(19) United States
`(12) Patent Application Publication (10) Pub. No.: US 2016/0219973 A1
`Cheney et al.
`(43) Pub. Date:
`Aug. 4, 2016
`
`US 20160219973A1
`
`(54) FLEXIBLE ARTICLE OF FOOTWEAR AND
`RELATED METHOD OF MANUFACTURE
`
`(71) Applicant: Wolverine World Wide, Inc., Rockford,
`MI (US)
`(72) Inventors: James H. Cheney, Northborough, MA
`(US); David Thorpe, Acton, MA (US);
`Alan Lazell, Dongguan City (CN)
`
`(21) Appl. No.: 14/609,828
`(22) Filed:
`Jan. 30, 2015
`
`Publication Classification
`
`(51) Int. Cl.
`A43B I3/4
`A43B I3/2
`
`(2006.01)
`(2006.01)
`
`(52) U.S. Cl.
`CPC ............... A43B 13/141 (2013.01); A43B 13/12
`(2013.01)
`
`(57)
`
`ABSTRACT
`
`An improved article of footwear and a related method of
`manufacture are provided. The article of footwear can include
`a sole construction including a midsole and an outsole that are
`configured to promote the natural motion of the wearer's foot
`and conformance to the ground. The sole construction can
`additionally include an insole construction having enhanced
`flexibility in the forefoot region to further accommodate
`dorsi-flexion and plantar-flexion of the wearer's foot. The
`related method of manufacture provides the assembly of an
`article of footwear having these and other features, which can
`be suitable for athletic wear, outdoor wear and casual wearby
`adults, adolescents and Small children.
`
`
`
`12
`
`14
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`Patent Application Publication
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`US 2016/0219973 Al
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`76
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`Pa
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`i-
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`{
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`64
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`66 Fig. 7
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`MacNeil Exhibit 2158
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`i
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`MacNeil IP, IPR2020-01139, Page 5
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`MacNeil Exhibit 2158
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`Patent Application Publication
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`Fig. 9
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`Patent Application Publication
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`Aug. 4, 2016 Sheet 6 of 14
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`54
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`50
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`Fig. 10
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`Fig.11
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`Patent Application Publication
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`
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`22 :
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`2
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`60
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`Patent Application
`Publication
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`Aug. 4, 2016 Sheet 10 of 14
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`Fig. 16
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`Aug. 4, 2016 Sheet 11 of 14
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`JOIN UPPER TO INSOLE ELEMENT
`WITH REMOVABLE PORTION
`
`1
`1 O
`
`FORMMDSOLE WITH GROOVES IN
`UPPER SURFACE OF MIDSOLE
`
`2
`11
`
`FORM OUTSOLE WITH GROOVES IN
`LOWER SURFACE OF OUTSOLE
`
`4
`11
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`JOIN OUTSOLE TO MDSOLE
`
`116
`
`JOIN MIDSOLE TO ASSEMBLED L
`UPPER WITH INSOLE ELEMENT
`118
`
`SEPARATE REMOVABLE PORTION
`FROM INSOLE ELEMENT
`
`O
`12
`
`POSITION FOOTBED OVER
`NSOLE ELEMENT
`
`2
`12
`
`Fig. 17
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`MacNeil Exhibit 2158
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`Patent Application Publication
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`Aug. 4, 2016 Sheet 13 of 14
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`Fig. 19
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`48
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`US 2016/0219973 A1
`
`Aug. 4, 2016
`
`FLEXBLE ARTICLE OF FOOTWEAR AND
`RELATED METHOD OF MANUFACTURE
`
`BACKGROUND OF THE INVENTION
`0001. The present invention relates to footwear and, more
`particularly, to footwear that promotes the natural movement
`of the wearer's foot and conformity to the ground.
`0002 Conventional footwear typically includes two pri
`mary elements: an upper and a sole construction. The upper at
`least partially covers the wearer's foot, and the Sole construc
`tion provides support for the wearer's sole. The sole construc
`tion can include multiple layers and materials. For example,
`conventional Sole constructions can include a molded foam
`midsole over a natural rubber outsole. The molded foam
`midsole can provide cushioning while the natural rubber out
`sole can provide traction and wear resistance.
`0003 Conventional sole constructions are primarily flex
`ible in a single direction. In particular, many sole construc
`tions are intended to flex in the upward direction, in which the
`ground engaging Surface of the outsole is convex. Flexibility
`of this kind is typically achieved with modifications to the
`outsole. For example, it is known to introduce grooves in the
`outsole to promote the bending of the outsole in the upward
`direction. It is also known to separate the outsole into indi
`vidual components that move away from each other as the
`outsole is bent in an upward direction.
`0004. The natural movement of the wearer's foot is not
`limited to flexure in the upward direction, however. In addi
`tion to upward flexure, or dorsi-flexion, the human foot natu
`rally exhibits downward flexure, or plantar-flexion. Conven
`tional Sole constructions typically exhibit significant
`resistance to plantar-flexion, however. For example, many
`conventional Sole constructions include an outsole or a mid
`sole that resists plantar-flexion of the wearer's foot. By
`opposing the natural ability of the human foot to flex down
`wardly, many Such sole constructions compromise stability
`and grip on all but even Surfaces.
`
`SUMMARY OF THE INVENTION
`0005. An improved article of footwear and a related
`method of manufacture are provided. The improved article of
`footwear includes a sole construction configured to promote
`the natural motion of the wearer's foot over a variety of
`surfaces and for a variety of activities. The sole construction
`includes enhanced flexibility in the forefoot region to accom
`modate planar-flexion and dorsi-flexion of the wearer's foot.
`The related method of manufacture provides the assembly of
`an article of footwear having these and other features, which
`can be suitable for athletic wear, outdoor wear and casual
`wear by adults, adolescents and small children. The related
`method of manufacture can be modified to meet the specific
`demands of the end-use application, thereby providing an
`article of footwear having the desired degree of cushioning
`and ground protection while also providing the desired degree
`of flexibility for the wearer.
`0006. In one embodiment, an article of footwear includes
`an insole element, a midsole, and an outsole. The insole
`element includes an opening or cutout, optionally including
`an elastic material spanning the opening or cutout. The open
`ing or cutout extends over flex grooves in the midsole that can
`define anatomical pods beneath the wearer's forefoot and that
`promote upward and downward flexibility. The outsole
`includes a lower Surface defining outsole flex grooves in
`
`general alignment with the midsole flex grooves. The midsole
`lower Surface and the outsole upper Surface define an inter
`face about which the article of footwear can be flexed to
`accommodate planar-flexion and dorsi-flexion of the wear
`er's forefoot.
`0007. The midsole can include an upper surface defining a
`plurality of lateral flex grooves and a plurality of longitudinal
`flex grooves. The plurality of lateral flex grooves include a
`first lateral flex groove extending generally beneath a junction
`between the wearers toe bones and metatarsal bones and a
`second lateral flex groove extending generally beneath the
`wearer's metatarsal bones. The plurality of longitudinal
`grooves intersect the plurality of lateral grooves in the fore
`foot region of the midsole. The midsole grooves, both longi
`tudinal and lateral, can define a depth that is a percentage of
`the thickness of the midsole. For example, the midsole flex
`grooves optionally define a depth between about 25% and
`95% of the thickness of the midsole, further optionally
`between about 70% and 90% of the thickness of the midsole.
`The midsole flex grooves can alternatively extend entirely
`through the thickness of the midsole. In other embodiments,
`the depth of the midsole flex grooves varies, such that the
`depth of one midsole flex groove is different from the depth of
`another of the midsole flex groove.
`0008. The outsole flex grooves can minor the midsole flex
`grooves, extending between adjacent tread elements of the
`outsole. The tread elements are optionally positioned below
`individual bones, joints and/or muscles and move indepen
`dently of each other, and are interconnected with each other.
`For example, individual tread elements are positioned
`beneath the wearer's toe bones, beneath the wearer's meta
`tarsal bones, beneath the wearer's tarsal bones, and/or
`beneath the wearer's calcaneus (heel) bone. The tread ele
`ments are optionally surrounded by a color dam, which acts as
`a separation element between the tread elements and the
`outsole flex grooves. The outsole flex grooves can define a
`depth that is a percentage of the thickness of the outsole
`(inclusive of the tread elements). The outsole flex grooves
`optionally define a depth between about 25% and 95% of the
`thickness of the outsole, further optionally between about
`50% and 70% of the thickness of the outsole. The outsole flex
`grooves can alternatively extend entirely through the thick
`ness of the outsole.
`0009. In another embodiment, a method of manufacturing
`an article of footwear is provided. The method generally
`includes lasting an upper with an insole element, forming a
`midsole including midsole grooves, forming an outsole
`including outsole grooves, joining the outsole to the midsole,
`joining the midsole to the insole element, removing an area of
`material from the forefoot region of the insole element, and
`positioning a footbed over the insole element. Joining the
`insole element to the upper can include sewing the insole
`element to the upper. In embodiments where the insole ele
`ment is a Strobel board, the insole element can be joined to the
`upper along a butt seam. In embodiments where the insole
`element is a lasting board, the insole element can be joined to
`the upper with cement. Joining the midsole to the insole
`element can include gluing the midsole to all except the
`forefoot portion of the insole element. Removing the area of
`material can include directly or indirectly pulling a perforated
`segment from the remainder of the insole element. The per
`forated segment can additionally include a pull tab sewn,
`cemented or otherwise joined to the perforated portion to aid
`
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`in the removal of the perforated segment. The remainder of
`the insole element can include a border around an opening in
`the forefoot region.
`0010. In these and other embodiments, the improved
`article of footwear can include a sole construction that pro
`motes the natural movement of the foot and ground conform
`ance. The sole construction is generally flexible longitudi
`nally, laterally, and diagonally, accommodating plantar
`flexion, dorsi-flexion, and twisting. The Sole construction
`provides a balance of dynamic, multi-directional, barefoot
`like movement and conformance with the ground and cush
`ioning with improved surface area contact. The improved
`Surface area contact can enhance stability, proprioception,
`traction and agility with effective ground protection for a
`variety of pursuits. Example pursuits include trail running,
`hiking, hunting, boating, and aquatic activities. Additional
`applications include footwear specifically adapted to promote
`walking for infants and small children. The related method of
`manufacture can be tailored to meet desired levels offlexibil
`ity and performance while providing the desired degree of
`Support to the wearer's sole.
`0011. These and other advantages and features of the
`invention will be more fully understood and appreciated by
`reference to the description of the current embodiments and
`the drawings.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`0012 FIG. 1 is an elevation view of an article of footwear
`in accordance with a current embodiment.
`0013 FIG. 2 is a plan view of a first insole element for the
`article of footwear of FIG. 1.
`0014 FIG. 3 is a plan view of a second insole element for
`the article of footwear of FIG. 1.
`0015 FIG. 4 is a plan view of a third insole element for the
`article of footwear of FIG. 1 with non-stretch webbing.
`0016 FIG.5 is a plan view of a first midsole for the article
`of footwear of FIG. 1 including flex grooves and anatomical
`pods.
`0017 FIG. 6 is a plan view of the midsole of FIG.5 having
`a Superimposed bone structure for the human foot.
`0018 FIG. 7 is a plan view of a second midsole for the
`article of footwear of FIG. 1 including flex grooves and ana
`tomical pods.
`0019 FIG.8 is a plan view of a third midsole for the article
`of footwear of FIG. 1 including flex grooves and anatomical
`pods.
`0020 FIG. 9 is a plan view of the underside of a midsole
`illustrating a protective film in the forefoot region of the
`midsole.
`0021
`FIG. 10 is a plan view of the underside of a midsole
`illustrating a protective film in the forefoot, mid-foot, and
`rearfoot regions of the midsole.
`0022 FIG. 11 is a plan view of the upper surface of a
`midsole in accordance with a current embodiment.
`0023 FIG. 12 is a plan view of the lower surface of an
`outsole in accordance with the embodiment of FIG. 11.
`0024 FIG. 13 is a cross-sectional view of the midsole of
`FIG. 11 and the outsole of FIG. 12 taken along line 13-13 in
`FIGS 11-12.
`0.025
`FIG. 14 is a second cross-sectional view of the mid
`sole of FIG. 11 and the outsole of FIG. 12 taken along line
`14-14 in FIGS. 11-12.
`
`0026 FIG. 15 is a third cross-sectional view of the midsole
`of FIG. 11 and the outsole of FIG. 12 taken along line 15-15
`in FIGS. 11-12.
`0027 FIG. 16 is a plan view of an outsole in accordance
`with a current embodiment illustrating anatomical tread ele
`mentS.
`0028 FIG. 17 is a flow-chart illustrating a method for
`manufacturing an article of footwear in accordance with an
`embodiment of the present invention.
`0029 FIG. 18 is a plan view of insole elements including
`perforations Surrounding a removable forefoot portion.
`0030 FIG. 19 is a plan view of an insole element including
`webbing joined to the removable forefoot portion of the
`insole element.
`0031
`FIG. 20 is a plan view of the underside of an insole
`element including non-stretch webbing extending across the
`forefoot region and joined to the upper.
`
`DESCRIPTION OF THE CURRENT
`EMBODIMENTS
`0032. The current embodiments relate to an improved
`article of footwear and a related method of manufacture. In
`these embodiments, the improved article of footwear includes
`a flexible sole construction adapted to promote the natural
`motion of the wearer's foot and conformance with the
`ground, while providing ground protection and Support for
`the wearer. The related method provides the manufacture of
`an article of footwear having a flexible sole construction for
`use across a range of activities.
`
`I. Construction
`0033 Referring now to FIG. 1, an article of footwear in
`accordance with one embodiment is illustrated and generally
`designated 10. The article of footwear 10 includes an upper 12
`and a sole construction 14. The upper 12 is formed from a
`variety of material elements that are joined together to cover
`at least a portion of the wearer's foot. The material elements
`can be selected based on the intended uses of the article of
`footwear 10, and can include synthetic textiles, mesh textiles,
`polymers or leather, for example. The upper 12 is generally
`constructed to not impede the flexibility of the sole construc
`tion 14, and can include stretchable or elastic material ele
`ments. For example, the material elements can include Lycra,
`Neoprene or Spandex. The upper 12 can include one or more
`closure elements 16, including for example shoelaces orhook
`and loop fasteners. The upper 12 additionally includes an
`upper opening 18 for receiving the wearer's foot and a lower
`periphery 20 for attachment to the sole construction 14.
`0034. The sole construction 14 is also illustrated in side
`profile FIG.1. The sole construction 14 is adapted to provide
`flexibility for a range of foot movements, including for
`example plantar-flexion and dorsi-flexion. The Sole construc
`tion 14 includes an insole element 22 (not shown in FIG. 1),
`a midsole 24 and an outsole 26, but greater or fewer elements
`of the sole construction 14 can be included in other embodi
`ments. For example, some embodiments can include only a
`midsole an outsole, while other embodiments can include
`only an insole element and an outsole. Still other embodi
`ments can include a unit Sole, in which the midsole and the
`outsole are combined into a single unitary element. The unit
`sole can include EVA foam with a cushioning top portion and
`a firmer, wear resistant bottom portion. Each of the insole
`
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`element 22, the midsole 24 and the outsole 26 can addition
`ally include aforefoot region 28, a mid-foot or arch region30,
`and a rearfoot region 32.
`0035. An insole element 22 in accordance with one
`embodiment is illustrated in FIG. 2. The insole element 22 is
`generally non-stretchable and lightweight and joined to the
`upper 12 to provide avoid for receipt of the wearer's foot. The
`insole element 22 includes enhanced flexibility in at least the
`forefoot region 28 in the illustrated embodiment, and can
`include increased flexibility in the mid-foot region 30 and
`rearfoot region 32 in other embodiments. The enhanced flex
`ibility is optionally achieved with an interior opening 34
`extending entirely through the thickness of the insole element
`22. The interior opening 34 generally overlies one or more
`flex grooves in the midsole 24 as discussed below. In addition,
`the interior opening 34 is enclosed by a peripheral lip 36. The
`peripheral lip 36 is generally flat, includes a generally uni
`form width, and is joined to the upper 12, optionally along a
`butt seam. The insole element 22 includes a Strobel board in
`the current embodiment, while in other embodiments the
`insole element 22 includes a lasting board. The insole element
`22 can be non-woven, woven or fibrous, and can beformed of
`nylon, polyester, or polypropylene. Still other constructions
`for the insole element 22 are possible in other embodiments
`where desired.
`0036. The outline of the interior opening 34 generally
`mimics the shape of the forefoot region of the insole element
`22. In particular, the outline of the interior opening 34 gen
`erally includes a straight portion 38 adjacent the mid-foot
`region 30 of the insole element 22 and a curved portion 40
`forward of the straight segment 38. The curved portion 40 is
`spaced apart from the outer periphery 42 of the insole element
`22 by 7 mm to 17 mm in the present embodiment, but can be
`spaced apart by other distances in other embodiments. For
`example, the spacing can be between 5 mm and 25 mm,
`further optionally between 10 mm and 15 mm.
`0037. The interior opening 34 can be modified as desired.
`As further optionally shown in FIG.3, for example, a flexible,
`stretchable covering 44 can extend over the opening 34 in the
`insole element 22. The flexible, stretchable covering 44 can
`include an elastic membrane that extends partially or com
`pletely over the opening 34 in the forefoot region 28 of the
`insole element 22, being generally secured to the downward
`facing surface of the insole element 22. The elastic membrane
`includes Lycra, Neoprene or Spandex in the illustrated
`embodiment, while in other embodiments other materials can
`be used as desired. The opening 34 can additionally include
`one or more web stiffeners. As shown in FIG. 4, two web
`stiffeners 46, 48 are arranged to extend across the opening 34.
`thereby providing an added degree of dimensional stability to
`the flexible covering 38. In the illustrated embodiment, the
`web stiffeners 46, 48 are formed separately from the insole
`element 22 and are glued, stitched or stapled thereto prior to
`the formation of the opening 34 in the insole element 22. In
`other embodiments the web stiffeners 46, 48 are formed of the
`same material as the insole element 22, and separate the
`opening 34 into Sub-openings. In still other embodiments, the
`interior opening is replaced by one or more web stiffeners 46,
`48 that are joined to the upper 12 and that span the forefoot
`region. As shown in FIG. 20 for example, the web stiffeners
`46, 48 are joined to the lower periphery of the upper 12,
`optionally by means of a butt seam, on the upward facing
`surface of the insole element 22. An optional flexible covering
`44 can extend across the remainder of the open area in the
`
`forefoot region, and can be Lycra, Neoprene or Spandex as
`generally discussed above in connection with FIGS. 3-4. The
`web stiffeners 46, 48 are generally cut or removed once the
`article of footwear is assembled as discussed below to
`enhance flexibility of the finished construction.
`0038 Amidsole 24 in accordance with one embodiment is
`illustrated in FIG. 5. The midsole 24 is positioned below the
`insole element 22, and includes a lower surface 50, an upper
`surface 52, and a sidewall 54 extending therebetween. The
`upper surface 52 can include multiple midsole grooves 60.
`The midsole grooves 60 are positioned to provide enhanced
`bending flexibility to the midsole, and in particular, bending
`flexibility in the downward (plantar-flexion) direction. The
`midsole grooves 60 generally underlie the insole opening 34.
`providing enhanced flexibility in the forefoot region 28. In
`addition, the midsole grooves 60 are contained within the
`midsole upper surface 52. In other embodiments, the midsole
`grooves 60 are contained within the midsole lower surface 50.
`In still other embodiments, both of the lower surface 50 and
`the upper surface 52 include midsole grooves 60. In yet other
`embodiments, the midsole grooves 60 extend to the edge of
`the midsole 24 and define a break in the midsole sidewall 54.
`0039. The midsole grooves 60 can assume a variety of
`configurations. In the illustrated embodiment of FIG. 5, the
`midsole grooves 60 include a depth that extends partially
`through the thickness of the midsole 24, such that the midsole
`grooves 60 are not in communication with the outsole 26. For
`example, the midsole 24 can include a local thickness of
`about 11 mm and the midsole grooves 60 can include a depth
`of about 9 mm, leaving a connecting portion of about 2 mm.
`These dimensions can vary in other embodiments as desired.
`In dimensionless terms, the midsole grooves 60 can define a
`depth between about 25% and 95% of the thickness of the
`midsole 24, further optionally between about 70% and 90%
`of the thickness of the midsole 24. In other embodiments the
`midsole grooves 60 include a depth that extends entirely
`through the thickness of the midsole 24, such that the midsole
`grooves 60 are in communication with the outsole 26. The
`midsole grooves 60 can include a width (gap) that is selected
`to provide the desired degree of flexibility for the sole con
`struction. For example, the width can be 1 mm in embodi
`ments where modest flexibility is desired, and 3 mm in
`embodiments where greater flexibility is desired.
`0040. Referring again to FIG. 5, the midsole grooves 60
`include multiple lateral grooves and multiple longitudinal
`grooves. The lateral grooves include a first lateral groove 62
`and a second lateral groove 64. The first lateral groove 62 is
`positioned to extend generally beneath the wearers toes and
`forefoot. The second lateral groove 64 is spaced apart from
`the first lateral groove 62 in the longitudinal (heel-to-toe)
`direction. As shown in FIG. 6 for example, the second lateral
`groove 64 is positioned to extend generally beneath and
`between a junction between the wearer's phalanges (toe
`bones) and metatarsals. As also shown in FIG. 6, the first and
`second lateral grooves 62, 64 are arcuate in the present
`embodiment, but can be straight, angled or segmented in
`other embodiments. The longitudinal grooves 66 extend in
`the heel-to-toe direction, and intersect the first and second
`lateral grooves 62, 64. The longitudinal grooves 66 are posi
`tioned generally beneath and between adjacent metatarsals/
`toes, and facilitate torsional and longitudinal bending of the
`midsole 24. While shown as being located in the forefoot
`region of the midsole in the present embodiment, the midsole
`
`MacNeil Exhibit 2158
`Yita v. MacNeil IP, IPR2020-01139, Page 18
`
`

`

`US 2016/0219973 A1
`
`Aug. 4, 2016
`
`grooves 60 can extend into the mid-foot region 30 and/or the
`rearfoot region 32 of the midsole in other embodiments.
`0041. The midsole grooves 60 can define anatomical pods
`68 that are shaped to generally correspond with one or more
`anatomical features of the human foot. As shown in FIG. 5,
`for example, eachanatomical pod 68 is bordered on two, three
`or four sides by the midsole grooves 60. A first row of ana
`tomical pods 70 is bordered by the first lateral groove 62 and
`by the longitudinal grooves 66. A second row of anatomical
`pods 72 is bordered by the first and second lateral grooves 62,
`64 and by the longitudinal grooves 66. A third row of ana
`tomical pods 74 is bordered by the second lateral groove 64
`and by the longitudinal grooves 66. In addition, eachanatomi
`cal pod 68 underlies one or more bones in the wearer's foot.
`The first and second rows of anatomical pods 70, 72 generally
`underlie the metatarsals, while the third row of anatomical
`pods 74 generally underlies the phalanges. The pods 68 can
`assume other anatomical or non-anatomical shapes or loca
`tions in other embodiments as desired.
`0042. The midsole grooves 60 can deform to accommo
`date movement of the wearer's foot. For example, the gap
`within each midsole groove 60 can widen or narrow depend
`ing on the curvature imposed on the midsole 24 and the
`predominate direction of the midsole groove 60. If the mid
`sole groove 60 is predominately laterally disposed (e.g.,
`grooves 62 and 64), the midsole groove 60 can widen as the
`midsole 24 is flexed upwardly or narrow as the midsole 24 is
`flexed downwardly. If the midsole groove 60 is longitudinally
`disposed (e.g., grooves 66), the midsole groove 60 can widen
`as the midsole 24 assumes a longitudinally convex curvature
`and can narrow as the midsole 24 assumes a longitudinally
`concave curvature. The presence of the lateral midsole
`grooves 62, 64 therefore assistin promoting the natural move
`ment of the human foot, and conformance to the ground,
`beyond that which is accommodated by conventional foot
`wear constructions.
`0043. The midsole grooves 60 can assume a variety of
`alternative configurations. For example, the midsole grooves
`60 can include a depth that extends entirely through the thick
`ness of the midsole 24, such that the midsole grooves 60 are
`in communication with the outsole 26, enhancing the flex
`ibility of the outsole 26. In other words, the midsole grooves
`60 define slots 76 that perforate the entire thickness of the
`midsole. As shown in FIG.7, the slots 76 (the shaded portions
`of the grooves 60) can penetrate the second lateral groove 64
`and the longitudinal grooves 66 at selective locations along
`the length of the longitudinal grooves 66. As shown in FIG. 8,
`the slots 76 can penetrate the first and second lateral grooves
`62, 64, the outermost longitudinal grooves 66, and the inner
`most longitudinal grooves 66 at Selective locations along their
`length. An optional third lateral groove 78 extends forward of
`the second lateral groove 64. Individual connectors 80 join
`adjacent anatomical pods 68 that would otherwise be discon
`nected from the remainder of the midsole 24. The outsole 26
`is generally viewable through the slots 76 (around the con
`nectors 80) in these embodiments, optionally extending
`upwardly into the slots 76. The connectors 80 can be severed
`or removed during the manufacture of the article of footwear,
`for example after joining the outsole 26 to the midsole 24. The
`connectors 80 can also be suspended above the outsole 26.
`That is, the midsole grooves 60 can define a relief in the upper
`Surface of the midsole 24 and can define a matching relief in
`the lower surface of the midsole 24. For example, the midsole
`24 can have a thickness of 8 mm, an upper midsole groove
`
`having a 3 mm depth, and a lower midsole groove having a 3
`mm depth, leaving a connector 80 having a thickness of 2 mm
`(in the vertical dimension) that is suspended above the outsole
`26. Different configurations can be utilized in other embodi
`ments where desired.
`0044) The midsole 24 can include essentially any material
`suitable for providing foot support. For example, the midsole
`24 can include ethylene-vinyl acetate, polyurethane, or ther
`moplastic elastomer. The midsole 24 can be compression
`molded in some embodiments, while in other embodiments
`the midsole 24 can be injection molded. Other manufacturing
`techniques can be used in other embodiments as desired. The
`midsole 24 can additionally include a protective film 82 (also
`referred to as a protective plate 82) that extends over the upper
`surface 52, the lower surface 50, or both the upper surface 52
`and the lower surface 50 of the midsole 24. As shown in FIG.
`9, for example, a 1 mm protective film 82 extends over the
`lower surface 50 of the forefoot region 28 of the midsole 24.
`As shown in FIG. 10, the protective film 82 extends over
`substantially the entire lower surface 50 of the midsole 24.
`The protective film 52 optionally includes ethylene-vinyl
`acetate plastic, thermoplastic polyurethane, or PebaXR (poly
`ether block amide, available from Arkema), which can pro
`vide enhanced strength to the midsole 24 without degrading
`the flexibility of the midsole 24. The midsole 24 can addition
`ally be formed of two or more materials having different
`material properties. For example, the midsole 24 can include
`a first material in a first one of the anatomical plurality pods
`68 and a second material in a second one of the plurality of
`anatomical pods 68. Further by example, the midsole 24 can
`include a first material in the forefoot region and a second
`material in the rearfoot or mid-foot region.
`0045 An outsole 26 in accordance with one embodiment
`is illustrated in FIG. 12. The outsole 26 includes a lower
`surface 84, an upper surface 86, and a sidewall 88 extending
`therebetween. The lower surface 84 additionally includes one
`or more tread elements 90 (shown in FIG. 12 as 92,94, and
`96). The tread elements 90 optionally include a two-dimen
`sional shape that corresponds to one or more anatomical
`features of the human foot. For example, the tread elements
`90 can include a two-dimensional shape (in plan view) that
`corresponds to the following anatomical features: the phalan
`ges, the metatarsal bones, the tarsal bones, the arch, and/or the
`calcaneus (heel) bone. As optionally shown in FIGS. 12 and
`16, the tread elements 90 include a first row of five tread
`elements 92 b