Sole assembly with thermoplastic polyurethane component thereon and and method of manufacturing same

Abstract

An article of footwear has a sole assembly that includes a midsole. The midsole has a bottom with a bottom surface, and an outer wall with a side surface. At least one of a thermoplastic polyurethane outsole and a thermoplastic polyurethane toe bumper is secured to the midsole. Specifically, a thermoplastic polyurethane outsole can be secured to the bottom surface of the midsole and a thermoplastic polyurethane toe bumper can be secured to the side surface of the midsole. Moreover, at least one of a thermoplastic polyurethane outsole and a thermoplastic polyurethane toe bumper is at least partially transparent. A method of manufacturing an article of footwear includes securing such a thermoplastic polyurethane outsole and/or a thermoplastic polyurethane toe bumper to the midsole.

What is claimed is: 
     
         1 . A sole assembly for an article of footwear comprising:
 a midsole having a bottom with a bottom surface, and having an outer wall with a side surface; and   at least one of a thermoplastic polyurethane outsole secured to the bottom surface of the midsole and a thermoplastic polyurethane toe bumper secured to the side surface of the midsole; wherein said at least one of a thermoplastic polyurethane outsole and a thermoplastic polyurethane toe bumper is at least partially transparent.   
     
     
         2 . The sole assembly of  claim 1 , wherein the outsole has an inward-facing side secured to the bottom surface of the midsole and an outward-facing side establishing a ground contact surface; and wherein the outsole has a laser-etched graphic on the outward-facing side. 
     
     
         3 . The sole assembly of  claim 1 , wherein the outsole has an inward-facing side secured to the bottom surface of the midsole; and wherein the outsole has a laser-etched graphic on the inward-facing side. 
     
     
         4 . The sole assembly of  claim 1 , wherein the toe bumper has an inward-facing side secured to the side surface of the midsole and an outward-facing side; and wherein the toe bumper has a laser-etched graphic on the outward-facing side. 
     
     
         5 . The sole assembly of  claim 1 , wherein the toe bumper has an inward-facing side secured to the side surface of the midsole; and wherein the toe bumper has a laser-etched graphic on the inward-facing side. 
     
     
         6 . The sole assembly of  claim 1 , wherein said at least one of the outsole and the toe bumper has an inward-facing side and an outward-facing side; and wherein said at least one of the outsole and the toe bumper is dyed a first color on the inward-facing side and a second color on the outward-facing side. 
     
     
         7 . The sole assembly of  claim 6 , wherein said at least one of the outsole and the toe bumper has a thickness; wherein said at least one of the outsole and the toe bumper is dyed a first color extending to approximately a first portion of the thickness; and wherein said at least one of the outsole and the toe bumper is dyed a second color extending to approximately a remaining portion of the thickness. 
     
     
         8 . The sole-assembly of  claim 6 , wherein said at least one of the outsole and the toe bumper has a laser-etched graphic on the outward-facing side. 
     
     
         9 . The sole-assembly of  claim 6 , wherein said at least one of the outsole and the toe bumper has a laser-etched graphic on the inward-facing side. 
     
     
         10 . The sole-assembly of  claim 6 , further comprising:
 a polymeric film with a graphic appearing thereon; wherein the polymeric film is attached to said at least one of the outsole and the toe bumper.   
     
     
         11 . The sole assembly of  claim 10 , wherein said at least one of the outsole and the toe bumper has an inward-facing side and an outward-facing side; and
 wherein the polymeric film is attached to the inward-facing side and the graphic is visible through said at least one of the outsole and the toe bumper.   
     
     
         12 . The sole assembly of  claim 11 , wherein said at least one of the outsole and the toe bumper is dyed a first color on the inward-facing side and a second color on the outward-facing side. 
     
     
         13 . The sole assembly of  claim 1 , wherein the midsole is rubber. 
     
     
         14 . The sole assembly of  claim 13 , further comprising:
 a double-coated adhesive film attaching the toe bumper to the midsole; wherein the film has:   a carrier with a first side and a second side;   a first adhesive on the first side;   a second adhesive on the second side; wherein the first adhesive is in contact with and configured to bond to the rubber of the midsole; and wherein the second adhesive is in contact with and configured to bond to the thermoplastic polyurethane of the toe bumper.   
     
     
         15 . The sole assembly of  claim 13 , further comprising:
 a double-coated adhesive film attaching the outsole to the midsole; wherein the film has:   a carrier with a first side and a second side;   a first adhesive on the first side;   a second adhesive on the second side; wherein the first adhesive is in contact with and configured to bond to the rubber of the midsole; and wherein the second adhesive is in contact with and configured to bond to the thermoplastic polyurethane of the outsole.   
     
     
         16 . The sole assembly of  claim 1 , wherein the midsole is a color different than a color of said at least one of the outsole and the toe bumper. 
     
     
         17 . The sole assembly of  claim 1 , wherein the midsole has a first texture; and
 wherein said at least one of the outsole and the toe bumper has a second texture different than the first texture.   
     
     
         18 . The sole assembly of  claim 1 , wherein the outsole has a series of tread elements arranged to extend laterally in a zig-zag pattern. 
     
     
         19 . The sole assembly of  claim 1 , wherein the outer wall defines a periphery of the sole assembly; and wherein the outer wall and the bottom surface are substantially orthogonal. 
     
     
         20 . The sole assembly of  claim 19 , in combination with a footwear upper; and wherein the outer wall surrounds a periphery of the footwear upper. 
     
     
         21 . The sole assembly of  claim 1 , wherein the midsole is a bladder element having:
 a first polymeric sheet; wherein the outer wall is a peripheral portion of the first polymeric sheet;   a second polymeric sheet attached to the first polymeric sheet at the outer wall such that the first and second polymeric sheets define an interior cavity; and wherein the second polymeric sheet defines the bottom and the bottom surface of the midsole.   
     
     
         22 . A sole assembly for an article of footwear comprising:
 a midsole having a bottom with a bottom surface, and having an outer wall with a side surface;   a thermoplastic polyurethane outsole secured to the bottom surface;   a thermoplastic polyurethane toe bumper secured to the side surface; wherein the outsole and the toe bumper are at least partially transparent;   wherein at least one of the outsole and the toe bumper has a laser-etched graphic thereon;   wherein at least one of the outsole and the toe bumper has a thickness and is dyed a first color extending to approximately a first portion of the thickness; and   wherein said at least one of the outsole and the toe bumper is dyed a second color extending to approximately a remaining portion of the thickness.   
     
     
         23 . The sole assembly of  claim 22 , wherein the midsole is rubber; and further comprising:
 a double-coated adhesive film attaching the outsole to the midsole; wherein the film has:   a carrier with a first side and a second side;   a first adhesive on the first side;
 a second adhesive on the second side; wherein the first adhesive is in contact with and configured to bond to the rubber of the midsole; and wherein the second adhesive is in contact with and configured to bond to the thermoplastic polyurethane of the outsole. 
   
     
     
         24 . The sole assembly of  claim 22 , further comprising:
 a polymeric film with a graphic appearing thereon; wherein the polymeric film is attached to one of the outsole and the toe bumper   
     
     
         25 . A method of manufacturing an article of footwear, comprising:
 securing at least one of a toe bumper and an outsole to a midsole; wherein said at least one of the toe bumper and the outsole is thermoplastic polyurethane.   
     
     
         26 . The method of  claim 25 , wherein said securing includes:
 applying a double-coated adhesive film so that a first side of the double-coated adhesive film bonds to the midsole and a second side of the double-coated adhesive film bonds to said at least one of a toe bumper and an outsole.   
     
     
         27 . The method of  claim 25 , wherein said securing is by one of bonding and radio frequency welding. 
     
     
         28 . The method of  claim 25 , further comprising:
 laser-etching a graphic on said at least one of a toe bumper and an outsole.   
     
     
         29 . The method of  claim 25 , further comprising:
 dyeing said at least one of a toe bumper and an outsole at least one color.   
     
     
         30 . The method of  claim 29 , wherein said dyeing said at least one of a toe bumper and an outsole includes dyeing a first color on a first side of said at least one of a toe bumper and an outsole and dying a second color on a second side of said at least one of a toe bumper and an outsole. 
     
     
         31 . The method of  claim 25 , further comprising:
 attaching a polymeric film to said at least one of a toe bumper and an outsole; wherein the polymeric film has a graphic appearing thereon.   
     
     
         32 . The method of  claim 25 , further comprising:
 receiving a customer selection of a visual characteristic of said at least one of a toe bumper and an outsole;   providing an article of footwear with said at least one of a toe bumper and an outsole; wherein said at least one of a toe bumper and an outsole has said visual characteristic.   
     
     
         33 . The method of  claim 32 , wherein the visual characteristic is one of a color and a graphic.