Article of Footwear Having Midsole with Support Pillars and Method of Manufacturing Same

Abstract

An article of footwear includes an upper, a sole assembly, and a support assembly positioned in the sole assembly and including a plurality of pillars. Each pillar includes an outer layer and an inner layer of cushioning material contained with the outer layer.

1 . An article of footwear comprising, in combination:
 an upper;   a sole assembly; and   a support assembly positioned in the sole assembly and including a plurality of pillars, each pillar comprising an outer layer and an inner layer of cushioning material contained within the outer layer such that the entire outer layer completely circumferentially surrounds the inner layer, substantially without any voids between the inner layer and the outer layer.   
     
     
         2 . The article of footwear of  claim 1 , wherein the outer layer includes a plurality of recesses formed of walls and a bottom, the inner layer of cushioning material being received in each recess. 
     
     
         3 . The article of footwear of  claim 2 , wherein at least one recess has four walls. 
     
     
         4 . The article of footwear of  claim 2 , wherein at least one recess has three walls. 
     
     
         5 . The article of footwear of  claim 2 , wherein the walls of at least one recess taper inwardly to the bottom of the at least one recess. 
     
     
         6 . The article of footwear of  claim 1 , wherein the outer layer is formed of TPU. 
     
     
         7 . The article of footwear of  claim 1 , wherein the cushioning material is formed of polyurethane. 
     
     
         8 . An article of footwear comprising, in combination:
 an upper;   a sole assembly; and   a support assembly positioned in the sole assembly and including a plurality of pillars, each pillar comprising an outer layer including a recess formed of walls and a bottom, and an inner layer of cushioning material contained within the recess such that the entire outer layer completely circumferentially surrounds the inner layer without any voids between the inner layer and the outer layer.   
     
     
         9 . The article of footwear of  claim 8 , wherein at least one recess has four walls. 
     
     
         10 . The article of footwear of  claim 8 , wherein at least one recess has three walls. 
     
     
         11 . The article of footwear of  claim 8 , wherein the walls of at least one recess taper inwardly to the bottom of the at least one recess. 
     
     
         12 . The article of footwear of  claim 8 , wherein the outer layer is formed of TPU. 
     
     
         13 . The article of footwear of  claim 8 , wherein the cushioning material is formed of polyurethane.