Sole structure having an outsole with integrated traction elements

Abstract

A sole structure including an outsole and a midsole disposed over the outsole. The outsole includes an outsole plate and a plurality of traction elements molded to the outsole plate. Each of the plurality of traction elements includes a plurality of overhangs. Each of the plurality of overhangs is cantilevered from the outsole plate. The midsole includes a plurality of discrete pods. Each of the plurality of discrete pods includes a midsole fluid-filled bladder. The midsole fluid-filled bladder defines an interior cavity and includes a first polymeric layer, a second polymeric layer, and a plurality of midsole tethers interconnecting the first polymeric layer and the second polymeric layer. Each of the plurality of midsole tethers is disposed in the interior cavity of the midsole fluid-filled bladder. Each of the plurality of discrete pods is disposed over and aligned with one of the plurality of traction elements.

What is claimed is: 
     
         1 . A sole structure, comprising:
 an outsole including an outsole plate and a plurality of traction elements molded to the outsole plate, each of the plurality of traction elements includes a plurality of overhangs, each of the plurality of overhangs is cantilevered from the outsole plate; and   a midsole disposed over the outsole, the midsole including a plurality of discrete pods, each of the plurality of discrete pods includes a midsole fluid-filled bladder, the midsole fluid-filled bladder defines an interior cavity, the midsole fluid-filled bladder includes a first polymeric layer, a second polymeric layer, and a plurality of midsole tethers interconnecting the first polymeric layer and the second polymeric layer, each of the plurality of midsole tethers is disposed in the interior cavity of the midsole fluid-filled bladder; and   wherein each of the plurality of discrete pods is disposed over and aligned with one of the plurality of traction elements to maximize an energy efficiency of the sole structure.   
     
     
         2 . The sole structure of  claim 1 , wherein the outsole is made of thermoplastic polyurethane, the thermoplastic polyurethane has a hardness measured in Shore A, and the hardness of the thermoplastic polyurethane is between 85 and 95 to promote flexion of the sole structure. 
     
     
         3 . The sole structure of  claim 1 , further comprising a foam layer and a strobel board, wherein the strobel board is disposed over the foam layer, and the foam layer is disposed between the strobel board and the plurality of discrete pods. 
     
     
         4 . The sole structure of  claim 3 , wherein the strobel board includes a strobel fluid-filled bladder, and the strobel fluid-filled bladder includes a first strobel layer, a second strobel layer, and a plurality of strobel tethers interconnecting the first strobel layer and the second strobel layer. 
     
     
         5 . The sole structure of  claim 4 , further comprising a string having a first string terminus and a second string terminus opposite the first string terminus, wherein the first string terminus is directly coupled to the midsole, and the second string terminus is configured to be directly coupled to an upper. 
     
     
         6 . The sole structure of  claim 1 , wherein the plurality of traction elements includes solely three traction elements. 
     
     
         7 . The sole structure of  claim 1 , wherein the outsole has a forefoot region, a heel region, and a midfoot region disposed between the forefoot region and the heel region, the plurality of traction elements solely includes a first forefoot traction element, a second forefoot traction element, and a heel traction element, the first forefoot traction element and the second forefoot traction element are disposed in the forefoot region of the outsole, and the heel traction element is disposed in the heel region of the outsole, and none of the plurality of traction elements is disposed in the midfoot region of the outsole. 
     
     
         8 . The sole structure of  claim 7 , wherein the heel traction element covers a majority of the heel region of the outsole, and the heel traction element is larger than the first forefoot traction element and the second forefoot traction element. 
     
     
         9 . The sole structure of  claim 8 , wherein adjacent overhangs of the plurality of overhangs of each of the plurality of traction elements are spaced apart from one another by a void. 
     
     
         10 . The sole structure of  claim 9 , wherein the void between the adjacent overhangs defines an acute angle from one of the adjacent overhangs to another of the adjacent overhangs to facilitate flexion along predefined flex lines. 
     
     
         11 . An article of footwear, comprising:
 an upper;   a sole structure coupled to the upper, wherein the sole structure includes:
 an outsole including an outsole plate and a plurality of traction elements molded to the outsole plate, each of the plurality of traction elements includes a plurality of overhangs, each of the plurality of overhangs is cantilevered from the outsole plate; and 
 a midsole disposed over the outsole, the midsole including a plurality of discrete pods, each of the plurality of discrete pods includes a midsole fluid-filled bladder, the midsole fluid-filled bladder defines an interior cavity, the midsole fluid-filled bladder includes a first polymeric layer and a second polymeric layer, and a plurality of midsole tethers interconnecting the first polymeric layer and the second polymeric layer, each of the plurality of midsole tethers is disposed in the interior cavity of the midsole fluid-filled bladder; and 
 wherein each of the plurality of discrete pods is disposed over and aligned with one of the plurality of traction elements to maximize an energy efficiency of the sole structure. 
   
     
     
         12 . The article of footwear of  claim 11 , wherein the outsole is made of thermoplastic polyurethane, the thermoplastic polyurethane has a hardness measured in Shore A, and the hardness of the thermoplastic polyurethane is between 85 and 95 to promote flexion of the sole structure. 
     
     
         13 . The article of footwear of  claim 11 , further comprising a foam layer and a strobel board disposed over the foam layer, wherein the foam layer is disposed between the strobel board and the plurality of discrete pods. 
     
     
         14 . The article of footwear of  claim 13 , wherein the strobel board includes a strobel fluid-filled bladder, and the strobel fluid-filled bladder includes a first strobel layer, a second strobel layer, and a plurality of strobel tethers interconnecting the first strobel layer and the second strobel layer. 
     
     
         15 . The article of footwear of  claim 14 , further comprising a string having a first string terminus and a second string terminus opposite the first string terminus, the first string terminus is directly coupled to the midsole, and the second string terminus is directly coupled to the upper. 
     
     
         16 . The article of footwear of  claim 11 , wherein the plurality of traction elements includes solely three traction elements. 
     
     
         17 . The article of footwear of  claim 11 , wherein the outsole has a forefoot region, a heel region, and a midfoot region disposed between the forefoot region and the heel region, the plurality of traction elements solely includes a first forefoot traction element, a second forefoot traction element, and a heel traction element, the first forefoot traction element and the second forefoot traction element are disposed in the forefoot region of the outsole, and the heel traction element is disposed in the heel region of the outsole, and none of the plurality of traction elements is disposed in the midfoot region of the outsole. 
     
     
         18 . The article of footwear of  claim 17 , wherein the heel traction element covers a majority of the heel region of the outsole, and the heel traction element is larger than the first forefoot traction element and the second forefoot traction element. 
     
     
         19 . The article of footwear of  claim 18 , wherein adjacent overhangs of the plurality of overhangs of each of the plurality of traction elements are spaced apart from one another by a void, and the void between the adjacent overhangs defines an acute angle from one of the adjacent overhangs to another of the adjacent overhangs to facilitate flexion along predefined flex lines. 
     
     
         20 . A method of manufacturing an outsole, comprising:
 injecting a molten polymeric material into a mold cavity of a mold, wherein the mold includes a mold body and a plurality of inserts detachably coupled to the mold body, the mold body defines the mold cavity, and the mold cavity is shaped as the outsole, wherein the plurality of inserts are shaped to form a plurality of gaps between an outsole plate of the outsole and each of a plurality of traction elements of the outsole;   cooling the polymeric material until the polymeric material solidifies; and   removing the plurality of inserts from the polymeric material after the polymeric material solidifies to form the plurality of gaps.   
     
     
         21 . The method of  claim 20 , wherein the removing the plurality of inserts includes hand picking the inserts from the polymeric material after the polymeric material solidifies. 
     
     
         22 . The method of  claim 21 , wherein removing the plurality of inserts includes applying a magnetic field toward the plurality of inserts to withdraw the plurality of inserts from the polymeric material after the polymeric material solidifies. 
     
     
         23 . A sole structure, comprising:
 an outsole having a forefoot region, a heel region, and a midfoot region disposed between the forefoot region and the heel region, wherein the outsole includes:
 an outsole plate; and 
 a plurality of traction elements molded to the outsole plate, wherein each of the plurality of traction elements includes a plurality of overhangs, and each of the plurality of overhangs is cantilevered from the outsole plate, the plurality of traction elements includes a first forefoot traction element, a second forefoot traction element, and a heel traction element, the first forefoot traction element and the second forefoot traction element are disposed in the forefoot region of the outsole, the heel traction element is disposed in the heel region of the outsole. 
   
     
     
         24 . The sole structure of  claim 23 , wherein the outsole is made of thermoplastic polyurethane, the thermoplastic polyurethane has a hardness measured in Shore A, and the hardness of the thermoplastic polyurethane is between 85 and 95 to promote flexion of the sole structure. 
     
     
         25 . The sole structure of  claim 23 , wherein adjacent overhangs of the plurality of overhangs of each of the plurality of traction elements are spaced apart from one another by a void. 
     
     
         26 . The sole structure of  claim 25 , wherein the void between the adjacent overhangs defines an acute angle from one of the adjacent overhangs to another of the adjacent overhangs to facilitate flexion along predefined flex lines. 
     
     
         27 . The sole structure of  claim 23 , wherein the heel traction element covers a majority of the heel region of the outsole, and the heel traction element is larger than the first forefoot traction element and the second forefoot traction element. 
     
     
         28 . The sole structure of  claim 23 , wherein the outsole plate extends through the forefoot region, the heel region, and the midfoot region of the outsole.