Sole structures and articles of footwear having separate outsole and midsole components

Abstract

Articles of footwear in accordance with some aspects of this technology include a simple construction with each component made from a single material and fit together in a releasable manner. The invention enhances the recyclability and sustainable nature of the article of footwear and shoe. At least one aspect of this technology relates to footwear structure that may include two main parts: (a) a foot support component having features of: an upper portion and a strobel structure attached to the upper portion that includes a bottom surface with a plurality of sole locking inserts; and (b) a sole structure component having features of: an outsole component and a midsole component located between the outsole component and the strobel structure, the midsole component including a plurality of sole cavities, wherein each of the plurality of sole locking inserts fit inside a corresponding each of the plurality sole cavities.

What is claimed is: 
     
         1 . A footwear structure comprising:
 a foot support component formed as a unitary, one-piece construction that includes: (i) an upper portion that defines an interior chamber, wherein the interior chamber includes a footbed portion formed by an interior surface of the upper portion, and (ii) a strobel structure attached to the upper portion that includes a top surface for supporting an entire plantar surface of a wearer's foot and a bottom surface opposite the top surface, wherein the bottom surface includes a plurality of sole locking inserts; and   a sole structure component formed as a unitary, one-piece construction that includes: (i) an outsole component that includes a ground-contacting surface for directly engaging the ground, and (ii) a midsole component located between the outsole component and the strobel structure, the midsole component including a midsole surface including a plurality of sole cavities, wherein each of the plurality of sole cavities includes a recess extending into an interior of the sole cavity and defines an undercut within the interior of each of the plurality of sole cavities,   wherein each of the plurality of sole locking inserts extends into a respective one of the plurality of recesses, wherein each of the plurality of sole locking inserts includes an enlarged free end positioned to engage a respective undercut and secure each of the plurality of sole locking inserts within a respective one of the plurality of recesses.   
     
     
         2 . The footwear structure according to  claim 1 , wherein the foot support component includes an integrally formed heel counter. 
     
     
         3 . The footwear structure according to  claim 1 , wherein the upper portion includes lace-engaging openings and the overall footwear structure further including a lace extending thru the lace-engaging openings. 
     
     
         4 . The footwear structure according to  claim 1 , wherein each of the sole locking inserts includes one or more slits. 
     
     
         5 . The footwear structure according to  claim 1 , wherein each of the plurality of free ends includes two enlarged sole locking insert components. 
     
     
         6 . The footwear structure according to  claim 1 , wherein each of the plurality of free ends includes three enlarged sole locking insert components. 
     
     
         7 . The footwear structure according to  claim 1 , wherein each of the plurality of free ends includes four enlarged sole locking insert components. 
     
     
         8 . The footwear structure according to  claim 1 , wherein the sole locking inserts engaging their corresponding sole cavities form the only means of fastening the shoe component parts together. 
     
     
         9 . The footwear structure according to  claim 1 , wherein an interior surface of each of the plurality of recesses defines a volume of 1,500 mm 3  or less. 
     
     
         10 . The footwear structure according to  claim 1 , wherein an interior surface of each of the plurality of recesses defines a volume between 100 mm 3  to 1,500 mm 3 . 
     
     
         11 . The footwear structure according to  claim 1 , wherein an interior surface of each of the plurality of recesses defines a volume between 300 mm 3  and 1,200 mm 3 . 
     
     
         12 . The footwear structure according to  claim 1 , wherein an interior surface of each of the plurality of recesses defines a volume between 500 mm 3  and 900 mm 3 . 
     
     
         13 . The footwear structure according to  claim 1 , wherein a volume ratio of an interior surface of each of the plurality of recesses to an outer surface of each of the plurality of sole locking inserts is within the range of 0.75 to 1.0. 
     
     
         14 . The footwear structure according to  claim 13 , wherein the volume ratio is within the range of 0.75 to 0.99. 
     
     
         15 . The footwear structure according to  claim 14 , wherein the volume ratio is within the range of 0.8 to 0.95.