Sole structure and shoe
A sole structure for a shoe and a method of manufacturing the sole structure with additive manufacturing is provided. A midsole structure is integrally formed with a midsole shell having an upper platform and lower platform integrally formed to define a cavity therebetween. A plurality of cushion elements is retained in the cavity. Each of the plurality of cushion elements is movable independently in the cavity. The midsole shell and the cushion elements formed together in a three-dimensional printing process.
1 . A sole structure for a shoe, comprising:
a midsole structure comprising:
a midsole shell having an upper platform and lower platform integrally formed as one piece to define a cavity therebetween; and
a plurality of cushion elements retained in the cavity, wherein each of the plurality of cushion elements is movable independently in the cavity, wherein the upper platform has a plurality of apertures that extend from the upper platform through to the cavity, wherein each of the plurality of apertures is sized smaller than each one of the plurality of cushion elements in at least one dimension so as to retain the plurality of cushion elements within the cavity and such that at least one of the plurality of cushion elements is exposed through at least one of the plurality of apertures for direct contact with a wearer's foot in a donned state by extending at least partially from inside the cavity present between the integrally formed upper platform and lower platform to at least partially outside the cavity present between the integrally formed upper platform and lower platform.
2 . The sole structure according to claim 1 , wherein the upper platform comprises an upper surface defining a footbed contoured to receive the wearer's foot.
3 . The sole structure according to claim 1 , wherein the midsole shell extends from a heel portion to a toe portion, wherein the midsole shell further comprises a medial side portion and a lateral side portion extending between the upper platform and the lower platform.
4 . The sole structure according to claim 3 , wherein the midsole shell defines the cavity as an enclosed cavity formed between the medial side portion, the lateral side portion, the upper platform, and the lower platform, wherein the plurality of cushion elements are contained in the enclosed cavity.
5 . The sole structure according to claim 1 , wherein the plurality of cushion elements comprise a first group of cushion elements having a first density and a second group of cushion elements having a second density different than the first density.
6 . The sole structure according to claim 1 , wherein the plurality of cushion elements comprise a first group of cushion elements being solid and a second group of cushion elements being hollow.
7 . The sole structure according to claim 1 , wherein the plurality of cushion elements have a generally spherical shape.
8 . The sole structure according to claim 1 , wherein the plurality of cushion elements are formed of at least two different shapes or two different sizes.
9 . The sole structure according to claim 1 , further comprising an outsole attached to the midsole structure.
10 . A sole structure for a shoe, comprising:
a midsole structure integrally formed with a 3D printing process, comprising:
a midsole shell having an upper platform and lower platform integrally formed as one piece with the 3D printing process to define a cavity therebetween; and
a cushion portion formed by the 3D printing process and retained in the cavity separate from the midsole shell,
wherein the upper platform has a plurality of apertures that extend from the upper platform through to the cavity, and
wherein each of the plurality of apertures is sized smaller than the cushion portion in at least one dimension so as to retain the cushion portion within the cavity and such that the cushion portion is exposed through at least one of the plurality of apertures for direct contact with a wearer's foot in a donned state.
11 . The sole structure according to claim 10 , further comprising an outsole integrally formed with the midsole structure by the 3D printing process.
12 . The sole structure according to claim 10 , wherein the cushion portion comprises a plurality of cushion elements comprising a first group of cushion elements having a first cushion characteristic and a second group of cushion elements having a second cushion characteristic that varies from the first cushion characteristic, wherein the first and second cushion characteristics comprise at least one of density, shape, size, hardness, and elasticity.
13 . The sole structure according to claim 12 , wherein each of the plurality of cushion elements is movable independently in the cavity.
14 . The sole structure according to claim 10 , wherein the cushion portion is exposed through at least one of the plurality of apertures for direct contact with the wearer's foot in the donned state by extending at least partially from inside the cavity present between the integrally formed upper platform and lower platform to at least partially outside the cavity present between the integrally formed upper platform and lower platform.
15 . A shoe comprising:
a shoe upper, and
a midsole structure attached to the shoe upper, the midsole structure comprising:
a midsole shell having an upper platform and lower platform integrally formed as one piece enclosing an internal cavity therebetween; and
a plurality of cushion elements retained in the cavity, wherein each of the plurality of cushion elements retained in the cavity is separate from the midsole shell, wherein the upper platform comprises a plurality of apertures that extend from the upper platform through to the cavity, wherein each of the plurality of apertures is sized smaller than each of the plurality of cushion elements in at least one dimension so as to retain the plurality of cushion elements within the cavity and such that at least one of the plurality of cushion elements is exposed through at least one of the plurality of apertures for direct contact with a wearer's foot in a donned state.
16 . The shoe according to claim 15 , further comprising an outsole attached to the midsole structure.
17 . The shoe according to claim 15 , further comprising an outsole integrally formed as the one piece with the midsole structure.
18 . The shoe according to claim 15 , wherein the plurality of cushion elements are movable independent in the cavity from the midsole shell.
19 . The shoe according to claim 15 , the cushion elements are exposed through the apertures for direct contact with the wearer's foot in the donned state by extending at least partially from inside the cavity present between the integrally formed upper platform and lower platform to at least partially outside the cavity present between the integrally formed upper platform and lower platform.
20 . The shoe according to claim 15 , wherein the plurality of cushion elements comprise a first group of cushion elements have a first cushioning characteristic and a second group of cushion elements have a second cushioning characteristic being different than the first cushioning characteristic.