CN110678095A

CN110678095A - Sole structure with apertures configured to form auxetic structures

Info

Publication number: CN110678095A
Application number: CN201880033682.2A
Authority: CN
Inventors: 托里·M·克罗斯; 布莱恩·N·法里斯; 伊丽莎白·兰格文
Original assignee: Nike Innovation LP
Current assignee: Nike Innovate CV USA; Nike Innovation LP
Priority date: 2017-05-25
Filing date: 2018-05-21
Publication date: 2020-01-10
Anticipated expiration: 2038-05-21
Also published as: CN110678095B; EP3629802A1; WO2018217614A1; EP3629802B1

Abstract

A sole structure (103) includes a sole component having an interior surface (132, 150, 170) and an exterior surface (134, 152, 172) opposite the interior surface (132, 150, 170). The sole element has a length and a thickness. The sole component includes a sole material, and the sole material has a density. At least one of the thickness or the density varies along a length of the sole element. The sole element defines a plurality of apertures (200) extending from at least one of the inner surface (132, 150, 170) and the outer surface (134, 152, 172) and configured to form an auxetic structure. The auxetic structure is configured such that when the sole element is tensioned in a first direction (410, 412), the sole element expands in the first direction (410, 412) and in a second direction (410, 412) orthogonal to the first direction (410, 412). The performance of the auxetic structure varies as a function of the density or thickness of the sole elements. A sole structure (103) includes a sole component having an interior surface (132, 150, 170) and an exterior surface (134, 152, 172) opposite the interior surface (132, 150, 170). The sole element has a length and a thickness. The sole component includes a sole material, and the sole material has a density. At least one of the thickness or the density varies along a length of the sole element. The sole element defines a plurality of apertures (200) extending from at least one of the inner surface (132, 150, 170) and the outer surface (134, 152, 172) and configured to form an auxetic structure. The auxetic structure is configured such that when the sole element is tensioned in a first direction (410, 412), the sole element expands in the first direction (410, 412) and in a second direction (410, 412) orthogonal to the first direction (410, 412). The performance of the auxetic structure varies as a function of the density or thickness of the sole elements.

Description

Sole structure with apertures configured to form auxetic structures

Cross Reference to Related Applications

This application claims the benefit of priority of U.S. patent application No. 15/604,705 filed on 25/5/2017 and published as US2017/0258180, which is incorporated herein by reference.

Technical Field

The present disclosure relates to auxetic structures, and more particularly, to sole structures having apertures with auxetic configurations.

Background

An article of footwear typically has at least two primary components, an upper that provides an enclosure for receiving a wearer's foot, and a sole secured to the upper, the sole being primarily in contact with the ground or playing surface. Footwear may also be secured around a wearer's foot using some type of fastening system, such as laces or straps, or a combination of the two. The sole may comprise three layers-an insole, a midsole and an outsole. The outsole is primarily in contact with the ground or playing surface. The outsole is typically provided with a tread pattern and/or cleats or studs or other protrusions that provide the footwear wearer with improved traction suitable for particular sports, work or physical activities, or for particular ground surfaces.

Drawings

FIG. 1 is an isometric view of an article of footwear;

FIG. 2 is an exploded isometric view of the article of footwear shown in FIG. 1, wherein the sole structure includes an inner sole component, a midsole component, and a plurality of outer sole components;

FIG. 3 is a bottom view of the article of footwear shown in FIG. 1;

FIG. 4 is a bottom isometric view of the article of footwear shown in FIG. 1;

FIG. 5 is an isometric enlarged view of the sole structure taken about area A of FIG. 4;

FIG. 6 is a bottom isometric view of the article of footwear shown in FIG. 1, depicting the sole structure undergoing auxetic expansion;

FIG. 7 is an isometric enlarged view of the sole element taken about area B of FIG. 6;

figure 8 is an isometric view of a sole component of a sole structure according to an embodiment of the present disclosure;

FIG. 9 is a cross-sectional view of the sole component taken along section line 9-9 of FIG. 8;

figure 10 is a chart illustrating the relationship between thickness and length of a sole element;

FIG. 11 is a chart illustrating the relationship between the density of the sole material and the length of the sole structure;

FIG. 12 is a chart illustrating the relationship between the density of the sole material and the spacing between the apertures in the sole component;

FIG. 13 is a chart illustrating the relationship between the thickness of the sole element and the spacing between the apertures in the sole element;

FIG. 14 is a chart illustrating the relationship between the density of the sole material and the number of apertures in the sole component;

figure 15 is a chart illustrating the relationship between the thickness of the sole element and the number of apertures in the sole element;

FIG. 16 is a graph illustrating the relationship between hole depth and density of sole material;

figure 17 is a graph illustrating the relationship between hole depth and thickness of a sole element.

Detailed Description

The present disclosure describes a sole structure for an article of footwear. In some embodiments, the sole structure includes a sole element having an interior surface and an exterior surface opposite the interior surface. The sole element has a length and a thickness. The sole component includes a sole material, and the sole material has a density. At least one of the thickness or the density varies along a length of the sole element. The sole element defines a plurality of apertures extending from at least one of the inner surface and the outer surface and configured to form an auxetic structure. The auxetic structure is configured such that when the sole element is tensioned in a first direction, the sole element expands in the first direction and in a second direction orthogonal to the first direction. The performance of the auxetic structure varies as a function of the density or thickness of the sole elements. The article of footwear may be adjusted using the auxetic structure. In the case of an auxetic structure, the ride, fit, and cushioning of the overall sole structure may be customized. Such customization is often not possible when using a unitary rubber or foam sole. The heel region is configured to absorb energy while providing lateral stability. The midfoot region may be stiffer and/or non-auxetic than the heel region because the foot applies less contact pressure in the midfoot portion when compared to the heel region. The forefoot region has sufficient firmness and structure to achieve good/firm kick-off without the need to dig out a porous pad.

The sole member includes a forefoot portion, a heel portion, and a midfoot portion disposed between the heel portion and the forefoot portion. The sole element thickness in the heel portion may be greater than the sole element thickness in the forefoot portion. The thickness of the sole element in the heel portion may be greater than the thickness of the sole element in the midfoot portion. The thickness of the sole element may decrease continuously from the heel portion to the forefoot portion. The thickness of the sole element may decrease linearly from the heel portion to the forefoot portion as a function of the length of the sole element. The sole component may be a midsole component.

The sole elements are made in whole or in part of a sole material such as foam. By way of non-limiting example, sole materials include Ethylene Vinyl Acetate (EVA) foam and blown nitrile rubber. The density of the sole material may vary along the length of the sole element. For example, the density of the sole material in the heel portion may be greater than the density of the sole material in the forefoot portion. The density of the sole material in the heel portion may be greater than the density of the sole material in the midfoot portion. As a non-limiting example, the density of the sole material may decrease continuously from the heel portion to the forefoot portion. For example, the density of the sole material may decrease linearly from the heel portion to the forefoot portion as a function of the length of the sole element. At least some of the apertures may be shaped as regular polygons. At least some of the apertures may be shaped as concave hexagons.

In some embodiments, the one or more properties of the auxetic structure may include, but are not limited to, size, shape, number, spacing, and depth of the holes. The size of the plurality of apertures may vary as a function of the thickness of the sole element and/or the density of the sole material. The shape of the apertures may vary as a function of the thickness of the sole elements and/or the density of the sole material. The number of apertures within a predetermined area of the length of the sole element may vary as a function of the thickness of the sole element and/or the density of the sole material. The spacing of the apertures may vary as a function of the thickness of the sole elements and/or the density of the sole material. The depth of the apertures may vary as a function of the thickness of the sole elements and/or the density of the sole material.

In other embodiments, the sole structure includes a sole component having an interior surface and an exterior surface opposite the interior surface. The sole element has a length extending in a longitudinal direction and a width extending in a lateral direction. The transverse direction is perpendicular to the longitudinal direction. The sole element has a thickness extending in a vertical direction. The vertical direction is perpendicular to the longitudinal direction and the lateral direction. The sole component includes a sole material, and the sole material has a density. The sole element defines a plurality of apertures extending from at least one of the inner surface and the outer surface and configured to form an auxetic structure. The auxetic structure is configured such that when the sole element is tensioned in one of a longitudinal direction or a lateral direction, the sole element expands in the longitudinal direction and in the lateral direction. One or more properties of the auxetic structure vary as a function of the density or thickness of the sole elements.

The above features and advantages and other features and advantages of the present teachings are readily apparent from the following detailed description of the best modes for carrying out the present teachings when taken in connection with the accompanying drawings.

Fig. 1 is an isometric view of an embodiment of an article of footwear 100. In an exemplary embodiment, article of footwear 100 has the form of an athletic shoe. However, in other embodiments, the article of footwear 100 provided in the discussion herein may be incorporated into other different types of footwear, including, but not limited to: basketball shoes, hiking shoes, soccer shoes, football shoes, athletic shoes, running shoes, cross-training shoes, football shoes, baseball shoes, and other types of shoes. Further, in some embodiments, the article of footwear 100 provided in the discussion herein may be incorporated into other different types of non-athletic related footwear, including, but not limited to: slippers, sandals, high-heeled shoes and sandals.

For clarity, the following detailed description discusses features of article of footwear 100 (also referred to simply as article 100). However, it will be understood that other embodiments may incorporate a corresponding article of footwear (e.g., a right article of footwear when article 100 is a left article of footwear) that may have some, and possibly all, of the features of article 100 described herein and shown in the drawings.

Embodiments may be characterized by various directional adjectives and reference portions. These directions and reference portions may be useful in describing portions of an article of footwear. In addition, these directions and reference portions may also be used in describing subcomponents of the article of footwear (e.g., directions and/or portions of an insole component, a midsole component, an outsole component, an upper, or any other component).

For consistency and convenience, directional adjectives are used throughout the detailed description that corresponds to the illustrated embodiments. The term "longitudinal," as used throughout the detailed description and in the claims, refers to a direction that extends the length of an element (e.g., an upper or sole element). In some cases, longitudinal direction LG may extend from a forefoot portion to a heel portion of the component. Also, the term "transverse" as used throughout the detailed description and in the claims refers to a direction extending along the width of a component. That is, the transverse direction LT may extend between the inner and outer sides of the component. Furthermore, the term "perpendicular" as used throughout the detailed description and in the claims refers to a direction that is generally perpendicular to the lateral and longitudinal directions. For example, in case the article is placed flat on the ground, the vertical direction V may extend upwards from the ground. The vertical direction V is perpendicular to the transverse direction LT and the longitudinal direction LG. The transverse direction LT is perpendicular to the longitudinal direction LG. Further, the term "inner" refers to a portion of the article that is disposed closer to the interior of the article or closer to the foot when the article is worn. Likewise, the term "outer" refers to a portion of the article that is disposed away from the interior of the article or away from the foot. Thus, for example, the inner surface of the component is disposed closer to the interior of the article than the outer surface of the component. Detailed description these directional adjectives are used in describing various components of articles, as well as articles that include an upper, a midsole structure, and/or an outsole structure.

The article 100 may be characterized by a plurality of distinct regions or portions. For example, article 100 may include a forefoot portion, a midfoot portion, a heel portion, and an ankle portion. In addition, components of article 100 may likewise include corresponding portions. Referring to fig. 1, article 100 may be divided into article forefoot portion 10, article midfoot portion 12, and article heel portion 14. Article forefoot portion 10 may generally be associated with the toes and the joints connecting the metatarsals with the phalanges. The midfoot portion 12 of the article may be generally associated with the arch of a foot. Likewise, the article heel portion 14 may generally be associated with the heel of a foot that includes the calcaneus bone. Article 100 may also include an ankle portion 15 (the ankle portion 15 may also be referred to as an upper portion). Further, article 100 may include an article exterior side 16 and an article interior side 18. In particular, article exterior 16 and article interior 18 may be opposite sides of article 100. In addition, both the article lateral side 16 and the article medial side 18 may extend through the article forefoot portion 10, the article midfoot portion 12, the article heel portion 14 and the ankle portion 15.

Fig. 2 illustrates an exploded isometric view of an embodiment of an article of footwear 100. Fig. 1-2 illustrate various components of an article of footwear 100 that includes an upper 102 and a sole structure 103.

In general, upper 102 may be any type of upper. In particular, upper 102 may have any design, shape, size, and/or color. For example, in embodiments where article 100 is a basketball shoe, upper 102 may be a high-top upper shaped to provide high support at the ankle. In embodiments where article 100 is a running shoe, upper 102 may be a low-top upper.

In some embodiments, upper 102 includes an ankle opening 114 that provides the foot with access to the interior void of upper 102. In some embodiments, upper 102 may also include a tongue (not shown) that provides cushioning and support over the instep of the foot. Some embodiments may include fastening devices including, but not limited to: laces, ropes, straps, buttons, zippers, and any other means known in the art for securing articles. In some embodiments, lace 125 may be utilized in fastening areas of upper 102.

Some embodiments may include an upper that extends under the foot, thereby providing 360 degrees of coverage in certain areas of the foot. However, other embodiments need not include an upper that extends under the foot. For example, in other embodiments, the 102 upper may have a lower periphery that is integrated with the sole structure and/or the sockliner.

Upper 102 may be formed from a variety of different manufacturing techniques that result in different types of upper structures. For example, in some embodiments, upper 102 may have a braided structure, a knitted (e.g., warp knitted) structure, or some other woven structure. In an exemplary embodiment, upper 102 may be a knit upper.

In some embodiments, sole structure 103 may be configured to provide traction for article 100. In addition to providing traction, sole structure 103 may attenuate ground reaction forces when compressed between the foot and the ground during walking, running, or other ambulatory activities. The configuration of sole structure 103 may vary significantly in different embodiments to include a variety of conventional or non-conventional structures. In some cases, sole structure 103 may be configured according to one or more types of ground on which sole structure 103 may be used. Examples of the ground include, but are not limited to: natural turf, artificial turf, dirt, hardwood floors, and other surfaces.

Sole structure 103 is secured to upper 102 and extends between the foot and the ground when article 100 is worn. In different embodiments, sole structure 103 may include different components. In the exemplary embodiment shown in fig. 1-2, sole structure 103 may include an inner sole component 120, a midsole component 122, and a plurality of outsole members 124. In some cases, inner bottom member 120 and/or outsole member 124 may be optional. In the depicted embodiment, midsole component 122 is a unitary (i.e., one-piece) structure. However, it is contemplated that midsole component 122 may include two or more interconnected portions. In the present disclosure, midsole component 122 may be referred to simply as a sole component.

Referring now to fig. 2, in some embodiments, the inner sole component 120 may be configured as an inner layer of a midsole. For example, as discussed in further detail below, inner sole component 120 may be integrated or received into a portion of midsole component 122. However, in other embodiments, the inner bottom member 120 can function as a footbed layer and/or as a strobel (strobel) layer. Accordingly, in at least some embodiments, to secure sole structure 103 to upper 102, insole component 120 may be bonded (e.g., stitched or glued) to lower portion 104 of upper 102.

The inner base member 120 may have an inner surface 132 and an outer surface 134. Interior surface 132 may be generally oriented toward upper 102. Outer surface 134 may be generally oriented toward midsole component 122. In addition, a peripheral sidewall surface 136 may extend between the inner surface 132 and the outer surface 134.

Midsole component 122 may be configured to provide cushioning, shock absorption, energy return, support, and possibly other means. To this end, midsole component 122 may have a geometry that provides structure and support to article 100. In particular, midsole component 122 may be seen to have a lower portion 140 and sidewall portions 142. Sidewall portion 142 may extend around an entire periphery 144 of midsole component 122. As seen in fig. 1, sidewall portions 142 may partially wrap the sides of article 100 to provide enhanced support along the bottom of the foot.

Midsole component 122 may further include an inner surface 150 and an outer surface 152 opposite inner surface 150. Interior surface 150 may be generally oriented toward upper 102, while exterior surface 152 may be oriented outward (i.e., away from upper 102). Further, in an exemplary embodiment, midsole component 122 may define a central recess 148 disposed in an interior surface 150. The middle recess 148 may be generally sized and configured to receive the inner base member 120.

Referring to fig. 3, in some embodiments, midsole component 122 may include a plurality of apertures 200, at least some of apertures 200 may extend through the entire thickness of midsole component 122. That is, the holes 200 may be blind holes and/or through holes. The aperture 200 extends from at least one of the inner surface 150 or the outer surface 152. In the exemplary embodiment shown in fig. 2, some of the holes 200 are visible within the intermediate recess 148. The apertures 200 of the midsole component 122 are configured to form an auxetic structure. Due to the auxetic configuration of apertures 220, midsole component 122 expands in both longitudinal direction LG and transverse direction LT when middle sole component 122 is under longitudinal tension, and midsole component 122 expands in both transverse direction LT and longitudinal direction LG when middle sole component 122 is under transverse tension. The particular size, shape, number, spacing, and depth of apertures 200 in midsole component 122 affects the particular response of apertures 200 and midsole component 122 to an applied force.

In various embodiments, midsole component 122 may generally incorporate various devices associated with a midsole. For example, in one embodiment, the midsole component may be formed from a polymer foam material that attenuates ground reaction forces (i.e., provides cushioning) during walking, running, and other ambulatory activities. For example, in various embodiments, midsole component 122 may also include fluid-filled chambers, plates, moderators, or other elements that further attenuate forces, enhance stability, or influence the motions of the foot.

Figure 3 illustrates a bottom view of the sole structure 103. As mentioned above, midsole component 122 may be referred to simply as a sole component. Midsole component 122 includes a forefoot sole portion 121, a heel sole portion 123, and a midfoot sole portion 127 disposed between heel sole portion 123 and forefoot portion 121. By way of non-limiting example, sole structure 103 may include four separate outsole members 124. Specifically, sole structure 103 includes a first outsole member 160, a second outsole member 162, a third outsole member 164, and a fourth outsole member 166. Although the exemplary embodiment includes four different outsole members 124, other embodiments may include any other number of outsole members 124. For example, in another embodiment, there may be only a single outsole member 124. In yet another embodiment, only two outsole members 124 may be used. In yet another embodiment, only three outsole members 124 may be used. In yet other embodiments, five or more outsole members 124 may be used. In other embodiments, sole structure 103 may not include outsole member 124.

In general, any outsole member 124 may be configured as a ground contacting member. In some embodiments, outsole member 124 may include properties associated with the outsole such as durability, wear-resistance, and increased traction. In other embodiments, outsole member 124 may include properties associated with the midsole including cushioning, strength, and support. In an exemplary embodiment, outsole member 124 may be configured as an outsole member that improves traction with the ground while maintaining wear-resistance.

In different embodiments, the location of one or more outsole members 124 may be different. In some embodiments, one or more outsole members 124 may be disposed in a forefoot portion of sole structure 103. In other embodiments, one or more outsole members 124 may be disposed in a midfoot portion of sole structure 103. In other embodiments, one or more outsole members may be provided in the heel portion of the sole structure. In an exemplary embodiment, first outsole member 160 and second outsole member 162 may be disposed in a forefoot portion of sole structure 103. More specifically, first outsole member 160 may be disposed on a medial side of sole structure 103, while second outsole member 162 may be disposed on a lateral side of sole structure 103. Moreover, in an exemplary embodiment, third outsole member 164 and fourth outsole member 166 may be disposed in a heel portion of sole structure 103. More specifically, third outsole member 164 may be disposed on a lateral side of sole structure 103, and fourth outsole member 166 may be disposed on a medial side of sole structure 103. In addition, first outsole member 160 and second outsole member 162 may be spaced apart from one another in the middle of the forefoot portion of sole structure 103, while third outsole member 164 and fourth outsole member 166 may be spaced apart from one another in the middle of the heel portion of sole structure 103. This exemplary configuration provides outsole member 124 at areas of increased ground contact during various lateral and medial cuts to improve traction during these movements.

The various outsole members 124 may vary in size. In an exemplary embodiment, first outsole member 160 may be the largest outsole member 124 of the plurality of outsole members 124. In addition, second outsole member 162 may be substantially smaller than first outsole member 160, such that traction is increased more on the medial side of sole structure 103 than on the lateral side in the forefoot portion of sole structure 103. In the heel portion, both third outsole member 164 and fourth outsole member 166 are widest along rear edge 109 of sole structure 103 and taper slightly toward the mid-foot portion of sole structure 103.

Referring to fig. 2 and 3, it can be seen that first outsole member 160 has an inner surface 170 and an outer surface 172. Inner surface 170 may generally be disposed against midsole component 122. The outer surface 172 may face outward and may be a ground-contacting surface. For clarity, only the inner and outer surfaces of first outsole member 160 are indicated in fig. 2-3; however, it will be appreciated that the remaining outsole members 124 may likewise include corresponding inner and outer surfaces having similar orientations relative to midsole component 122.

In an exemplary embodiment, inner bottom component 120 may be disposed within a central recess 148 of midsole component 122. More specifically, outer surface 134 of inner bottom component 120 may be oriented toward an inner surface 150 of midsole component 122 and in contact with inner surface 150 of midsole component 122. Further, in some cases, the peripheral sidewall surface 136 may also contact the inner surface 150 along the inner recessed sidewall 149. Additionally, outsole member 124 may be disposed against an outer surface 152 of midsole component 122. For example, inner surface 170 of first outsole member 160 may face toward outer surface 152 of midsole component 122 and be in direct contact with outer surface 152 of midsole component 122. In some embodiments, when assembled, midsole component 122 and inner bottom component 120 may comprise a composite midsole assembly, or a dual-layer midsole assembly.

In different embodiments, upper 102 and sole structure 103 may be combined in various ways. In some embodiments, upper 102 may be bonded to inner base member 120, for example, using an adhesive or by stitching. In other embodiments, upper 102 may be bonded to midsole component 122, for example, along sidewall portions 142. In other embodiments, upper 102 may be joined with both inner bottom piece 120 and midsole piece 122. Further, these components may be joined using any method known in the art for joining a sole component to an upper, including various lasting techniques and measures (e.g., plate lasting, slip lasting, etc.).

In different embodiments, the attachment configuration of the various components of article 100 may be different. For example, in some embodiments, inner sole component 120 may be bonded or otherwise attached to midsole component 122. Such bonding or attachment may be accomplished using any known method for bonding components of an article of footwear, including but not limited to: adhesives, films, tapes, air tacks, stitching or other methods. In some other embodiments, it is contemplated that inner bottom component 120 may not be bonded or attached to midsole component 122, but may be free floating. In at least some embodiments, inner bottom component 120 can have a friction fit with intermediate recess 148 of midsole component 122.

Outsole member 124 may likewise be bonded or otherwise attached to midsole component 122. Such bonding or attachment may be accomplished using any known method for bonding components of an article of footwear, including but not limited to: adhesives, films, tapes, air tacks, stitching or other methods.

In at least some embodiments, two or more of inner bottom member 120, midsole member 122, and/or outsole member 124 can be molded together and/or bonded together during the molding process. For example, in some embodiments, upon forming midsole component 122, inner base component 120 may be molded within medial recess 148.

Embodiments may include means to promote expansion and/or compliance of the sole structure during dynamic motion. In some embodiments, the sole structure may be configured with an auxetic device. In particular, one or more components of the sole structure may be capable of undergoing auxetic motions (e.g., expansion and/or contraction).

Sole structure 103, as shown in fig. 1-5 and as described in further detail below, has an auxetic structure or configuration. Sole Structures incorporating Auxetic Structures are described in the name of cross-over U.S. patent application serial No. 14/030,002 (now U.S. patent No. 9,402,439), filed on 18.9.2013, entitled "Auxetic Structures and Footwear Having Soles with Auxetic Structures" (automatic Structures and Footwear with gases Having automatic Structures) ("Auxetic structure applications"), the entire contents of which are incorporated herein by reference.

As described in auxetic structure applications, auxetic materials have a negative poisson's ratio such that when they are under tension in a first direction, their magnitude increases in the first direction and in a second direction that is orthogonal or perpendicular to the first direction. This auxetic behavior is illustrated in fig. 4-7 and described below.

Referring to fig. 3-7, the midsole component 122 has a length LGT extending along the longitudinal direction LG and a width W extending along the lateral direction LT. As mentioned above, the transverse direction LT is perpendicular to the longitudinal direction LG. As seen in fig. 3, sole structure 103 may include a plurality of apertures 200. As used herein, the term "hole" refers to any hollow or recessed area in a component. In some cases, the hole may be a through hole (i.e., a through hole) in which the hole extends between two opposing surfaces of the component. In other cases, the holes may be blind holes, in which the holes may not extend through the entire thickness of the component and may therefore be open only on one side. Furthermore, as discussed in further detail below, the component may use a combination of through holes and blind holes. Further, the term "pore" may be used interchangeably with "pore" or "recess" in some instances.

Sole structure 103 may be further associated with a plurality of separate sole portions 320 in areas that include one or more apertures. In particular, sole portion 320 includes portions of sole structure 103 that extend between plurality of apertures 200. It can also be seen that a plurality of apertures 200 extend between sole portions 320. Thus, it will be appreciated that each aperture may be surrounded by a plurality of sole portions such that the boundary of each aperture may be defined by an edge of a sole portion. This arrangement between the apertures (or apertures) and the sole portion is discussed in further detail in auxetic structure applications.

As seen in fig. 3, apertures 200 may extend through a majority of midsole component 122. In some embodiments, a plurality of apertures 200 may extend through forefoot portion 121, midfoot portion 127, and heel portion 123 of midsole component 122. For example, the aperture 200 may extend along a majority of the length LGT and the width W of the midsole component 122. In other embodiments, the plurality of holes 200 may not extend through each of these portions.

Apertures 200 may also extend through a plurality of outsole members 124. In exemplary embodiments, each of the first, second, third and

fourth outsole members

160, 162, 164, 166 includes two or more apertures. However, in other embodiments, one or more of the outsole members may not include any apertures.

In different embodiments, the geometry of one or more of the apertures may be different. Examples of different geometries that may be used in an auxetic sole structure are disclosed in auxetic structure applications. In addition, embodiments may also use any other geometry, such as using sole portions having a parallelogram geometry or other polygonal geometry arranged in a pattern to provide an auxetic structure for the sole. In an exemplary embodiment, some of the holes 200 have a tri-star geometry, including three arms or tips extending from the same center. For example, at least some of apertures 200 may be shaped as regular polygons to provide an auxetic configuration for midsole component 122. As a non-limiting example, at least some of apertures 200 may be shaped as auxetic hexagons (i.e., concave hexagons) to provide a polygon to provide an auxetic configuration for midsole component 122. At least some of the apertures 200 may be shaped to line the slits and arranged in a crisscross pattern. The shape of apertures 200 may be varied as a function of the thickness of midsole component 122 (or any other sole component) and/or the density of the sole material to optimize sole cushioning. For example, apertures 200 in heel portion 123 of the sole may be shaped as regular polygons, apertures 200 in midfoot portion 127 of the sole may be shaped as auxetic hexagons (i.e., concave hexagons), and apertures 200 in forefoot portion 121 of the sole may be shaped as lines of stitching and arranged in a crisscross pattern.

The geometry of one or more sole portions may also be different. Examples of different geometries that may be used in an auxetic sole structure are disclosed in auxetic structure applications. It will be appreciated that the geometry of the sole portion may be determined by the geometry of the apertures in the auxetic pattern and vice versa. In an exemplary embodiment, each sole portion has an approximately triangular geometry.

Apertures 200 may be disposed in sole structure 103 in an auxetic pattern or an auxetic configuration. That is, the holes 200 are arranged to form an auxetic structure. Accordingly, apertures 200 may be provided in midsole component 122 and/or outsole member 124 in a manner that allows these components to undergo auxetic movements, such as expansion or contraction. Examples of the auxetic expansion that occurs as a result of the auxetic configuration of the plurality of apertures 200 are shown in fig. 4-7. First, in fig. 4 and 5, sole structure 103 is in a non-tensioned state. In this state, the hole 200 has a non-tensioned region. For purposes of illustration, only area 400 of midsole component 122 is shown, wherein area 400 includes a subset of apertures 200.

As shown in fig. 6 and 7, when tension is applied across sole structure 103 along an example linear direction 410 (e.g., longitudinal direction LG), sole structure 103 undergoes auxetic expansion. That is, sole structure 103 expands along direction 410 and in a second direction 412 (e.g., lateral direction LT) that is perpendicular to direction 410. In fig. 5, it is seen that as the size of the hole 200 increases, the representative region 400 expands in both the direction 410 and the direction 412 (e.g., the longitudinal direction LG and the lateral direction LT) simultaneously.

Embodiments may include means for varying the degree to which certain portions of the sole structure (including portions of the midsole component and/or the outsole member) may experience auxetic expansion. Since expansion of the sole structure may result in increased surface contact and/or increased flexibility of regions of the sole structure, varying the degree of expansion (or contraction) of different regions or portions under tension (or compression) may allow the traction performance and/or flexibility of these different regions to be adjusted. Varying the degree to which the midsole component undergoes auxetic expansion can be accomplished by varying the properties of the different openings. For example, embodiments of the midsole component may include some through holes and some blind holes, as the through holes may generally expand more than the blind holes (relative to their initial configuration) during the auxetic motion.

Referring to fig. 8-11, midsole component 122 has a thickness T that extends along a vertical direction V. The thickness T of midsole component 122 is defined from an inner surface 150 to an outer surface 152 of midsole component 122. As discussed above, the vertical direction V is perpendicular to the lateral direction LT and the longitudinal direction LG. The thickness T of midsole component 122 varies along the length LGT of midsole component 122 to provide different force responses at different regions along the length LGT of midsole component 122. That is, the thickness T of the midsole component 122 varies along the longitudinal direction LG to provide different applied force responses in different regions along the longitudinal direction LG. Injection molding or 3D (three dimensional) printing may be used to manufacture midsole component 122 with varying thicknesses. To provide optimal cushioning, apertures 200 and their corresponding auxetic configuration may be matched to thickness T of midsole component 122. For example, apertures 200 (and corresponding auxetic configurations) in relatively thick regions of midsole component 122 may differ from apertures 200 (and corresponding auxetic configurations) in relatively thin regions of midsole component 122.

By way of non-limiting example, a thickness T of midsole component 122 in heel portion 123 of the sole may be greater than a thickness T of midsole component 122 in forefoot portion 121 of the sole. In particular, sole heel portion 123 may have a heel thickness HT defined from inner surface 150 to outer surface 152, and sole forefoot portion 121 has a forefoot thickness FT defined from inner surface 150 to outer surface 152. The heel thickness HT is greater than the forefoot thickness FT to provide optimal cushioning for a stiff heel plate. The apertures 200 of the midsole component 122 are disposed in an auxetic configuration.

The stability of the hard heel plate can be maximized by matching the relatively thick sole heel portion 123 with the particular type of auxetic configuration of the aperture 200. The thickness T of midsole component 122 in heel portion 123 of the sole may be greater than the thickness T of midsole component 122 in midfoot portion 127. Midfoot portion 127 has a midsole thickness MT defined from inner surface 150 to outer surface 152. The heel thickness HT may be greater than the midsole thickness MT in order to maximize cushioning at the sole heel portion 123 and to maximize comfort during a runner stride. The heel thickness HT may be greater than the midsole thickness and the forefoot thickness FT to maximize comfort during the entire heel-on-toe stride. For example, the thickness T of midsole component 122 may continuously decrease from heel portion 123 to forefoot portion 121 to provide optimal cushioning while enhancing energy return at forefoot portion 121. For example, heel portion 123 may have a maximum sole thickness MXT at a rearwardmost portion 129 of midsole component 122, and forefoot portion 121 may have a minimum sole thickness MNT at a forwardmost portion 131 of midsole component 122. The maximum sole thickness MXT may range between fifteen (15) millimeters and ten (10) millimeters, and the minimum sole thickness MNT may range between ten (10) millimeters and five (5) millimeters. These thickness ranges provide optimal cushioning at the sole heel portion 127 while enhancing energy return at the sole forefoot portion 121. As graphically illustrated in fig. 10, the thickness T of midsole component 122 may decrease linearly from the heel portion 123 of the sole to the forefoot portion 121 of the sole as a function of the length LGT of midsole component 122 to optimize sole cushioning.

In addition to the thickness T of the midsole component, the density of the material forming midsole component 122 (i.e., the sole material) may vary along the length LGT of midsole component 122. Injection molding or 3D printing may be used to manufacture midsole component 122 with varying densities. In fig. 9, different concentrations of spots along the length LGT of midsole component 122 illustrate different densities of the material forming midsole component 122. The material (partially or completely) forming midsole component 122 may be referred to as a sole material. By way of non-limiting example, the sole material may be (or may include) Ethylene Vinyl Acetate (EVA) foam and blown nitrile rubber. The density of the sole material in the sole heel portion 123 may be greater than the density of the sole material in the sole forefoot portion 121. The stability of the hard heel plate may be optimized by maximizing the density of midsole component 122 in the heel portion 123 of the sole. In addition, by maximizing the density and thickness of midsole component 122 in heel portion 123 of the sole, further stability optimization is possible. The density of the sole material in the sole heel portion 127 may be greater than the density of the sole material in the sole midfoot portion 127 to maximize cushioning at the sole heel portion 123 and to maximize comfort during a runner's stride. The density of the sole material in the sole heel portion 123 may be greater than the density of the sole material in the sole midfoot portion 127 and sole forefoot portion 121 to maximize comfort during the full heel-on-toe stride. For example, the density of the sole material may decrease continuously from the sole heel portion 123 to the sole forefoot portion 121 to provide optimal cushioning while increasing energy return at the sole forefoot portion 121. The specific gravity of the sole material of midsole component 122 may range between 0.15 and 0.3 along a length LGT of midsole component 122. In the present disclosure, the term "specific gravity" means the ratio of the density of the sole material to the density of water. By way of non-limiting example, the specific gravity of the sole material in the sole heel portion 123 may range between 0.3 and 0.25, and the specific gravity of the sole material in the midsole component 122 in the sole forefoot portion 121 may range between 0.15 and 0.2. These specific gravity ranges provide optimal cushioning at the sole heel portion 123 while enhancing energy return at the sole forefoot portion 121. As graphically illustrated in FIG. 11, the density of the sole material may decrease linearly from the heel portion 123 of the sole to the forefoot portion 121 of the sole as a function of the length LGT of the midsole component 122 to optimize sole cushioning. It is contemplated that the midsole component 122 may have a different thickness T and/or density along its length LGT.

The sole material may be in whole or in part a foam material as described, for example, in U.S. patent 7,941,938, which is hereby incorporated by reference in its entirety. The foam material may have the feel of a light sponge. The resilience of the foam material used for the sole material may be greater than 40%, greater than 45%, at least 50%, and in one aspect from 50-70%. The compression set may be 60% or less, 50% or less, 45% or less, and in some cases, in the range of 20 to 60%. The foam material may have a hardness (Asker durometer type C) of, for example, 25 to 50, 25 to 45, 25 to 35, or 35 to 45, depending, for example, on the type of footwear. The tensile strength of the foam material may be at least 15kg/cm2, and is typically 15 to 40kg/cm 2. The% elongation is from 150 to 500, usually more than 250. The tear strength is 6-15kg/cm, usually more than 7. The sole material may have lower energy losses and may be lighter than conventional EVA foam. As an additional example, if desired, at least a portion of midsole component 122 may be formed from a foam material used in the LUNAR family of footwear products available from Nick, Biftton, Oreg. The properties (including class) of the foam material used for any sole component described in this disclosure improve the support provided by sole structure 103 to the wearer's foot without compromising the auxetic properties of sole structure 103.

Referring to fig. 12, as discussed above, the apertures 200 are configured to form auxetic structures. One or more properties of the auxetic structure may be a function of a thickness T of midsole component 122 and/or a density of the sole material. The properties of the auxetic structure may be referred to herein as "auxetic properties". Auxetic properties include, but are not limited to, the size, shape, number, spacing, and depth of the holes 200. As shown in FIG. 12, the spacing between the apertures 200 may be varied as a function of the density of the sole material to optimize sole cushioning. As used herein, the term "spacing between holes" means the maximum distance of two or more adjacent holes 200. The density of the sole material may be proportional to the spacing between the apertures 200. For example, as discussed below, the spacing between the apertures 200 decreases as the density of the sole material increases along the length LGT of the midsole component 122 (or any sole component). Thus, in this example, the spacing between apertures 200 may increase from forefoot portion 121 (fig. 9) to heel portion 123 (fig. 9) as the density of the sole material may increase from forefoot portion 121 (fig. 9) to heel portion 123 (fig. 9).

Referring to fig. 13, the spacing between apertures 200 may be varied as a function of the thickness T of midsole component 122 (or any sole component) to optimize sole cushioning. The thickness T of midsole component 122 (or any sole component) may be inversely proportional to the spacing between apertures 200. For example, as discussed below, the spacing between apertures 200 decreases from the sole heel portion 123 (fig. 9) to the sole forefoot portion 121 (fig. 9) as the thickness T of the sole material increases along the length LGT of the midsole component 122 (or any sole component) from the sole forefoot portion 121 (fig. 9) to the sole heel portion 123 (fig. 9).

Referring to fig. 14, the number of apertures 200 may be varied as a function of the density of the sole material to optimize sole cushioning. As used herein, the term "number of holes" means the number of holes 200 within a predetermined area of midsole component 122 (or any other sole component). The density of the sole material may be directly proportional to the number of apertures 200. For example, as discussed below, the number of apertures 200 decreases as the density of the sole material increases along the length LGT of the midsole component 122 (or any sole component). Thus, in this example, the number of apertures 200 may decrease from the sole heel portion 123 (fig. 9) to the sole forefoot portion 121 (fig. 9) as the density of the sole material decreases from the sole heel portion 123 (fig. 9) to the sole forefoot portion 121).

Referring to fig. 15, the number of apertures 200 may be varied as a function of the thickness T of midsole component 122 (or any sole component) to optimize sole cushioning. The thickness T of midsole component 122 (or any sole component) may be inversely proportional to the number of apertures 200. For example, as discussed below, the number of apertures 200 decreases as the thickness T of the midsole component 122 (or any sole component) increases along the length LGT of the midsole component 122 (or any sole component). Thus, in this example, the number of apertures 200 may decrease from the sole heel portion 123 (fig. 9) to the sole forefoot portion 121 (fig. 9) as the thickness T of the midsole component 122 (or any sole component) decreases from the sole heel portion 123 (fig. 9) to the sole forefoot portion 121 (fig. 9).

Referring to fig. 16, the depth of the apertures 200 (i.e., the aperture depth HD as shown in fig. 9) may be varied as a function of the density of the sole material to optimize sole cushioning. The density of the sole material may be proportional to the hole depth HD (fig. 9) of the holes 200. For example, as discussed below, the hole depth HD (fig. 9) of the holes 200 decreases as the density of the sole material decreases along the length LGT of the midsole component 122 (or any sole component). Thus, in this example, the hole depth HD (fig. 9) of the holes 200 may increase from the sole heel portion 123 (fig. 9) to the sole forefoot portion 121 (fig. 9) as the density of the sole material increases from the sole heel portion 123 (fig. 9) to the sole forefoot portion 121.

Referring to fig. 17, the hole depth HD (fig. 9) of the holes 200 may be varied as a function of the thickness T of the midsole component 122 (or any sole component) to optimize sole cushioning. The thickness T of midsole component 122 (or any sole component) may be proportional to the hole depth HD (fig. 9) of hole 200. For example, as discussed below, the hole depth HD (fig. 9) of the hole 200 decreases from the sole heel portion 123 (fig. 9) to the sole forefoot portion 121 as the thickness T of the midsole component 122 (or any sole component) decreases along the length LGT of the midsole component 122 from the sole heel portion 123 (fig. 9) to the sole forefoot portion 121 (fig. 9).

While the best modes for carrying out the present teachings have been described in detail, those familiar with the art to which this disclosure relates will recognize various alternative designs and embodiments for practicing the present teachings within the scope of the appended claims. The article of footwear 100 illustratively disclosed herein may be suitably practiced in the absence of any element not specifically disclosed herein. Furthermore, features of the embodiments shown in the drawings or of the various embodiments mentioned in the present description are not necessarily to be understood as embodiments independent of each other. Rather, it is possible that each feature described in one example of an embodiment may be combined with one or more other desired features from other embodiments, resulting in other embodiments that are not described in text or with reference to the figures.

Claims

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

a sole component having an interior surface and an exterior surface opposite the interior surface, wherein the sole component has a length and a thickness, the sole component comprises a sole material, and the sole material has a density;

wherein the density varies along the length of the sole component;

wherein the sole element defines a plurality of apertures extending from at least one of the inner surface and the outer surface and configured to form an auxetic structure;

wherein the auxetic structure is configured such that when the sole element is tensioned in a first direction, the sole element expands in both the first direction and in a second direction orthogonal to the first direction; and

wherein a property of the auxetic structure varies as a function of the density of the sole component.

2. The sole structure of claim 1, wherein the sole component includes a forefoot portion, a heel portion, and a midfoot portion disposed between the heel portion and the forefoot portion, and the thickness of the sole component in the heel portion is greater than the thickness of the sole component in the forefoot portion.

3. The sole structure of claim 2, wherein the thickness of the sole component in the heel portion is greater than the thickness of the sole component in the midfoot portion.

4. The sole structure of claim 2, wherein the thickness of the sole component decreases continuously from the heel portion to the forefoot portion.

5. The sole structure of claim 2, wherein the thickness of the sole component decreases linearly from the heel portion to the forefoot portion as a function of the length of the sole component.

6. The sole structure of claim 1, wherein the sole component is a midsole component.

7. The sole structure of claim 1, wherein the sole material includes Ethylene Vinyl Acetate (EVA) foam and blown nitrile rubber.

8. The sole structure of claim 1, wherein the sole component includes a forefoot portion, a heel portion, and a midfoot portion disposed between the heel portion and the forefoot portion, and the density of the sole material in the heel portion is greater than the density of the sole material in the forefoot portion.

9. A sole structure according to claim 8, wherein the density of the sole material in the heel portion is greater than the density of the sole material in the midfoot portion.

10. The sole structure according to claim 9, wherein the density of the sole material decreases continuously from the heel portion to the forefoot portion.

11. The sole structure of claim 10, wherein the density of the sole material decreases linearly from the heel portion to the forefoot portion as a function of the length of the sole structure.

12. The sole structure of claim 1, wherein at least a portion of the plurality of apertures are shaped as regular polygons.

13. The sole structure of claim 1, wherein at least a portion of the plurality of apertures are shaped as concave hexagons.

14. The sole structure of claim 1, wherein the property of the auxetic structure includes a size of the plurality of apertures, and the size of the plurality of apertures varies as a function of the density or the thickness of the sole component.

15. The sole structure of claim 14, wherein the property of the auxetic structure includes a shape of the plurality of apertures, and the shape of the plurality of apertures varies as a function of the density or the thickness of the sole component.

16. The sole structure of claim 15, wherein the property of the auxetic structure includes a number of the plurality of apertures within an area of the length of the sole component, and the number of the plurality of apertures varies as a function of the density or the thickness of the sole component.

17. The sole structure according to claim 16, wherein the property of the auxetic structure includes a spacing of the plurality of apertures, and the spacing of the plurality of apertures varies as a function of the density or the thickness of the sole component.

18. The sole structure of claim 17, wherein the property of the auxetic structure includes a depth of the plurality of apertures, and the depth of the plurality of apertures varies as a function of the density or the thickness of the sole component.

19. An article of footwear comprising:

a sole structure including a sole component having an interior surface and an exterior surface opposite the interior surface, wherein the sole component has a length extending along a longitudinal direction, the sole component has a width extending along a lateral direction, the lateral direction is perpendicular to the longitudinal direction, the sole component has a thickness extending along a vertical direction, the vertical direction is perpendicular to the longitudinal direction and the lateral direction, the sole component includes a sole material, and the sole material has a density;

wherein the auxetic structure is configured such that when the sole element is tensioned in one of the longitudinal direction or the lateral direction, the sole element expands in both the longitudinal direction and in the lateral direction; and

wherein a property of the auxetic structure varies as a function of the density of the sole component, and wherein the density of the auxetic structure varies throughout the sole component.

20. The article of footwear according to claim 19, wherein the sole component includes a forefoot portion, a heel portion, and a midfoot portion disposed between the heel portion and the forefoot portion, and the density of the sole material in the heel portion is greater than the density of the sole material in the forefoot portion.

21. The article of footwear of claim 20, wherein the density of the sole material in the heel portion is greater than the density of the sole material in the midfoot portion.

22. The article of footwear of claim 21, wherein the density of the sole material decreases continuously from the heel portion to the forefoot portion.

23. The article of footwear according to claim 22, wherein the density of the sole material decreases linearly from the heel portion to the forefoot portion as a function of the length of the sole component.

24. The article of footwear of claim 23, wherein the sole material includes Ethylene Vinyl Acetate (EVA) foam and blown nitrile rubber.

25. The article of footwear according to claim 24, wherein the thickness of the sole element in the heel portion is greater than the thickness of the sole element in the forefoot portion.

26. The article of footwear of claim 25, wherein the thickness of the sole material in the heel portion is greater than the thickness of the sole material in the midfoot portion.

27. The article of footwear of claim 26, wherein the thickness of the sole material decreases continuously from the heel portion to the forefoot portion.

28. The article of footwear according to claim 27, wherein the thickness of the sole material decreases linearly from the heel portion to the forefoot portion as a function of the length of the sole component.

29. The article of footwear according to claim 19, wherein the sole component is a midsole component.

30. The article of footwear of claim 19, wherein at least a portion of the plurality of apertures are shaped as regular polygons.

31. The article of footwear of claim 19, wherein at least a portion of the plurality of apertures are shaped as concave hexagons.

32. The article of footwear according to claim 19, wherein the property of the auxetic structure includes a size of the plurality of apertures, and the size of the plurality of apertures varies as a function of the density or the thickness of the sole component.

33. The article of footwear according to claim 19, wherein the property of the auxetic structure includes a shape of the plurality of apertures, and the shape of the plurality of apertures varies as a function of the density of the sole component.

34. The article of footwear recited in claim 19, wherein the property of the auxetic structure includes a number of the plurality of apertures within an area of the length of the sole component, and the number of the plurality of apertures varies as a function of the density or the thickness of the sole component.

35. The article of footwear according to claim 19, wherein the property of the auxetic structure includes a spacing of the plurality of apertures, and the spacing of the plurality of apertures varies as a function of the density or the thickness of the sole component.

36. The article of footwear according to claim 19, wherein the property of the auxetic structure includes a depth of the plurality of apertures, and the depth of the plurality of apertures varies as a function of the density or the thickness of the sole component.