no gap between thechassis plate102 and theforefoot cushioning element103. In an exemplary embodiment, theforefoot cushioning element103 is not subject to compressive forces from thechassis plate102 during a state of rest of the article of footwear10, or is otherwise subject to substantially minimal compressive forces from thechassis plate102 during a state of rest. The state of rest may correspond to the article of footwear10 not being engaged by a foot of a user. Alternatively, thechassis plate102 may apply a compressive force to theforefoot cushioning element103. In the alternative, the compressive force of thechassis plate102 applies preloading to theforefoot cushioning element103.
Alternative Embodiments
• Referring toFIGS.7-13, an alternative embodiment of thesole structure101 may includechassis plate102,forefoot cushioning element703,outsole plate704, amoderator plate105, and agasket106.
• With reference toFIG.7,chassis plate102 may be substantially similar as depicted and described with respect toFIGS.1-6. When assembled,chassis plate102 may be attached (e.g. directly attached) toforefoot cushioning element703. There may be substantially no gap between thechassis plate102 and theforefoot cushioning element703.
• Referring toFIG.8,forefoot cushioning element703 may be similar toforefoot cushioning element103. For example,forefoot cushioning element703 may extend outwardly from its center toward ananterior segment710, aposterior segment712, alateral segment714, and amedial segment716. Aportion717 of the path extending between the ends of segments may be concave when viewed from a radially exterior position. Each of the portions of the path may be convex when viewed from a center offorefoot cushioning element703, although other configurations are contemplated. In other words, the exterior path may bound theforefoot cushioning element103 and may follow an inwardly curved path between the ends of segments of the forefoot cushioning element.
• Segment710 may have an area that is larger than that ofsegment712.Segments714 may be similar tosegment716, but the anterior most part ofsegment714 may be anterior to the most anterior part ofsegment716. In other words,segments714 and716 may generally be similar to one another, but the anterior most portions of thesegments714 and716 may be offset from one another. Additionally, each ofsegments710,714, and716 may have similar outer extending dimensions (i.e. width and length) that may be greater than the outer extending dimensions ofsegment712. Thus,forefoot cushioning element103 may be irregular in shape.
• Referring toFIGS.9 and10,moderator plate105 may have a similar cross or plus-sign shape asforefoot cushioning element703, and extend outwardly from its center toward theanterior end18,posterior end20, themedial side22, and thelateral side24.Moderator plate105 may have atop surface726 and abottom surface728. The portions extending outwardly from the center of themoderator plate105 may define an outer boundary ofmoderator plate105.Moderator plate105 may have disposed on its bottom surface a plurality oftraction elements724. Further,element105 may be flexible so as to impart a desired support characteristic to the article of footwear10.
• Referring toFIG.11,gasket106 may include alower periphery718, anupper periphery720, asidewall719, and anopening722.Sidewall719 may extend vertically upward from thelower periphery718 to theupper periphery720. When viewed from above,upper periphery720 may follow an undulating path corresponding to the undulating path of thelower periphery718.Upper periphery720 andlower periphery718 may form respective flanges of thegasket106. Thus,lower periphery718 may receive and contact themoderator plate105. Thelower periphery718 of thegasket106 may encloseopening722. Opening722 may be bound by the path of thetop surface718. The upward facing surface ofsidewall719 may receiveforefoot cushioning assembly703.
• Outsole plate704 may extend continuously from theanterior end18 of the article of footwear10 to theposterior end20 of the article of footwear.Outsole plate704 may include a narrowedportion705 at the midfoot region. Theoutsole plate704 may further include anupper surface702 facing the upper100 and a lower surface formed on an opposite side of theoutsole plate704 from theupper surface702.Outsole plate104 may have the plurality oftraction elements318 disposed on itslower surface705. Asidewall706 may extend vertically upward from theupper surface702.Sidewall706 may further define an outer periphery of theoutsole plate704. Theupper surface702 of theoutsole plate704 may be attached to the bottom surface of thechassis102.
• Theoutsole plate704 may further include anopening708. Opening708 may be bounded by an undulating path that is generally complementary in shape to forefootcushioning element703,moderator plate105, andgasket106. Theopening708 may be configured to receive thegasket106,moderator plate105, and/orcushioning element703.
• Themoderator plate105 may attach to a ground-facing surface of theforefoot cushioning element703. Themoderator plate105 and theforefoot cushioning element703 may have corresponding geometries, and themoderator plate105 may rest within the inner bounds of the segments of theforefoot cushioning element703. Theforefoot cushioning element703 may be disposed on thetop surface718 of thegasket106. Themoderator plate105 may rest flush within the inner bounds of thegasket106. In other words, each of theforefoot cushioning element703, themoderator plate105, and thegasket106 have corresponding geometries to communicate and rest flush with another. The combination of thegasket106 and themoderator plate105 may form a portion of a ground-engaging surface. Theoutsole plate704 may form another portion of the ground-engaging surface. In other words, theoutsole plate704, along with themoderator plate105, and thegasket106 resting within theopening708, may form the entirety of the ground-engaging surface of the article of footwear.
• Referring toFIG.14, an alternative embodiment of thesole structure101 may include thechassis board1402, aforefoot cushioning element1403, anexternal plate1404, amoderator plate1405, and agasket1406.
• Chassis board1402 may extend continuously from theball portion12B of theforefoot region12 through thetoe portion12T of theforefoot region12 to theanterior end18, and may span a width of thesole structure101 from themedial side22 to thelateral side24. In other words, thechassis board1402 may be disposed solely within theforefoot region12. Thechassis board1402 may further comprise a top (upper) surface facing the bottom of the upper100, and a bottom (lower) surface formed on an opposite side of thechassis board1402 from the top surface, facing in the direction of a ground surface. A distance from the top surface to the bottom surface may define a thickness of thechassis board1402. In the present embodiment, the top surface of thechassis board1402 may be positioned against the strobel of the upper100 (shown inFIG.1) from theanterior end18 to the end of theball portion12B closest to themidfoot region14. In some examples, the entire top surface of thechassis board1402 may be attached (e.g., directly attached) to the strobel of the upper100, such that the upper surface of thechassis board1402 may define a profile of the footbed in theforefoot region12. It is contemplated that, in other examples,chassis board1402 may be attached (e.g. directly attached) to asockliner1401 of the upper100. Thesockliner1401 may include resilient materials to provide a desired form of support and stability when coupled with thechassis board1402.
• Chassis board1402 may be formed of an injection molded material. While shown as a separate component,chassis board1402 may be integrally formed in the upper100. It is contemplated that thechassis board1402 may be used in lieu ofchassis102. In alternative embodiments, thechassis board1402 may be used in conjunction withchassis102 to provide a desired form of cushioning, support, and stability.
• It is contemplated that in other alternative embodiments, thechassis board1402 may be disposed in theforefoot region12 and a portion of themid-foot region14. It is further contemplated that in other alternative embodiments, thechassis board1402 may be disposed within any of theforefoot region12, themid-foot portion14, and theheel portion16 so as to provide a desired level of support, stability, and comfortability to the article of footwear10.
• Forefoot cushioning element1403 may be substantially similar as depicted and described with respect toFIGS.1-6.
• Moderator plate1405 may be substantially similar tomoderator plate106 as depicted and described with respect toFIGS.7,9,10, and13.Moderator plate1405 may have a substantially cross or plus-sign shape corresponding to forefootcushioning element1403.
• Gasket1406 may be substantially similar togasket106 as depicted and described with respect toFIGS.7,11, and13.Gasket1406 may have a corresponding geometry to that ofmoderator plate1405 andforefoot cushioning element1403.
• External plate1404 may be substantially similar tooutsole plate104 as depicted and described with respect toFIGS.7,12, and13.External plate1404 may provide a desired level of stiffness, structure, and flexibility.
• Themoderator plate1405, theforefoot cushioning element1403, and thegasket1406 may be attached in a similar manner as depicted and described inFIGS.7-13.
• Referring toFIG.15, an alternative embodiment of thesole structure101 may include thechassis board1502, aforefoot cushioning element1503, and anexternal plate1504.
• Chassis board1502 may be substantially similar tochassis board1402 as depicted and described with respect toFIG.14.
• Forefoot cushioning element1503 may be substantially similar toforefoot cushioning element703 as depicted and described with respect toFIGS.7-13. In other embodiments, theforefoot cushioning element1503 may have a shape that is larger or smaller than theforefoot cushioning element703. For example, respective segments of theforefoot cushioning element1503 may be narrower than any one or more of thesegments710,712,714, and716. As another example, respective segments of theforefoot cushioning element1503 may be wider than any one or more ofsegments710,712,714, and716.
• Areceptacle1506 may be disposed within theexternal plate1504 and may be substantially similar toreceptacle308 as depicted and described with respect toFIG.2.Receptacle1506 may have a corresponding geometry to that offorefoot cushioning element1503.
• External plate1504 may be substantially similar tooutsole plate1404 as depicted and described with respect toFIG.14.External plate1504 may provide a desired level of stiffness, structure, and flexibility.
• Thechassis board1502, theforefoot cushioning element1503, and theexternal plate1504 may be attached in a similar manner as depicted and described inFIGS.1-6.
• A cross-sectional view of the alternative embodiment of thesole structure101 is shown inFIG.16. The cross-sectional view may be taken perpendicular to a plane extending from theanterior end18 to theposterior end20. Theforefoot cushioning element1503 is disposed within thereceptacle1506 of theoutsole plate1504. Thechassis board1502 is disposed on a side of theforefoot cushioning element1503 opposite thereceptacle1506.
• FIG.17 shows a bottom view of theoutsole plate1504 and thereceptacle1506 including a set ofmajor cleats1518 andminor cleats1522aand1522b. Themajor cleats1518 andminor cleats1522aand1522 are disposed on a ground-facingsurface1520 of thereceptacle1506. Themajor cleats1518 include a substantially crescent shape.Major cleats1518 may be any other shape, such as ovular, circular, rectangular, or the like. Theminor cleats1522aand1522binclude a substantially triangular shape.Minor cleats1522aand1522bmay be any other shape such as ovular, circular, rectangular, or the like. Theminor cleats1522aand1522bare disposed at opposing ends of the ground-facingsurface1520. Themajor cleats1518 are disposed between the opposingminor cleats1522aand1522b. One or more of themajor cleats1518 may be disposed near theminor cleat1522aand another one of the one or moremajor cleats1518 may be disposed near theminor cleat1522b. Opposing ones of themajor cleats1518 may include opposing inner surfaces. For example, onemajor cleat1518 may have a concave inner surface while an opposingmajor cleat1518 may have a convex inner surface. In another example, onemajor cleat1518 may have a concave inner surface while an opposingmajor cleat1518 may have a concave inner surface. In another example, onemajor cleat1518 may have a convex inner surface while an opposingmajor cleat1518 may have a convex inner surface.
Materials
• The barrier layers offorefoot cushioning element103/703 may each be produced from an elastomeric material that includes one or more thermoplastic polymers and/or one or more cross-linkable polymers. In an aspect, the elastomeric material may include one or more thermoplastic elastomeric materials, such as one or more thermoplastic polyurethane (TPU) copolymers, one or more ethylene-vinyl alcohol (EVOH) copolymers, and the like.
• As used herein, “polyurethane” refers to a copolymer (including oligomers) that contains a urethane group (—N(C═O)O—). These polyurethanes may contain additional groups such as ester, ether, urea, allophanate, biuret, carbodiimide, oxazolidinyl, isocynaurate, uretdione, carbonate, and the like, in addition to urethane groups. In an aspect, one or more of the polyurethanes may be produced by polymerizing one or more isocyanates with one or more polyols to produce copolymer chains having (—N(C═O)O—) linkages.
• Examples of suitable isocyanates for producing the polyurethane copolymer chains include diisocyanates, such as aromatic diisocyanates, aliphatic diisocyanates, and combinations thereof. Examples of suitable aromatic diisocyanates include toluene diisocyanate (TDI), TDI adducts with trimethyloylpropane (TMP), methylene diphenyl diisocyanate (MDI), xylene diisocyanate (XDI), tetramethylxylylene diisocyanate (TMXDI), hydrogenated xylene diisocyanate (HXDI), naphthalene 1,5-diisocyanate (NDI), 1,5-tetrahydronaphthalene diisocyanate, para-phenylene diisocyanate (PPDI), 3,3′-dimethyldiphenyl-4,4′-diisocyanate (DDDI), 4,4′-dibenzyl diisocyanate (DBDI), 4-chloro-1,3-phenylene diisocyanate, and combinations thereof. In some embodiments, the copolymer chains are substantially free of aromatic groups.
• In particular aspects, the polyurethane polymer chains are produced from diisocynates including HMDI, TDI, MDI, H12 aliphatics, and combinations thereof. In an aspect, the thermoplastic TPU may include polyester-based TPU, polyether-based TPU, polycaprolactone[1] based TPU, polycarbonate-based TPU, polysiloxane-based TPU, or combinations thereof.
• In another aspect, the polymeric layer may be formed of one or more of the following: EVOH copolymers, poly(vinyl chloride), polyvinylidene polymers and copolymers (e.g., polyvinylidene chloride), polyamides (e.g., amorphous polyamides), amide-based copolymers, acrylonitrile polymers (e.g., acrylonitrile-methyl acrylate copolymers), polyethylene terephthalate, polyether imides, polyacrylic imides, and other polymeric materials known to have relatively low gas transmission rates. Blends of these materials, as well as with the TPU copolymers described herein and optionally including combinations of polyimides and crystalline polymers, are also suitable.
• One or more of theelements102 and103 may be formed of a resilient polymeric material, such as foam or rubber, to impart properties of cushioning, responsiveness, and energy distribution to the foot of the wearer. Theelements102 and103 may be affixed within the sole structure using a fusing process, using an adhesive, or by suspending the elements in a different resilient polymeric material. As discussed above, theelements102,103, and104 may be formed with cooperating geometries (e.g., steps, protrusions) for restricting relative motion between theelements102,103, and104 of the sole structure.
• Example resilient polymeric materials for theelements102 and103 may include those based on foaming or molding one or more polymers, such as one or more elastomers (e.g., thermoplastic elastomers (TPE)). The one or more polymers may include aliphatic polymers, aromatic polymers, or mixtures of both; and may include homopolymers, copolymers (including terpolymers), or mixtures of both.
• In some aspects, the one or more polymers may include olefinic homopolymers, olefinic copolymers, or blends thereof. Examples of olefinic polymers include polyethylene, polypropylene, and combinations thereof. In other aspects, the one or more polymers may include one or more ethylene copolymers, such as, ethylene-vinyl acetate (EVA) copolymers, EVOH copolymers, ethylene-ethyl acrylate copolymers, ethylene-unsaturated mono-fatty acid copolymers, and combinations thereof.
• In further aspects, the one or more polymers may include one or more polyacrylates, such as polyacrylic acid, esters of polyacrylic acid, polyacrylonitrile, polyacrylic acetate, polymethyl acrylate, polyethyl acrylate, polybutyl acrylate, polymethyl methacrylate, and polyvinyl acetate; including derivatives thereof, copolymers thereof, and any combinations thereof.
• In yet further aspects, the one or more polymers may include one or more ionomeric polymers. In these aspects, the ionomeric polymers may include polymers with carboxylic acid functional groups, sulfonic acid functional groups, salts thereof (e.g., sodium, magnesium, potassium, etc.), and/or anhydrides thereof. For instance, the ionomeric polymer(s) may include one or more fatty acid-modified ionomeric polymers, polystyrene sulfonate, ethylene-methacrylic acid copolymers, and combinations thereof.
• In further aspects, the one or more polymers may include one or more styrenic block copolymers, such as acrylonitrile butadiene styrene block copolymers, styrene acrylonitrile block copolymers, styrene ethylene butylene styrene block copolymers, styrene ethylene butadiene styrene block copolymers, styrene ethylene propylene styrene block copolymers, styrene butadiene styrene block copolymers, and combinations thereof.
• In further aspects, the one or more polymers may include one or more polyamide copolymers (e.g., polyamide-polyether copolymers) and/or one or more polyurethanes (e.g., cross-linked polyurethanes and/or thermoplastic polyurethanes). Alternatively, the one or more polymers may include one or more natural and/or synthetic rubbers, such as butadiene and isoprene.
• When the resilient polymeric material is a foamed polymeric material, the foamed material may be foamed using a physical blowing agent which phase transitions to a gas based on a change in temperature and/or pressure, or a chemical blowing agent which forms a gas when heated above its activation temperature. For example, the chemical blowing agent may be an azo compound such as adodicarbonamide, sodium bicarbonate, and/or an isocyanate.
• In some embodiments, the foamed polymeric material may be a cross-linked foamed material. In these embodiments, a peroxide-based crosslinking agent such as dicumyl peroxide may be used. Furthermore, the foamed polymeric material may include one or more fillers such as pigments, modified or natural clays, modified or unmodified synthetic clays, talc glass fiber, powdered glass, modified or natural silica, calcium carbonate, mica, paper, wood chips, and the like.
• The resilient polymeric material may be formed using a molding process. In one example, when the resilient polymeric material is a molded elastomer, the uncured elastomer (e.g., rubber) may be mixed in a Banbury mixer with an optional filler and a curing package such as a sulfur-based or peroxide-based curing package, calendared, formed into shape, placed in a mold, and vulcanized.
• In another example, when the resilient polymeric material is a foamed material, the material may be foamed during a molding process, such as an injection molding process. A thermoplastic polymeric material may be melted in the barrel of an injection molding system and combined with a physical or chemical blowing agent and optionally a crosslinking agent, and then injected into a mold under conditions which activate the blowing agent, forming a molded foam.
• Optionally, when the resilient polymeric material is a foamed material, the foamed material may be a compression molded foam. Compression molding may be used to alter the physical properties (e.g., density, stiffness and/or durometer) of a foam, or to alter the physical appearance of the foam (e.g., to fuse two or more pieces of foam, to shape the foam, etc.), or both.
• The compression molding process desirably starts by forming one or more foam preforms, such as by injection molding and foaming a polymeric material, by forming foamed particles or beads, by cutting foamed sheet stock, and the like. The compression molded foam may then be made by placing the one or more preforms formed of foamed polymeric material(s) in a compression mold, and applying sufficient pressure to the one or more preforms to compress the one or more preforms in a closed mold. Once the mold is closed, sufficient heat and/or pressure is applied to the one or more preforms in the closed mold for a sufficient duration of time to alter the preform(s) by forming a skin on the outer surface of the compression molded foam, fuse individual foam particles to each other, permanently increase the density of the foam(s), or any combination thereof. Following the heating and/or application of pressure, the mold is opened and the molded foam article is removed from the mold.
• The barrier layers402 and404 may include two or more sublayers (multilayer film) such as shown in Mitchell et al., U.S. Pat. No. 5,713,141 and Mitchell et al., U.S. Pat. No. 5,952,065, the disclosures of which are incorporated by reference in their entirety. In embodiments where the barrier layers402 and404 include two or more sublayers, examples of suitable multilayer films include microlayer films, such as those disclosed in Bonk et al., U.S. Pat. No. 6,582,786, which is incorporated by reference in its entirety. In further embodiments, the barrier layers402 and404 may each independently include alternating sublayers of one or more TPU copolymer materials and one or more EVOH copolymer materials, where the total number of sublayers in each of the barrier layers402 and404 includes at least four (4) sublayers, at least ten (10) sublayers, at least twenty (20) sublayers, at least forty (40) sublayers, and/or at least sixty (60) sublayers.
• Theforefoot cushioning element103 may be provided in a fluid-filled (shown inFIG.4A) or in an unfilled state. Theforefoot cushioning element103 may be filled to include any suitable fluid, such as a gas or liquid. In an aspect, the gas may include air, nitrogen (N₂), or any other suitable gas. In other aspects, theforefoot cushioning element103 may alternatively include other media, such as pellets, beads, ground recycled material, and the like (e.g., foamed beads and/or rubber beads).
• The following clauses provide an exemplary configuration for an article of footwear and sole structure described above.
• Clause 1. A sole structure for an article of footwear, the sole structure including a forefoot region and a heel region; a chassis plate; an outsole plate extending from the forefoot region to the heel region, the outsole plate including a recess disposed in a top surface, wherein the outsole plate is disposed below the chassis plate; and a cushioning element disposed within the recess.
• Clause 2. The sole structure of clause 1, wherein the cushioning element includes a fluid-filled bladder.
• Clause 3. The sole structure of clause 1, wherein a top surface of the cushioning element is flush with the top surface of the outsole plate when the cushioning element is disposed within the recess.
• Clause 4. The sole structure of clause 1, wherein the outsole plate includes; a bottom surface; and a plurality of traction elements disposed on the bottom surface of the outsole plate.
• Clause 5. The sole structure of clause 4, wherein the plurality of traction elements are integrally molded into the bottom surface of the outsole plate.
• Clause 6. The sole structure of clause 1, wherein a bottom surface of the outsole plate forms a ground-contacting surface of the sole structure.
• Clause 7. The sole structure of clause 1, wherein the outsole plate has a longitudinal length, and a midpoint along the longitudinal length, wherein the outsole plate includes an anterior area that is anterior to the midpoint, and wherein an area of the cushioning element is less than about 70% of the anterior area.
• Clause 8. The sole structure of clause 1, wherein the chassis plate and outsole plate have substantially the same length.
• Clause 9. An article of footwear comprising the sole structure of clause 1.
• Clause 10. A sole structure for an article of footwear, the sole structure including a forefoot region and a heel region; a chassis plate; an outsole plate extending from the forefoot region to the heel region, the outsole plate including an opening in the forefoot region, wherein the outsole plate is disposed below the chassis plate; and a cushioning element disposed in the opening.
• Clause 11. The sole structure of clause 10, further including a moderator plate disposed in the opening and in contact with the cushioning element.
• Clause 12. The sole structure of clause 11, wherein a bottom surface of the outsole plate and a bottom surface of the moderator plate form a portion of a ground-contacting surface of the sole structure.
• Clause 13. The sole structure ofclause 12, further including a gasket disposed within the opening, wherein the gasket radially surrounds the moderator plate and the cushioning element.
• Clause 14. The sole structure of clause 11, wherein a bottom surface of the moderator plate includes one or more traction elements.
• Clause 15. The sole structure of clause 10, wherein a bottom surface of the outsole plate includes one or more traction elements.
• Clause 16. The sole structure of clause 10, wherein the cushioning element includes a fluid-filled bladder.
• Clause 17. An article of footwear comprising the sole structure of clause 10.
• Clause 18. A sole structure for an article of footwear, the sole structure including a forefoot region and a heel region; an outsole plate extending from the forefoot region to the heel region, the outsole plate including an opening in the forefoot region; a moderator plate disposed within the opening; and a gasket surrounding the moderator plate.
• Clause 19. The sole structure ofclause 18, wherein the outsole plate, the moderator plate, and the gasket, form a ground-contacting surface of the sole structure.
• Clause 20. An article of footwear comprising the sole structure ofclause 18.

Claims (21)

1-20. (canceled)

21. A sole structure for an article of footwear, the sole structure comprising:

a forefoot region and a heel region;

a rigid chassis plate;

a rigid outsole plate extending from the forefoot region to the heel region, wherein the outsole plate is disposed below the chassis plate; and

a cushioning element disposed between the chassis plate and the outsole plate.

22. The sole structure ofclaim 21, wherein the cushioning element includes a fluid-filled bladder.

23. The sole structure ofclaim 21, wherein a top surface of the cushioning element is flush with the top surface of the outsole plate when the cushioning element is disposed within the recess.

24. The sole structure ofclaim 21, wherein the outsole plate includes;

a bottom surface; and

a plurality of traction elements disposed on the bottom surface of the outsole plate.

25. The sole structure ofclaim 24, wherein the plurality of traction elements are integrally molded into the bottom surface of the outsole plate.

26. The sole structure ofclaim 21, wherein a bottom surface of the outsole plate forms a ground-contacting surface of the sole structure.

27. The sole structure ofclaim 21, wherein the outsole plate has a longitudinal length, and a midpoint along the longitudinal length, wherein the outsole plate includes an anterior area that is anterior to the midpoint, and wherein an area of the cushioning element is less than about 70% of the anterior area.

28. The sole structure ofclaim 21, wherein the chassis plate and outsole plate have substantially the same length.

29. The sole structure ofclaim 21, wherein the chassis plate has an oblong shape.

30. The sole structure ofclaim 21, wherein the chassis plate is disposed in the forefoot region.

31. The sole structure ofclaim 21, wherein the outsole plate includes a recess, and wherein the cushioning element is disposed within the recess of the outsole plate.

32. An article of footwear comprising the sole structure ofclaim 21.

33. A sole structure for an article of footwear, the sole structure comprising:

a forefoot region and a heel region;

a chassis plate disposed in the forefoot region, the chassis plate having an oblong shape;

a cleated outsole plate extending from the forefoot region to the heel region, wherein the outsole plate is disposed below the chassis plate; and

a fluid-filled bladder disposed within the recess between the chassis plate and the outsole plate.

34. The sole structure ofclaim 33, wherein a bottom surface of the outsole plate includes one or more traction elements.

35. The sole structure ofclaim 33, wherein the cushioning element includes a fluid-filled bladder.

36. An article of footwear comprising the sole structure ofclaim 33.

37. The sole structure ofclaim 33, wherein the chassis plate is disposed solely in the forefoot region.

38. The sole structure ofclaim 33, wherein the chassis plate is disposed solely in the forefoot region and a midfoot region.

39. The sole structure ofclaim 33, wherein the chassis plate is not disposed in the heel region.

40. The sole structure ofclaim 33, wherein the chassis plate is formed of a rigid material, and wherein the cleated outsole plate is formed of a rigid material.

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