Sole structure for an article of footwear having hollow polymeric elements and method of manufacturing same

Abstract

A sole structure for an article of footwear includes a sole component having a plurality of hollow polymeric elements in contact with one another or with binder between the hollow polymeric elements and fixed relative to one another. Each of the hollow polymeric elements defines a sealed, fluid-filled internal cavity capable of retaining fluid at a predetermined pressure. A method of manufacturing a sole structure for an article of footwear includes placing a plurality of hollow polymeric elements in contact with one another or with binder between the hollow polymeric elements, and fixing the plurality of hollow polymeric elements relative to one another to form a sole component. Each of the hollow polymeric elements has a sealed, fluid-filled internal cavity capable of retaining fluid at a predetermined pressure.

What is claimed is: 
     
         1 . A sole structure for an article of footwear comprising:
 a sole component formed from a plurality of hollow polymeric elements in contact with one another or with binder between the hollow polymeric elements, and fixed relative to one another; and   wherein each of the hollow polymeric elements defines a sealed, fluid-filled internal cavity capable of retaining fluid at a predetermined pressure.   
     
     
         2 . The sole structure for the article of footwear of  claim 1 , wherein the hollow polymeric elements comprise a thermoplastic polyurethane (TPU). 
     
     
         3 . The sole structure for the article of footwear of  claim 2 , wherein the TPU is present on at least an outer surface of the hollow polymeric elements. 
     
     
         4 . The sole structure for the article of footwear of  claim 2 , wherein the plurality of hollow polymeric elements are fixed relative to one another by chemical bonds formed between outer surfaces of the hollow polymeric elements. 
     
     
         5 . The sole structure for the article of footwear of  claim 4 , wherein the chemical bonds are formed between outer surfaces of the hollow polymeric elements during an ultraviolet light curing process such that the chemical bonds fix the hollow polymeric elements relative to one another to retain a shape of the sole component. 
     
     
         6 . The sole structure for the article of footwear of  claim 1 , wherein the hollow polymeric elements comprise a thermoplastic urethane, a polyurethane, a polyester, a polyester polyurethane, or a polyether polyurethane. 
     
     
         7 . The sole structure for the article of footwear of  claim 1 , wherein the sole component further includes the binder; and wherein the hollow polymeric elements are fixed relative to one another at least in part by the binder. 
     
     
         8 . The sole structure for the article of footwear of  claim 7 , wherein the binder comprises a polymeric resin binder. 
     
     
         9 . The sole structure for the article of footwear of  claim 8 , wherein the polymeric resin binder comprises at least one of a dimer fatty-acid based polyol binder or a dimer diol-based binder. 
     
     
         10 . The sole structure for the article of footwear of  claim 1 , wherein the fluid is a gas, and the gas is present at the predetermined pressure in the fluid-filled internal cavities. 
     
     
         11 . The sole structure for the article of footwear of  claim 10 , wherein the predetermined pressure is less than or equal to ambient pressure. 
     
     
         12 . The sole structure for the article of footwear of  claim 10 , wherein the predetermined pressure is greater than or equal to ambient pressure. 
     
     
         13 . The sole structure for the article of footwear of  claim 12 , wherein the predetermined pressure is from about 5 pounds per square inch (psi) to about 25 psi. 
     
     
         14 . The sole structure for the article of footwear of  claim 1 , wherein each of the hollow polymeric elements is formed from at least one multi-layer polymeric sheet. 
     
     
         15 . The sole structure for the article of footwear of  claim 14 , wherein each of said at least one multi-layer sheet is a laminate membrane having:
 at least a first layer comprising the TPU; and   at least a second layer comprising a gas barrier polymer.   
     
     
         16 . The sole structure for the article of footwear of  claim 15 , wherein the gas barrier polymer comprises an ethylene-vinyl alcohol copolymer. 
     
     
         17 . The sole structure for the article of footwear of  claim 16 , wherein the at least a first layer consists essentially of the TPU, and the at least a second layer consists essentially of the ethylene-vinyl alcohol copolymer. 
     
     
         18 . The sole structure for the article of footwear of  claim 1 , wherein each of the hollow polymeric elements is formed from a first polymeric sheet bonded to a second polymeric sheet. 
     
     
         19 . The sole structure for the article of footwear of  claim 1 , wherein the sole component is substantially translucent. 
     
     
         20 . The sole structure for the article of footwear of  claim 1 , wherein a majority of the hollow polymeric elements have a hardness of approximately 85 to 89 durometer on a Shore A scale. 
     
     
         21 . The sole structure for the article of footwear of  claim 1 , wherein the hollow polymeric elements are substantially spherical. 
     
     
         22 . The sole structure for an article of footwear of  claim 21 , wherein the sole component has a first region and a second region; wherein a majority of the hollow polymeric elements in the first region each have an outer diameter within a first range of diameters; wherein a majority of the hollow polymeric elements in the second region each have an outer diameter within a second range of diameters; and wherein diameters included in the first range of diameters are at least five percent larger than diameters included in the first range of diameters. 
     
     
         23 . The sole structure for the article of footwear of  claim 22 , wherein the sole component has an outer surface with a groove; and wherein the groove is located between the first region and the second region. 
     
     
         24 . The sole structure for the article of footwear of  claim 1 , wherein the first region is a heel region and the second region is a forefoot region. 
     
     
         25 . The sole structure for the article of footwear of  claim 1 , wherein the sole component has a third region extending from the second region to the first region and at least partially surrounding a perimeter of the first region;
 wherein a majority of the hollow polymeric elements in the third region have an outer diameter within a third range of diameters; and   wherein diameters included in the third range of diameters are at least five percent smaller than diameters included in the second range of diameters.   
     
     
         26 . The sole structure for the article of footwear of  claim 25 , wherein the midsole has a fourth region forward of the second region; and
 wherein a majority of the hollow polymeric elements in the fourth region have an outer diameter within the third range of diameters.   
     
     
         27 . The sole structure for the article of footwear of  claim 1 , further comprising:
 a reinforcing element fixed to the hollow polymeric elements in the sole component.   
     
     
         28 . The sole structure for the article of footwear of  claim 1 , wherein the sole component is a midsole, and in combination with:
 at least one of a footwear upper or an outsole fixed to the midsole.   
     
     
         29 . The sole structure for the article of footwear of  claim 1 , wherein the hollow polymeric elements are substantially spherical;
 wherein each of the hollow polymeric elements has an outer diameter from about 5 millimeters to about 8 millimeters.   
     
     
         30 - 50 . (canceled)