Article of footwear with a perforated midsole

• US 20060156579A1
• Filed: 01/18/2005
• Published: 07/20/2006
• Est. Priority Date: 01/18/2005
• Status: Active Grant

• Current Assignee: Nike, Inc.
• Original Assignee: Nike, Inc.
• Inventors: Hurd, John, Hoffer, Kevin W.
• Granted Patent: US 7,475,497 B2
• Time in Patent Office: Days
• US Class Current: 36/28
• CPC Class Codes: A43B 1/0009 made at least partially of alveolar or honeycomb material
• 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 13/189 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

Abstract

An article of footwear is disclosed that includes an upper and a sole structure secured to the upper. The sole structure includes a midsole element, an upper sheet, and a lower sheet. The midsole element has an upper surface and an opposite lower surface. In addition, the midsole element defines a plurality of bores extending from the upper surface to the lower surface. The upper sheet is secured to the upper surface and extends over at least a portion of the bores. The lower sheet is secured to the lower surface, and the lower sheet is positioned to correspond in location with the upper sheet and extend under the portion of the bores.

Claims

1. An article of footwear having an upper and a sole structure secured to the upper, the sole structure comprising:

a midsole element formed from a polymer material and having a first surface and an opposite second surface the midsole element extending substantially through a longitudinal length of the sole structure and from a lateral side to a medial side of the sole structure, the midsole element defining a plurality of bores extending through the polymer material and from the first surface to the second surface;

a first sheet secured to the first she and extending over at least a portion of the bores; and

a second sheet secured to the second surface, the second sheet being positioned to correspond in location with the first sheet and extend under the portion of the bores.

2. The article of footwear recited in claim 1, wherein the bores have a hexagonal shape.

3. The article of footwear recited in claim 1, wherein a s of the bores is selected from a group consisting of triangular, square, pentagonal, and round.

4. The article of footwear recited in claim 1, wherein the bores form a tessellation.

5. The article of footwear recited in claim 1, wherein the bores are tapered.

6. The article of footwear recited in claim 1, wherein dimensions of the bores vary throughout the midsole element.

7. The article of footwear recited in claim 1, wherein one of the bores is positioned in a heel region of the footwear and in a location that corresponds with a calcaneas bone of a foot, the one of the bores having dimensions that are greater than dimensions of a remainder of the bores.

8. The article of footwear recited in claim 1, wherein the bores have a substantially vertical orientation.

9. The article of footwear recited in claim 1, wherein the first sheet exposes another portion of the bores.

10. The article of footwear recited in claim 1, wherein the first sheet and the second sheet are positioned in a heel region of the footwear.

11. The article of footwear recited in claim 1, wherein the first sheet and the second sheet are positioned in a forefoot region of the footwear.

12. The article of footwear recited in claim 1, wherein the first sheet and the second sheet are positioned adjacent the medial side.

13. The article of footwear recited in claim 1, wherein the first sheet forms three discrete portions that are respectively positioned in a heel region of the footwear, at least one of a forefoot region and a midfoot region of the footwear, and the forefoot region.

14. The article of footwear recited in claim 13, wherein the second sheet trims three discrete portions positioned to correspond in location with the three discrete portions of the first sheet.

15. The article of footwear recited in claim 13, wherein at least one of the three discrete portions is positioned adjacent the medial side, and another of the three discrete portions is positioned adjacent the lateral side.

16. The article of footwear recited in claim 1, wherein the first sheet and the second sheet are formed from a polymer material, and the first sheet and the second sheet are bonded to the midsole element.

17. The article of footwear recited in claim 1, wherein the first sheet and the second sheet seal a fluid within the bores.

18. The article of footwear recited in claim 1, wherein the second sheet is an outsole.

19. An article of footwear having an upper and a sole structure secured to the upper, the sole structure comprising:

a midsole element formed from a polymer Ha material and having an upper surface and an opposite lower surface, the midsole element defining a plurality of bores extending through the polymer material and from the upper surface to the lower surface;

a first upper sheet secured to the upper surface and extending over a first portion of the bores;

a second upper sheet secured to the upper surface and extending over a second portion of the bores; and

at least one lower sheet secured to the lower surface, the lower sheet being positioned to correspond in location with the first upper sheet and the second upper sheet, and the lower sheet extending under the first portion and the second portion of the bores,

wherein the first upper sheet and the lower sheet seal a fluid within the first portion of the bores, the second upper sheet and the lower sheet seal the fluid within the second portion of the bores, and neither the first upper sheet nor the second upper sheet extend over a third portion of the bores.

20. The article of footwear recited in claim 19, wherein the midsole element extends substantially through a longitudinal length of the sole structure and from a lateral side to a medial side of the sole structure.

21. The article of footwear recited in claim 19, wherein the bores have a hexagonal shape.

22. The article of footwear recited in claim 19, wherein a shape of the bores is selected from a group consisting of triangular, square, pentagonal, and round.

23. The article of footwear recited in claim 19, wherein the bores form a tessellated configuration.

24. The article of footwear recited in claim 19, wherein the bores are tapered.

25. The article of footwear recited in claim 19, wherein dimensions of the bores vary throughout the midsole element.

26. The article of footwear recited in claim 19, wherein one of the bores is positioned in a heel region of the footwear and in a location that corresponds with a calcaneus bone of a foot, the one of the bores having dimensions that are greater than dimensions of a remainder of the bores.

27. The article of footwear recited in claim 19, wherein the bores have a substantially vertical orientation.

28. The article of footwear recited in claim 19, wherein the first upper sheet is positioned in a heel region of the footwear.

29. The article of footwear recited in claim 28, wherein the second upper sheet is positioned in a forefoot region of the footwear.

30. The article of footwear recited in claim 29, wherein the second upper sheet is positioned adjacent a medial side of the sole structure.

31. The article of footwear recited in claim 19, wherein the lower sheet is an outsole.

32. An article of footwear having an upper and a sole structure secured to the upper, at least a portion of the sole structure consisting of:

a midsole element formed from a polymer material and having a first surface and an opposite second surface, the midsole element defining a plurality of bores extending from the first surface to the second surface, the bores forming a tessellation in at least a portion of the midsole element;

a first sheet secured to the first surface and ending over at least a portion of the bores; and

a second sheet secured to die second surface and extending under the portion of the bores.

33. The article of footwear recited in claim 32, wherein the midsole element extends substantially through a longitudinal length of the sole structure and from a lateral side to a medial side of the sole structure.

34. The article of footwear recited in claim 32, wherein the second sheet is positioned to correspond in location with the first sheet.

35. The article of footwear recited in claim 32, wherein the bores are oriented to be substantially vertical.

36. The article of footwear recited in claim 32, wherein a shape of the bores is selected from a group consisting of triangular, square, and hexagonal.

37. The article of footwear recited in claim 32, wherein the bores are tapered

38. The article of footwear recited in claim 32, wherein the first sheet exposes another portion of the bores.

39. The article of footwear recited in claim 32, wherein the first sheet forms three discrete portions that are respectively positioned in a heel region of the footwear, at least one of a forefoot region and a midfoot region of the footwear, and the forefoot region.

40. The article of footwear recited in claim 39, wherein the second sheet forms three discrete portions positioned to correspond in location with the three discrete portions of the first sheet.

41. The article of footwear recited in claim 32, wherein the fit sheet and the second sheet seal a fluid within the bores.

42. The article of footwear recited in claim 32, wherein the second sheet is an outsole.

43. An article of footwear having an upper and a sole structure secured to the upper, the sole structure comprising:

a midsole element formed from a polymer foam material and having an upper surface and an opposite lower surface, the midsole element extending substantially through a forefoot region, a midfoot region, and a heel region of the sole structure and from a lateral side to a medial side of the sole structure, the midsole element defining a plurality of substantially vertical bores extending through the polymer foam material and from the upper surface to the lower surface;

a first upper sheet secured to the upper surface and unending over at least a first portion of the bores, the first upper sheet being positioned in the heel region;

a second upper sheet secured to the upper surface and extending over at least a second portion of the bores, the second upper sheet being positioned in at least one of the midfoot region and the forefoot region, and the second upper sheet being positioned adjacent the lateral side;

a third upper sheet secured to the upper surface and extending over at least a third portion of the bores, the third upper sheet being positioned in the forefoot region, and the third upper sheet being positioned adjacent the medial side; and

at least one lower sheet secured to the lower surface and extending under the first portion, the second portion, and the third portion,

wherein the first upper sheet, the second upper sheet, the third upper sheet, and the lower sheet seal a fluid within the first portion, the second portion, and the third portion of the bores, and a fourth portion of the bores are not seated.

44. The article of footwear recited in claim 43, wherein the bores have a hexagonal shape.

45. The article of footwear recited in claim 43, wherein a shape of the bores is selected from a group consisting of triangular, square, pentagonal, and round.

46. The article of footwear recited in claim 43, wherein the bores form a tessellation.

47. The article of footwear recited in claim 43, wherein the bores are tapered.

48. The article of footwear recited in claim 43, wherein dimensions of the bores vary throughout the midsole element.

49. The article of footwear recited in claim 43, wherein one of the bores is positioned in a heel region of the footwear and in a location that corresponds with a calcaneus bone of a foot, the one of the bores having dimensions that are greater than dimensions of a remainder of the bores.

50. The article of footwear recited in claim 43, wherein the first upper sheet, the second upper sheet, the third upper sheet, and the lower sheet are formed from a polymer material, and the first upper sheet, the second upper sheet, the third upper sheet, and the lower sheet are bonded to the midsole element.

51. The article of footwear recited in claim 43, wherein the lower sheet is an outsole.

52. A method of manufacturing an article of footwear, the method comprising steps of:

molding a midsole element from a polymer foam material to define a plurality of bores extending between a first surface and an opposite second surface of the midsole element;

securing a first sheet and a second sheet to the midsole element, the first sheet being secured to the first surface to extend over a portion of the bores, and the second sheet being secured to the second surface to extend under the portion of the bores; and

incorporating the midsole element, the first sheet, and the second sheet into the article of footwear.

53. The method recited in claim 52, wherein the step of molding includes forming the bores to have a hexagonal shape.

54. The method recited in claim 52, wherein the step of molding includes forming the bores to have a shape selected from a group consisting of triangular, square, pentagonal, and round.

55. The method recited in claim 52, wherein the step of molding includes forming the bores to define a tessellation.

56. The method recited in claim 52, wherein the step of molding includes tapering the bores.

57. The method recited in claim 52, wherein the step of securing includes forming the first sheet to be at least two discrete sheets of a polymer material that are bonded to the first surface.

58. The method recited in claim 52, wherein the step of securing includes sealing a fluid within the portion of the bores.

59. The method recited in claim 52, wherein the step of securing includes forming the second sheet to be an outsole.

60. A method of manufacturing an article of footwear, the method coming steps of:

molding a midsole element from a polymer foam material to define a plurality of bores extending between a first surface and an opposite second surface of the midsole element, the bores forming a tessellation on at least one of the first surface and the second surface;

securing a first sheet and a second sheet to the midsole element to seal a fluid within a portion of the bores, the first sheet being secured to the first surface to extend over the portion of the bores, and the second sheet being secured to the second surface to extend under the portion of the bores; and

incorporating the midsole element, the first sheet, and the second sheet into the article of footwear.

61. The method recited in claim 60, wherein the step of molding includes forming the bores to have a shape selected from a group consisting of triangular, square, and hexagonal.

62. The method recited in claim 60, wherein the step of molding includes tapering the bores.

63. The method recited in claim 60, wherein the step of securing includes forming the first sheet to be at least two discrete sheets of a polymer material that are bonded to the first surface.

64. The method recited in claim 60, wherein the stop of securing includes forming the second sheet to be an outsole.