Sole structure with bladder for article of footwear and method of manufacturing the same

• US 10,299,536 B2
• Filed: 11/09/2016
• Issued: 05/28/2019
• Est. Priority Date: 09/16/2014
• Status: Active Grant

• Current Assignee: Nike, Inc.
• Original Assignee: Nike, Inc.
• Inventors: Ernst, Travis K., Schindler, Eric S.
• Primary Examiner(s): Huson, Monica A
• Application Number:
  US15/346,868
• Publication Number:
  US 20170049184A1
• Time in Patent Office: 930 Days
• Field of Search: None
• CPC Class Codes: A43B 13/04 Plastics, rubber or vulcanised fibre
• CPC Class Codes: A43B 13/122 characterised by the outsole or external layer
• CPC Class Codes: A43B 13/125 characterised by the midsole or middle layer
• CPC Class Codes: A43B 13/127 the midsole being multilayer
• CPC Class Codes: A43B 13/141 with a part of the sole being flexible, e.g. permitting articulation or torsion
• CPC Class Codes: A43B 13/181 Resiliency achieved by the structure of the sole
• CPC Class Codes: A43B 13/186 Differential cushioning region, e.g. cushioning located under the ball of the foot resilient heel not included in the sole A43B21/26; resilient supports for the heel of the foot A43B21/32
• CPC Class Codes: A43B 13/188 Differential cushioning regions
• CPC Class Codes: A43B 13/189 filled with a non-compressible fluid, e.g. gel, water
• CPC Class Codes: A43B 13/20 Pneumatic soles filled with a compressible fluid, e.g. air, gas inflatable linings for skiboots A43B5/0407
• CPC Class Codes: B29C 49/22 using multilayered preforms or parisons
• CPC Class Codes: B29C 49/4802 with means for locally compressing part(s) of the parison in the main blowing cavity
• CPC Class Codes: B29C 49/4812 and welding opposite wall parts of the parisons or preforms to each other
• CPC Class Codes: B29C 49/50 having cutting or deflashing means
• CPC Class Codes: B29C 51/105 Twin sheet thermoforming, i.e. deforming two parallel opposing sheets or foils at the same time by using one common mould cavity and without welding them together during thermoforming B29C51/267, B29C49/0691 take precedence
• CPC Class Codes: B29C 51/32 having cutting means
• CPC Class Codes: B29C 51/36 specially adapted for vacuum forming , Manufacture thereof
• CPC Class Codes: B29C 65/70 by moulding using a particular moulding technique, see the relevant technique , e.g. by injection B29C45/14467
• CPC Class Codes: B29D 35/0054 by compression moulding, vulcanising or the like; Apparatus therefor
• CPC Class Codes: B29D 35/122 Soles
• CPC Class Codes: B29D 35/128 : Moulds or apparatus therefor
• CPC Class Codes: B29D 35/142 : Soles
• CPC Class Codes: B29D 35/148 : Moulds or apparatus therefor
• CPC Class Codes: B29K 2105/256 : Sheets, plates, blanks or films

Abstract

A method of manufacturing a sole structure includes providing a plate within a cavity of a mold. The plate includes a base and a rib, and the base includes a first surface and a second surface. The first surface faces the upper, the second surface faces away from the first surface, and the rib projects from the second surface of the base. Moreover, the method includes providing a preform bladder member within the cavity of the mold, wherein the preform bladder member including a first member and a second member. The method additionally includes forming a bladder from the first and second members using the mold. Also, the method includes attaching the first member to the plate using the mold. Attaching the first member to the plate includes shaping the first member according to surfaces of the rib.

Claims

1. A sole structure for an article of footwear including an upper, the

sole structure comprising:

a plate including a first surface opposing the upper, a second surface formed on an opposite side of the plate than the first surface, and at least one rib projecting from the second surface, the at least one rib including a first side surface extending away from the second surface, a second side surface extending away from the second surface, and an end surface extending between the first side surface and the second side surface; and

a bladder including a first member and a second member that define an interior chamber within the bladder, the first member (i) attached to the first side surface, the second side surface, and the end surface of the at least one rib and (ii) layered substantially continuously across the second surface, the first side surface, the second side surface, and the end surface.

2. The sole structure of claim 1, wherein the at least one rib includes a first segment and a second segment, the first segment being spaced apart from the second segment to define a break between the first segment and the second segment.

3. The sole structure of claim 2, wherein the first member is attached to the plate within the break.

4. The sole structure of claim 2, wherein the plate includes a peripheral edge having a notch extending into the plate and in a direction toward the at least one rib.

5. The sole structure of claim 4, wherein the notch is substantially aligned with the break.

6. The sole structure of claim 1, wherein the plate includes an outer peripheral edge, the at least one rib being spaced apart from the outer peripheral edge to define an outer area of the second surface extending between the outer peripheral edge and the rib.

7. The sole structure of claim 6, wherein the first member is attached to the second surface within the outer area.

8. The sole structure of claim 1, wherein the plate defines a heel region configured to support a heel of a wearer, the at least one rib being disposed within the heel region.

9. The sole structure of claim 8, wherein the plate includes a medial edge, a lateral edge, and a rear edge, the at least one rib extending along and spaced apart from the medial edge, the rear edge, and the lateral edge.

10. The sole structure of claim 9, wherein the first member is layered continuously on the plate from the medial edge to the lateral edge.

11. A sole structure for an article of footwear including an upper, the sole structure comprising:

a plate including a first surface opposing the upper, a second surface formed on an opposite side of the plate than the first surface, a first rib projecting from the second surface and extending along and spaced apart from one of a medial edge and a lateral edge of the plate, and a second rib projecting from the second surface and extending along and spaced apart from the other of the medial edge and the lateral edge of the plate, the second rib being spaced apart from the first rib; and

a bladder including a first member and a second member that define an interior chamber within the bladder, the first member being attached to the first rib, the second rib, and the second surface in an area between the first rib and the second rib.

12. The sole structure of claim 11, wherein the first member is layered substantially continuously across the second surface between the medial edge and the lateral edge.

13. The sole structure of claim 11, further comprising a break defined between the first rib and the second rib.

14. The sole structure of claim 13, wherein the first member is attached to the plate within the break.

15. The sole structure of claim 13, wherein the plate includes a peripheral edge having a notch extending into the plate, the notch being substantially aligned with the break.

16. The sole structure of claim 11, wherein the plate includes an outer peripheral edge, the first rib and the second rib being spaced apart from the outer peripheral edge to define an outer area of the second surface.

17. The sole structure of claim 16, wherein the first member is attached to the second surface within the outer area.

18. The sole structure of claim 11, wherein the first member is attached to the second surface in an area between the first rib and the one of the medial edge and the lateral edge and/or in an area between the second rib and the other of the medial edge and the lateral edge.