Article of Footwear Having a Midsole and Methods of Making the Same

Abstract

An article of footwear including a midsole for providing cushioning for a wearer's foot and providing structure for coupling the midsole to an upper. The midsole may include a body and a flange integrally formed with the body and extending outwardly from an outer perimeter of the body. The flange may be configured to couple with the upper. The midsole may be a single integrally formed piece. The midsole may eliminate the need to include a strobel board as part of the article of footwear. Methods for manufacturing an article of footwear including a midsole are also provided.

What is claimed is: 
     
         1 . An article of footwear, comprising:
 an upper,   a midsole comprising a body and a flange integrally formed with the body, the flange extending outwardly from an outer perimeter of the body and coupled to the upper, and   an outsole comprising a sidewall coupled to the upper and a base having a ground contacting surface and an open cavity disposed opposite the ground contacting surface, the open cavity having an upper surface defining a recess configured to receive a portion of the body of the midsole.   
     
     
         2 . The article of footwear of  claim 1 , wherein the flange of the midsole is stitched to the upper and wherein the sidewall of the outsole is stitched to the upper. 
     
     
         3 . The article of footwear of  claim 2 , wherein the stitching between the midsole and the upper is a substantially vertical stitch running along an outer perimeter of the flange, and wherein the stitching between the upper and the outsole is oriented substantially perpendicular to the stitching between the midsole and the upper. 
     
     
         4 . The article of footwear of  claim 3 , wherein the stitching between the upper and the outsole is located above the stitching between the midsole and the upper. 
     
     
         5 . The article of footwear of  claim 1 , wherein the body of the midsole comprises a core from which the flange extends and a platform extending from a bottom of the core, and wherein the recess is configured to receive the entire platform of the midsole. 
     
     
         6 . The article of footwear of  claim 1 , wherein the cavity of the outsole receives the entire midsole. 
     
     
         7 . The article of footwear of  claim 1 , wherein an underside of the flange is disposed on the upper surface of the cavity disposed around the recess. 
     
     
         8 . The article of footwear of  claim 1 , wherein the upper surface of the cavity comprises a plurality of projections that define a perimeter of the recess in the cavity. 
     
     
         9 . The article of footwear of  claim 8 , wherein the plurality of projections comprise a lattice structure. 
     
     
         10 . The article of footwear of  claim 8 , wherein the plurality of projections comprise a first set of projections and a second set of projections. 
     
     
         11 . The article of footwear of  claim 10 , wherein the first set of projections are disposed in a forefoot portion of the outsole and are oriented in a direction substantially perpendicular to a longitudinal axis of the outsole, and wherein the second set of projections are disposed in the midfoot and heel portions of the outsole and are oriented in a direction substantially parallel to the longitudinal axis of the outsole. 
     
     
         12 . The article of footwear of  claim 5 , wherein the platform of the midsole tapers in thickness from a heel portion of the article of footwear towards a forefoot portion of the article of footwear. 
     
     
         13 . The article of footwear of  claim 12 , wherein the midsole has a T-shaped cross-sectional shape at the heel portion of the article of footwear. 
     
     
         14 . The article of footwear of  claim 1 , wherein the article of footwear does not include a strobel board. 
     
     
         15 . The article of footwear of  claim 1 , wherein the flange extends outwardly from the body in a forefoot portion, a midfoot portion, and a heel portion of the midsole. 
     
     
         16 . The article of footwear of  claim 1 , wherein the flange has an outer perimeter that is larger than and disposed around the outer perimeter of the body. 
     
     
         17 . The article of footwear of  claim 1 , wherein a top surface of the flange is flush with a proximal surface of the midsole. 
     
     
         18 . An article of footwear, comprising:
 an upper,   an integrally molded midsole comprising a proximal surface, a platform, and a flange extending laterally from the proximal surface and coupled to the upper, and   a cupsole comprising a sidewall coupled to the upper and a base having a ground contacting surface and an open cavity disposed opposite the ground contacting surface, the open cavity comprising a plurality of projections defining an outer perimeter of a recess, the recess configured to receive the platform of the midsole.   
     
     
         19 . The article of footwear of  claim 18 , wherein the flange of the midsole is stitched to the upper and wherein the sidewall of the cupsole is stitched to the upper. 
     
     
         20 . The article of footwear of  claim 19 , wherein the stitching between the flange and the upper is oriented in a direction substantially perpendicular to the orientation of the stitching between the cupsole and the upper. 
     
     
         21 . The article of footwear of  claim 19 , wherein the stitching between the flange and the upper is horizontally and vertically offset from the stitching between the cupsole and the upper. 
     
     
         22 . The article of footwear of  claim 18 , wherein a top surface of the flange is flush with the proximal surface of the midsole. 
     
     
         23 . A method of manufacturing an article of footwear having an upper and a midsole having a body and a flange extending from an upper perimeter of the body, the method comprising:
 stitching the midsole to the upper by vertically stitching along the flange;   coupling an outsole to the midsole such that the body of the midsole is received within a cavity formed in the outsole; and   stitching the outsole to the upper,   wherein the stitching between the upper and the outsole is oriented substantially perpendicular to the stitching between the midsole and the upper.   
     
     
         24 . The method of  claim 23 , wherein the midsole is a single integrally molded piece.