Extruded Components For Articles Of Footwear And Methods Of Making The Same

Abstract

Extruded components for articles of footwear and methods of making such articles of footwear are disclosed. A carrier can be formed from a first material, the carrier including an attachment surface configured to attach to an upper and a receiving surface having a plurality of receptacles. A second material can be extruded into a plurality of the receptacles to form cushioning elements of a sole.

What is claimed is: 
     
         1 . An article of footwear comprising:
 an upper;   a carrier attached to the upper, the carrier comprising:
 an attachment surface configured to attach the carrier to the upper, and 
 a receiving surface comprising a plurality of receptacles; and 
   a plurality of cushioning elements disposed in the receptacles.   
     
     
         2 . The article of footwear of  claim 1 , wherein at least one receptacle comprises a protrusion extending from the receiving surface of the carrier, the protrusion having a sidewall defining a rim and an interior cavity, and wherein at least one cushioning element extends beyond the rim of a protrusion. 
     
     
         3 . The article of footwear of  claim 1 , wherein at least one cushioning element comprises an extruded material having a dome-shaped exterior surface. 
     
     
         4 . The article of footwear of  claim 3 , wherein the carrier comprises a thermoplastic polyurethane (TPU) or ethylene-vinyl acetate (EVA) film and at least one cushioning element comprises polyurethane elastomer or polyurethane foam. 
     
     
         5 . The article of footwear of  claim 1 , wherein at least one receptacle comprises a cavity in the receiving surface of the carrier. 
     
     
         6 . The article of footwear of  claim 1 , wherein the carrier comprises a forefoot region, a midfoot region, and a heel region, wherein one of the plurality of receptacles is disposed in the heel region and has an interior volume greater than one of the plurality of receptacles that is disposed in the midfoot region, and wherein the one of the plurality of receptacles that is disposed in the midfoot region has an interior volume greater than one of the plurality of receptacles that is disposed in the forefoot region. 
     
     
         7 . The article of footwear of  claim 1 , wherein the carrier comprises a forefoot region, a midfoot region, and a heel region, and wherein one of the plurality of receptacles is disposed in the heel region and has a rim that follows a rear contour of the heel region. 
     
     
         8 . The article of footwear of  claim 1 , wherein a majority of the receptacles have a circular rim. 
     
     
         9 . The article of footwear of  claim 1 , wherein the plurality of receptacles comprises more than five receptacles. 
     
     
         10 . The article of footwear of  claim 1 , wherein the plurality of cushioning elements disposed in the receptacles is based on a pressure profile of a foot. 
     
     
         11 . The article of footwear of  claim 1 , wherein the plurality of cushioning elements is configured to be an outsole of the article of footwear. 
     
     
         12 . The article of footwear of  claim 1 , further comprising an outsole material disposed on the plurality of cushioning elements. 
     
     
         13 . The article of footwear of  claim 1 , wherein the carrier is attached to the upper by an adhesive. 
     
     
         14 . The article of footwear of  claim 1 , wherein the attachment surface of the carrier is concave and attached to a bottom surface of the upper. 
     
     
         15 . The article of footwear of  claim 1 , wherein the attachment surface comprises a sidewall that contacts an exterior surface of the upper. 
     
     
         16 . An article of footwear comprising:
 an upper;   a carrier attached to the upper, the carrier comprising:
 an attachment surface configured to attach the carrier to the upper, and 
 a receiving surface comprising a plurality of receptacles, each receptacle comprising a sidewall defining a rim and an interior cavity, wherein two adjacent receptacles of the plurality of receptacles share a sidewall; and 
   a plurality of cushioning elements disposed in the receptacles.   
     
     
         17 . The article of footwear of  claim 16 , wherein at least one of the plurality of cushioning elements extends beyond the rim of at least one of the plurality of receptacles. 
     
     
         18 . The article of footwear of  claim 16 , wherein a majority of the receptacles have a circular rim. 
     
     
         19 . The article of footwear of  claim 16 , wherein the attachment surface of the carrier is concave and attached to a bottom surface of the upper. 
     
     
         20 . The article of footwear of  claim 16 , wherein the attachment surface comprises a sidewall that contacts an exterior surface of the upper.