Sole structures and articles of footwear having a lightweight midsole member with protective elements

• US 9,301,566 B2
• Filed: 03/15/2013
• Issued: 04/05/2016
• Est. Priority Date: 03/15/2013
• Status: Active Grant

• Current Assignee: Nike, Inc.
• Original Assignee: Nike, Inc.
• Inventors: Dojan, Frederick J., Holmes, Matthew J., Lindner, Troy C., Nethongkome, Benjamin, Thompson, Dolores S.
• Primary Examiner(s): Hurley, Shaun R
• Assistant Examiner(s): Nguyen, Bao-Thieu L
• Application Number:
  US13/835,715
• Publication Number:
  US 20140259788A1
• Time in Patent Office: 1,117 Days
• Field of Search: 361/03, 36/25.R, 36/3.B
• US Class Current: 1/1
• CPC Class Codes: A43B 1/0018 made at least partially of flexible, bellow-like shaped material
• CPC Class Codes: A43B 13/04 Plastics, rubber or vulcanised fibre
• 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 13/16 Pieced soles with several layers of different material A43B13/12
• 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 13/223 Profiled soles
• CPC Class Codes: A43B 7/14 with foot-supporting parts
• CPC Class Codes: A43B 7/1425 situated under the ball of the foot, i.e. the joint between the first metatarsal and first phalange
• CPC Class Codes: A43B 7/1435 situated under the joint between the fifth phalange and the fifth metatarsal bone
• CPC Class Codes: A43B 7/144 situated under the heel, i.e. the calcaneus bone
• CPC Class Codes: A43B 7/1445 situated under the midfoot, i.e. the second, third or fourth metatarsal

Abstract

Sole structures for articles of footwear, including athletic footwear, include a relatively soft and lightweight foam midsole component partially covered by at least one more rigid and/or dense cage (protective) component(s) and/or other protective component(s). The sole structure may include a first polymeric foam member, wherein an exposed outer edge of the first polymeric foam member includes a billows structure that extends continuously from a medial midfoot or forefoot area of the first polymeric foam member proximate to a lateral midfoot or forefoot area of the first polymeric foam member, and wherein the billows structure includes billow outer ridges connected by billow interstitial areas located between adjacent billow outer ridges.

Claims

1. An article of footwear, comprising:

an upper; and

a sole structure engaged with the upper, wherein the sole structure includes a first polymeric foam member configured to support at least a heel and midfoot area of a wearer'"'"'s foot, wherein an exposed outer edge of the first polymeric foam member includes a billows structure that extends continuously from a medial midfoot or forefoot area of the first polymeric foam member proximate to a lateral midfoot or forefoot area of the first polymeric foam member, and wherein the billows structure includes five billow outer ridges connected by four billow interstitial areas located between adjacent billow outer ridges of the five billow outer ridges,

wherein the billow ridges extend upwardly at an angle from front ends of the ridges to rear ends of the ridges.

2. An article of footwear according to claim 1, wherein, at a rear heel area of the first polymeric foam member, a highest billow outer ridge is vertically separated from a lowest billow outer ridge by a vertical distance of at least 1.5 inches when the sole structure is oriented on a horizontal surface.

3. An article of footwear according to claim 1, wherein, at a rear heel area of the first polymeric foam member, a central billow outer ridge extends rearward a distance greater than a distance that any other billow outer ridge extends when the sole structure is oriented on a horizontal surface.

4. An article of footwear according to claim 1, wherein the sole structure is configured to support an entire plantar surface of a wearer'"'"'s foot.

5. An article of footwear according to claim 1, wherein the first polymeric foam member constitutes an outer shell including the billows structure, wherein the outer shell includes:

a lateral side wall,

a medial side wall,

a rear heel wall connecting the medial side wall and the lateral side wall, and

a bottom wall connecting the medial side wall, the lateral side wall, and the rear heel wall,

wherein the billows structure extends continuously around an exterior surface of the lateral side wall, the rear heel wall, and the medial side wall.

6. An article of footwear according to claim 5, wherein the sole structure further includes a second polymeric foam member having a heel portion received in a space defined between the lateral side wall, the medial side wall, the rear heel wall, and the bottom wall of the first polymeric foam member, and wherein a forefoot end of the second polymeric foam member extends beyond a forward end of the lateral side wall and a forward end of the medial side wall of the first polymeric foam member.

7. An article of footwear according to claim 6, wherein an exposed outer edge of the second polymeric foam member includes a billows structure that extends around a front toe area of the sole structure, wherein the billows structure of the second polymeric foam member includes three billow outer ridges connected by two billow interstitial areas located between adjacent billow outer ridges of the three billow outer ridges of the second polymeric foam member.

8. An article of footwear according to claim 7, wherein the billows structure of the second polymeric foam member is not continuous with the billows structure of the first polymeric foam member.

9. An article of footwear according to claim 7, wherein the billows structure of the second polymeric foam member is separated from the billows structure of the first polymeric foam member at a lateral forefoot area of the sole structure and at a medial forefoot area of the sole structure.

10. An article of footwear according to claim 6, wherein a bottom surface of the second polymeric foam member is exposed at least at a forefoot portion of a bottom surface of the sole structure.

11. An article of footwear according to claim 10, wherein the sole structure further includes a first outsole member engaged with a bottom surface of the second polymeric foam member.

12. An article of footwear according to claim 11, wherein the sole structure further includes a second outsole member engaged with a bottom surface of the first polymeric foam member.

13. An article of footwear according to claim 6, wherein the bottom wall of the outer shell of the first polymeric foam member has an opening defined through it, and wherein a bottom surface of the second polymer foam member is exposed through the opening.

14. An article of footwear according to claim 1, wherein the sole structure further includes an outsole member engaged with a bottom surface of the first polymeric foam member.

15. An article of footwear, comprising:

an upper; and

a sole structure engaged with the upper, wherein the sole structure includes a polymeric foam member configured to support at least a heel and midfoot area of a wearer'"'"'s foot, wherein an exposed outer edge of the polymeric foam member includes;

a first billows structure that includes;

a first outer billow ridge, a second outer billow ridge, a third outer billow ridge, a first interstitial region located between the first and second outer billow ridges, and a second interstitial region located between the second and third outer billow ridges, and

a second billows structure that includes;

a fourth outer billow ridge, a fifth outer billow ridge, and a third interstitial region located between the fourth and fifth outer billow ridges,

wherein the fourth outer billow ridge originates in the first interstitial region and the fifth outer billow ridge originates in the second interstitial region, and

wherein the billow ridges extend upwardly at an angle from front ends of the ridges to rear ends of the ridges.

16. An article of footwear according to claim 15, wherein the first billows structure extends around a rear heel area of the sole structure, and wherein the second billows structure is located at a side midfoot region of the sole structure.

17. An article of footwear according to claim 15, wherein the sole structure further includes an outsole component engaged with a bottom surface of the polymeric foam member.

18. An article of footwear according to claim 17, wherein the polymeric foam member includes a foam material having a density of less than 0.25 g/cm³.

19. An article of footwear according to claim 15, wherein a window element extends through the polymeric foam member at a location between the first and second outer billow ridges.

20. An article of footwear according to claim 15, wherein the exposed outer edge of the polymeric foam member further includes a third billows structure having a sixth outer billow ridge, wherein the sixth outer billow ridge originates in the third interstitial region.