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

• US 9,468,255 B2
• Filed: 04/04/2016
• Issued: 10/18/2016
• 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:
  US15/090,052
• Publication Number:
  US 20160213091A1
• Time in Patent Office: 197 Days
• Field of Search: 361/03, 36/3.B, 36/25.R
• 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).

Claims

1. An article of footwear, comprising:

an upper;

a sole structure engaged with the upper, wherein the sole structure includes a first portion configured to support at least a heel and midfoot area of a wearer'"'"'s foot, wherein an exposed outer edge of the first portion includes a billows structure that extends continuously from a medial midfoot or forefoot area of the sole structured to a lateral midfoot or forefoot area of the sole structure, and wherein the billows structure includes a plurality of billow outer ridges connected by billow interstitial areas located between adjacent billow outer ridges of the billow outer ridges, the plurality being fewer than five billow outer ridges, wherein at least some of the billow ridges extend downwardly from rear ends of the ridges toward a midfoot of the sole structure, wherein at least some of the billow ridges extend downwardly from front ends of the ridges toward a midfoot of the sole structure, and wherein an upper surface of the billows structure is secured to the upper; and

an outsole assembly secured to a bottom surface of the sole structure.

2. The article of footwear of claim 1, wherein the outsole assembly comprises a plurality of outsole components.

3. The article of footwear of claim 2, wherein the outsole components are secured to a bottom surface of the sole structure.

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

5. The article of footwear of claim 1, wherein the first portion is a polymeric foam member.

6. The article of footwear of claim 5,

wherein the 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, and

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

7. The article of footwear of claim 1, wherein the first portion includes a foam material having a hardness of between 25 and 45 Asker C.

8. The article of footwear of claim 1, wherein the first portion includes a foam material having a hardness of between 25 and 35 Asker C.

9. The article of footwear of claim 1, wherein the first portion includes a foam material having a hardness of between 35 and 45 Asker C.

10. The article of footwear of claim 1, wherein the first portion includes a foam material having a density of less than 0.25 g/cm3.

11. The article of footwear of claim 1, wherein, at a rear heel area of the first portion, 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.

12. The article of footwear of claim 1, wherein the billow ridges have a thickness at a rear end of the first portion that is larger than a thickness at a front end of the first portion.

13. The article of footwear of claim 1, wherein a rear end of an uppermost of the billow ridges extends rearwardly less than at least one of the billow ridges below the uppermost billow ridge.