CN114080168A

CN114080168A - Footwear sole structure and upper with an insert plate

Info

Publication number: CN114080168A
Application number: CN202080049510.1A
Authority: CN
Inventors: 亚历克斯·巴迪尼
Original assignee: Nike Innovate CV USA
Current assignee: Nike Innovate CV USA
Priority date: 2019-09-20
Filing date: 2020-09-18
Publication date: 2022-02-22
Anticipated expiration: 2040-09-18
Also published as: US20210085021A1; CN114080168B; WO2021055724A1; EP4030953A1

Abstract

An article of footwear includes an upper including a first upper portion defining an ankle opening. An article of footwear includes a footwear plate comprising a composite material. The footwear plate includes a covered plate portion and an exposed plate portion coupled to the exposed plate portion. The article of footwear also includes a sole structure that includes a second upper portion. The second upper portion is an extension of the first upper portion and extends partially around the footwear plate. The second upper portion defines a ground-facing surface and an interior upper surface opposite the ground-facing surface. The second upper portion defines a sole opening extending through the interior upper surface and the ground-facing surface. The second upper portion covers the covered plate portion, and the exposed plate portion is aligned with the sole opening to expose the exposed plate portion.

Description

Footwear sole structure and upper with an insert plate

Cross Reference to Related Applications

This application claims priority and benefit from U.S. provisional patent application No. 62/903,007 filed on 2019, month 9, and day 20.

Technical Field

The present teachings relate generally to a sole structure for an article of footwear, and more particularly, to a footwear sole structure with an embedded plate (embedded plate).

Background

This section provides background information related to the present disclosure that is not necessarily prior art.

An article of footwear includes an upper and a sole structure. The upper may be formed from any suitable material that receives, secures, and supports the foot on the sole structure. The upper may cooperate with laces, straps, or other fasteners to adjust the fit of the upper around the foot. A bottom portion of the upper, proximate a bottom surface of the foot, is attached to the sole structure.

The sole structure includes a layered arrangement extending between the ground surface and the upper. One layer of the sole structure includes an outsole that provides both wear-resistance and traction with the ground surface. The outsole may be formed of rubber or other material that imparts durability and wear-resistance, as well as enhanced traction with the ground surface. Another layer of the sole structure includes a midsole that is disposed between the outsole and the upper. The midsole provides cushioning for the foot and is at least partially formed from a polymer foam material that resiliently compresses under an applied load to cushion the foot by attenuating ground reaction forces. The midsole may define a bottom surface on a side opposite the outsole and a footbed (foot) on an opposite side that may be contoured to conform to a contour of the bottom surface of the foot. The sole structure may also include an enhanced-comfort insole or sockliner located within the cavity adjacent a bottom portion of the upper.

It is known that during running movements, the Metatarsophalangeal (MTP) joint of the foot absorbs energy when it bends by dorsiflexion. Since the foot does not move by plantarflexion until it steps off the ground surface, the MTP joint returns little of its absorbed energy to the running motion and is therefore the source of energy expenditure during the running motion. Embedding a flat and rigid plate having longitudinal stiffness (stiffness) within the sole structure increases the overall stiffness of the sole structure.

Brief Description of Drawings

Fig. 1 is a schematic illustration of a lateral side view of an article of footwear.

Fig. 2 is a schematic illustration of a rear view of the article of footwear shown in fig. 1.

Fig. 3 is a schematic illustration of a medial side view of the article of footwear of fig. 1.

Fig. 4 is a schematic illustration of a front view of an article of footwear.

Fig. 5 is a schematic illustration of a bottom view of an article of footwear.

FIG. 6 is a schematic illustration of a cross-sectional view of the article of footwear taken along section line 6-6 of FIG. 3.

Fig. 7 is a flow chart of a method for manufacturing an article of footwear.

Fig. 8 is a schematic illustration of a strobel board placed on a last (last).

Fig. 9 is a schematic illustration of an upper placed on a last when the strobel board is on the last.

Fig. 10 is a schematic illustration of a footwear plate (foodwear plate) inserted through a sole opening of an upper.

Fig. 11 is a schematic illustration of a cross-sectional view of an article of footwear according to aspects of the present disclosure, with a midsole disposed on top of a footwear plate.

Fig. 12 is a schematic illustration of a cross-sectional view of an article of footwear according to aspects of the present disclosure, wherein a midsole is disposed beneath a footwear plate.

Description of the invention

The present disclosure describes an article of footwear that may be used for soccer (or soccerone), known in the united states as soccer. In some aspects of the present disclosure, an article of footwear includes an upper including a first upper portion. The first upper portion defines an ankle opening. An article of footwear includes a footwear plate comprising a composite material. The footwear plate includes a covered plate portion and an exposed plate portion coupled to the exposed plate portion. An article of footwear includes a sole structure that includes a second upper portion. The second upper portion is an extension of the first upper portion. The second upper portion extends partially around the footwear plate. The second upper portion defines a ground-facing surface and an interior upper surface opposite the ground-facing surface. The second upper portion defines a sole opening extending through the interior upper surface and the ground-facing surface. The covered plate portion is disposed on an interior upper surface of the second upper portion. In this way, the second upper portion covers the covered plate portion. The exposed plate portion is aligned with the sole opening to expose the exposed plate portion.

The first upper portion is integrally joined to the second upper portion to form a one-piece structure. The footwear plate may be oriented along the longitudinal axis. The second upper portion defines a first edge and a second edge. The first edge may be coupled to the second edge along the longitudinal axis. The sole structure includes a cleat structure (clear structure) that is directly coupled to the second upper portion.

The covered plate portion may be in direct contact with the interior upper surface of the second upper portion. The first upper portion may be directly coupled to the second upper portion. The sole structure has a heel region, a forefoot region, and a midfoot region between the forefoot region and the heel region. The cleat structures may be referred to as forward cleat structures disposed at a forefoot region. The article of footwear may also include a rear cleat structure. The rear cleat structure is disposed at the heel region.

The front stud structure defines a body opening. The body opening is aligned with the exposed plate portion to expose the footwear plate at the forefoot region. The front cleat structure may be directly coupled to the ground-facing surface of the second upper portion at the forefoot region. The rear cleat structure may be directly coupled to the ground-facing surface of the second upper portion at the heel region.

Each of the front cleat structures and the rear cleat structures may include a primary outsole body and a plurality of traction elements directly coupled to the primary outsole body. Each of the first upper portion and the second upper portion includes an upper material. The primary outsole body and the plurality of traction elements include an outsole material, and the outsole material is more rigid than the upper material to enhance traction.

The footwear plate may be oriented along the longitudinal axis. The second upper portion defines a first edge and a second edge. The first edge may be coupled to the second edge along the longitudinal axis.

The sole structure includes a heel region, a forefoot region, and a midfoot region between the forefoot region and the heel region. The sole structure includes a forward stud structure directly coupled to the second upper portion, the article of footwear further includes a rear stud structure directly coupled to the second upper portion, and the forward stud structure is disposed at a forefoot region, the rear stud structure is disposed at a heel region, each of the forward stud structure and the rear stud structure includes a primary outsole body and a plurality of traction elements directly coupled to the primary outsole body, the footwear plate includes a carbon fiber reinforced polymer, each of the first upper portion and the second upper portion includes an upper material, the primary outsole body and the plurality of traction elements include an outsole material, and the outsole material is more rigid than the upper material to enhance traction, and the carbon fiber reinforced polymer is more rigid than the upper material and the outsole material to enhance stability of the sole structure. The upper material may be textile (textile) and the outsole material may be rubber.

The sole structure includes a heel region, a forefoot region, and a midfoot region between the forefoot region and the heel region. The footwear plate may extend through a heel region, a midfoot region, and a forefoot region of the sole structure to enhance stability of the article of footwear.

The footwear plate may be oriented along the longitudinal axis. The second upper portion defines a first edge and a second edge. The first edge may be stitched to the second edge from a heel region to a midfoot region of the sole structure.

The sole structure may include a front cleat structure coupled to the second upper portion. The article of footwear also includes a rear cleat structure coupled to the second upper portion. The front stud structure may be disposed at the forefoot region. The rear cleat structure may be disposed at the heel region. The front cleat structure may define a first body opening and a second body opening, each sized to expose the footwear plate at the forefoot region. The front cleat structure may include an outsole web (outsole web) separating the first body opening from the second body opening.

The sole structure includes a heel region, a forefoot region, and a midfoot region between the forefoot region and the heel region. The sole structure may also include a strobel board disposed on the footwear board at the forefoot region.

The footwear panel defines an interior panel surface and a ground-engaging panel surface opposite the interior panel surface. The strobel board may be in direct contact with the interior board surface of the footwear board. The strobel board may be separately disposed at a forefoot region of the sole structure.

The present disclosure also describes a method of manufacturing the above-described article of footwear. The method may include placing the upper on a last. The upper has a first upper portion and a second upper portion extending from the first upper portion. The first upper portion defines an ankle opening. The second upper partially defines a sole structure of the article of footwear. The sole structure has a forefoot region, a heel region, and a midfoot region between the forefoot region and the heel region, and the second upper portion defines a sole opening. The method also includes inserting the footwear plate between the last and the upper at the heel region and continuing to move the footwear plate toward the sole opening until a portion is inserted through the sole opening at the forefoot region. The sole structure may also include a midsole disposed below or on top of the footwear plate.

The method may also include placing the strobel board on a last prior to placing the upper on the last. In addition, the method may include coupling the strobel board to the upper prior to inserting the footwear board between the last and the upper at the heel region. Further, the method may include coupling the cleat structure to the second upper portion. The upper may be made entirely of textile, and the footwear plate may be made entirely of carbon fiber reinforced polymer. The stud structure may be made of a more rigid polymer material than the textile.

The above features and advantages and other features and advantages of the present teachings are readily apparent from the following detailed description of the modes for carrying out the present teachings when taken in connection with the accompanying drawings.

Example configurations will now be described more fully with reference to the accompanying drawings. Example configurations are provided so that this disclosure will be thorough, and will fully convey the scope of the disclosure to those skilled in the art. Specific details are set forth such as examples of specific components, devices, and methods in order to provide a thorough understanding of the configurations of the present disclosure. It will be apparent to one of ordinary skill in the art that specific details need not be employed, that example configurations may be embodied in many different forms, and that specific details and example configurations should not be construed as limiting the scope of the disclosure.

The terminology used herein is for the purpose of describing particular example configurations only and is not intended to be limiting. As used herein, the singular articles "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms "comprises," "comprising," "including," and "having" are inclusive and therefore specify the presence of stated features, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. Additional or alternative steps may be employed.

When an element or layer is referred to as being "on," "engaged to," "connected to," "attached to" or "coupled to" another element or layer, it may be directly on, engaged, connected, attached or coupled to the other element or layer or intervening elements or layers may be present. In contrast, when an element is referred to as being "directly on," "directly engaged to," "directly connected to," "directly attached to" or "directly coupled to" another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a similar manner (e.g., "between," "adjacent" with respect to "directly adjacent," etc.). As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed items.

The terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections. These elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as "first," "second," and other numerical terms do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, first component, first region, first layer, or first section discussed below could be termed a second element, second component, second region, second layer, or second section without departing from the teachings of the example configurations.

Referring to fig. 1-6, article of footwear 10 includes an upper 100 and a sole structure 200, sole structure 200 being formed in part from upper 100. Article of footwear 10 (and components thereof, such as upper 100 and sole structure 200) may be divided into one or more portions. These portions may include a forefoot portion 12, a midfoot portion 14, and a heel portion 16. During use of footwear 10, forefoot portion 12 may correspond with the toes and the joints connecting the metatarsals with the phalanges of the foot. Forefoot portion 12 may correspond with a Metatarsophalangeal (MTP) joint of the foot. During use of the article of footwear 10, midfoot portion 14 may correspond with an arch area of the foot, and heel portion 16 may correspond with a rear portion of the foot including the calcaneus bone. Footwear 10 may include a lateral side 18 and a medial side 20, respectively, with lateral side 18 and medial side 20 corresponding with opposite sides of footwear 10 and extending through

portions

12, 14, and 16.

Upper 100 includes an interior surface that defines an interior void 102, and during use of article of footwear 10, interior void 102 receives and secures the foot for support on sole structure 200. An ankle opening 104 in heel portion 16 may provide access to interior cavity 102. For example, the ankle opening 104 may receive the foot to secure the foot within the interior void 102 and facilitate entry of the foot into the interior void 102 and removal of the foot from the interior void 102. In some examples, one or more fasteners 106 extend along upper 100 to adjust the fit of interior void 102 around the foot while accommodating entry and removal of the foot from interior void 102. Upper 100 may include apertures, such as eyelet members and/or other engagement features, such as loops of fabric or mesh (fabric) that receive fasteners 106. The fasteners 106 may include laces, straps, cords, staples, or any other suitable type of fastener. Upper 100 may also include a heel cup (heel cup)115 at heel portion 16 to support the heel of a footwear user.

Upper 100 may include a tongue portion 110 (fig. 4) that extends between interior void 102 and fastener 106. Upper 100 may be formed from one or more materials (i.e., an upper material) that are stitched or adhesively bonded together to form interior void 102. Suitable materials for the upper may include, but are not limited to, textiles, fabrics, foam, leather, and synthetic leather. The materials may be selected and positioned to impart properties of durability, breathability, abrasion resistance, flexibility, and comfort.

In some embodiments, sole structure 200 may include

cleat structures

210a, 210b and a strobel board 220 (fig. 6) disposed at forefoot region 12. The strobel board 220 is optional and may include a cushioning component. Sole structure 200 is oriented along a longitudinal axis L that extends longitudinally between a forward extremity of forefoot portion 12 and a rearward extremity of heel portion 16.

In some embodiments,

outsole members

210a, 210b may define cleat structures operable to intrude into a ground surface, thereby providing increased ground traction for the wearer/article of footwear 10. As such, outsole member 210a may be referred to as a first outsole member or forefoot outsole member, or as a front cleat structure 210 a. Likewise, another outsole member 210b may be referred to as a second outsole member or heel outsole member 210b, or as a rear cleat structure 210 b.

Each of the

cleat structures

210a, 210b includes a lower surface/ground engaging surface 212 and an opposing upper surface/inner surface 214. The

cleat structures

210a, 210b generally provide wear resistance and traction with the ground surface during use of the article of footwear 10. The

cleat structures

210a, 210b may be formed from one or more materials that impart durability and wear resistance, as well as enhanced traction with the ground surface. For example, the

cleat structures

210a, 210b may be formed from a polymeric material that includes at least one of rubber, polyurethane, ionomer, and/or engineering plastic. In a particular embodiment, at least a portion of the

cleat structures

210a, 210b may include rubber.

Each of

cleat structures

210a and 210b includes a primary outsole body 211 and one or more traction elements 215, such as spikes (spikes) or cleats (clean). In some examples, the forward stud structure 210a is disposed entirely at the forefoot portion 12 and the rear stud structure 210b is disposed entirely at the heel portion 16 to enhance engagement with the ground surface during running activities.

In some examples, one or more traction elements 215 (e.g., cleats or studs) extend directly from primary outsole body 211 in a direction away from upper 100 to provide traction with soft ground surfaces, such as turf, and enhance the structural integrity of

outsole members

210a, 210 b. For example, in some embodiments, each traction element 215 may be attached to primary outsole body 211 of

cleat structures

210a, 210b and extend in a direction substantially perpendicular to longitudinal axis L of sole structure 200. In the example shown, traction elements 215 include cleats extending from primary outsole body 211 at forefoot portion 12 and heel portion 16.

The strobel board 220 can include a bottom surface/ground-facing surface 222 and an opposing upper surface/footbed surface 224. Strobel board 220 may be secured to upper 100 at least in part by using stitching and/or adhesives that attach strobel board 220 to upper 100. In some embodiments, at least a portion of the upper (e.g., the textile in continuous relationship with the sidewall of the upper) may extend around the strobel board 220 such that it is located between the strobel board 220 and at least one of the first cleat structure 210a or the rear cleat structure 210 b.

In one embodiment, article of footwear 100 also includes a footwear plate 300. Footwear plate 300 may be directly attached to upper 100 and may be in direct contact with strobel plate 220. Footwear plate 300 may be partially or entirely made of a composite material, such as a carbon fiber composite material, to enhance the stiffness of article of footwear 10. For this reason, footwear panel 300 may be referred to as a composite panel. As used herein, the term "composite material" means a material made of two or more constituent materials having significantly different physical or chemical properties that, when combined, result in a material having different characteristics than the individual components, while the individual components remain separate and independent in the finished structure, thereby distinguishing the composite material from mixtures and solid solutions. Footwear plate 300 may be made, in whole or in part, of a carbon fiber reinforced polymer that is more rigid than the upper material forming upper 100, and further more rigid than the outsole material forming

outsole members

210a, 210b to enhance the stability of sole structure 200. Footwear plate 300 is part of sole structure 200 to reduce energy loss at the MTP joint during running activities, while enhancing rolling of the foot as footwear 10 rolls for engagement with a ground surface. Footwear plate 300 may define a length that extends through at least a portion of the length of sole structure 200. In some examples, a length of plate 300 extends through forefoot portion 12, midfoot portion 14, and heel portion 16 of sole structure 200 to enhance the structural integrity of sole structure 200. The footwear plate 300 is oriented along a longitudinal axis L that extends longitudinally between a forward extremity of the forefoot portion 12 and a rearward extremity of the heel portion 16. In other examples, the length of plate 300 extends through forefoot portion 12 and midfoot portion 14, and is not present in heel portion 16. Footwear plate 300 functions as an insole and chassis (chassis).

The length of footwear plate 300 may be oriented along longitudinal axis L between first end 301 (fig. 5) and second end 302 (fig. 5) of footwear plate 300. First end 301 may be disposed proximate heel portion 16 of sole structure 200 and second end 302 may be disposed proximate forefoot portion 12 of sole structure 200. First end 301 may also be referred to as the "rearmost point" of footwear plate 300, while second end 302 may also be referred to as the "foremost point" of footwear plate 300. Footwear plate 300 may have a thickness extending substantially perpendicular to longitudinal axis L of sole structure 200 and a width extending between lateral side 18 and medial side 20.

The strobel board 220 may be disposed on the footwear board 300 at the forefoot region 12 of the sole structure 200 for providing cushioning when the exposed plate portion 310 directly contacts the ground during a running motion. In this manner, the strobel board 220 is in direct contact with the exposed plate portion 310 of the footwear board 300. Specifically, the strobel board 220 may be in direct contact with the inner board surface 304 and may be disposed only at the forefoot region 12 of the sole structure 200 for providing cushioning when the exposed board portion 310 directly contacts the ground during running activities.

Upper 100 includes a first or upper portion 112 and a second or lower upper portion 114, with second or lower upper portion 114 extending from first upper portion 112 around at least a portion of footwear plate 300. First upper portion 112 may be what is most commonly referred to as upper 100, and is the portion that defines ankle opening 104 and interior void 102. Second upper portion 114 is an extension of first upper portion 112 and may be more appropriately considered a portion of sole structure 200 as a result of being wrapped around at least a portion of footwear plate 300. Second upper portion 114 may be integrally coupled to first upper portion 112 to form a single-piece structure. Accordingly, each of first upper portion 112 and second upper portion 114 are made, in whole or in part, of the same material (i.e., upper material). The upper material may be, for example, a textile. In this configuration, second upper portion 114 may include a ground-facing surface 116 and an opposite interior upper surface 119.

In some embodiments, each of the

cleat structures

210a, 210b may be directly coupled to the second upper portion 114. Second upper portion 114 defines a first edge 118 and a second edge 120. First edge 118 may be stitched (or otherwise attached) to second edge 120 along longitudinal axis L to maintain stability of sole structure 200 during running motions. In other words, stitches 124 may couple first edge 118 to second edge 120 along longitudinal axis L to maintain stability of sole structure 200 during a running motion. In the depicted embodiment, first edge 118 is directly coupled to second edge 120 to enhance the structural integrity of sole structure 200.

In one embodiment, at least a portion of second upper portion 114 may extend between footwear plate 300 and at least one of front cleat structure 210a or rear cleat structure 210 b. Additionally, in at least a portion of sole structure 200, footwear plate 300 may extend between second upper portion 114 and at least one of forward stud structure 210a or rearward stud structure 210 b. Such a configuration may enable footwear plate 300 to be at least partially concealed and partially exposed by wrapped second upper portion 114.

To achieve this partially concealed/partially exposed design, in one configuration, second upper portion 114 defines a sole opening 122, such as a slit, aperture, and/or gap, through which footwear plate 300 may pass. As such, a portion of the footwear plate 300 extends through the sole opening 122 to partially expose the footwear plate 300 and thereby allow the footwear plate 300 to directly contact the ground during a running motion. By allowing footwear plate 300 to directly contact the ground during a running motion, rolling of the foot is enhanced as footwear 10 rolls during the running motion for engagement with the ground surface. Sole opening 122 is disposed mostly or entirely at forefoot portion 12 of sole structure 200 to enhance rolling of the foot when footwear 10 rolls for engagement with a ground surface during running activities. The outsole member 210a also defines one or more body openings 213 extending through the primary outsole body 211 to expose the footwear plate 300, thereby allowing the footwear plate 300 to directly contact the ground during running activities. As discussed above, it is desirable to expose the footwear plate 300 to allow the footwear plate 300 to directly contact the ground surface during running activities. The outsole member 210a may include an outsole web 217 that traverses the body opening 213 to enhance traction at the forefoot portion 12 of the sole structure 200. In the depicted embodiment, outsole member 210a defines two body openings 213 separated by outsole web 217. The two body openings 213 allow the footwear plate 300 to be exposed. One or more traction elements 215 extend directly from outsole web 217 to enhance traction at forefoot portion 12 of sole structure 200. As discussed above, sole structure 200 is defined by second upper portion 114 of upper 100, footwear plate 300, and

outsole members

210a, 210 b. Stitches 124 may extend only from heel region 16 to midfoot region 14 to allow footwear plate 300 to be exposed, thereby allowing footwear plate 300 to directly contact the ground during running activities. Footwear plate 300 defines an inner plate surface 304 and a ground-engaging plate surface 306 opposite inner plate surface 304.

Footwear plate 300 includes a covered plate portion 308 and an exposed plate portion 310 coupled to covered plate portion 308. Covered plate portion 308 may be directly coupled to exposed plate portion 310 to enhance the structural integrity of footwear plate 300. A covered plate portion 308 is disposed on the interior upper surface 119 of the second upper portion 114. In this manner, second upper portion 114 covers covered plate portion 308. The covered plate portion 308 may be in direct contact with the interior upper surface 119 of the second upper portion 114 to enhance the structural integrity of the sole structure 200. The exposed plate portion 310 is aligned with the sole opening 122 to expose the exposed plate portion 310. One or more of the body openings 213 are aligned with the exposed plate portion 310 to expose the footwear plate 300 at forefoot region 12.

As discussed above, upper 100 may be made, in whole or in part, from one or more materials (i.e., upper materials) stitched or adhesively bonded together to form interior void 102. Suitable materials for the upper may include, but are not limited to, textiles, foam, leather, and synthetic leather. The materials may be selected and positioned to impart properties of durability, breathability, abrasion resistance, flexibility, and comfort. However,

outsole members

210a, 210b are made, in whole or in part, of one or more materials (i.e., outsole materials) that are more rigid than the material forming the upper (i.e., upper material) to enhance traction.

Fig. 7 is a flow chart of a method of manufacturing article of footwear 10. Method 400 begins at block 402, which entails placing strobel board 220 on last 500, as shown in fig. 8. The last 500 is shaped as a human foot, and the strobel board 220 is placed at the forefoot last region 502 of the last 500. The method 400 then proceeds to block 404. At block 404, upper 100 is placed on last 500. When upper 110 is placed on last 500, forefoot last area 502 is inserted through sole opening 122, thereby exposing strobel board 220, as shown in fig. 9. Next, the method 400 proceeds to block 406. Block 406 entails coupling (e.g., stitching) upper 100 to strobel board 220 while upper 100 and strobel board 220 remain on last 500. The method 400 then continues to block 408. Block 408 entails inserting the footwear plate 300 between the last 500 and the upper 100 at the heel region 16 of the upper 100, and then continuing to move the footwear plate 300 toward the sole opening 122 until a portion of the footwear plate 300 (i.e., the exposed plate portion 310) is inserted through the sole opening 122 at the forefoot region 12 of the upper 100, as shown in fig. 10. The method 400 then proceeds to block 410. At block 410, one or more 210a, 210b (e.g., stud structures) are coupled to upper 100. Specifically, one or more 210a, 210b (e.g., cleat structures) are coupled to second upper portion 114. The front cleat structure 210a may be coupled to the footwear plate 300 and the second upper portion 114 to secure the footwear plate 300 to the second upper portion 114.

Referring to fig. 11, sole structure 200 of article of footwear 10 may additionally include a midsole 202 for providing cushioning to a footwear user. To this end, the midsole 202 may be made of a polymer material (such as rubber or foam). Midsole 202 may be disposed on top of footwear plate 300 to enhance the comfort of the footwear wearer. A sockliner may also be provided on top of the midsole 202 to provide comfort. Midsole 202 may extend continuously along forefoot portion 12, midfoot portion 14, and heel portion 16 to provide cushioning to the entire foot of a footwear wearer.

Referring to fig. 12, a midsole 202 may be disposed below the footwear plate 300 for providing cushioning as a footwear user performs activities on a hard surface (such as running, baseball, tennis, etc.). To this end, the midsole 202 may be made of a polymer material (such as rubber or foam). Midsole 202 may extend continuously along forefoot portion 12, midfoot portion 14, and heel portion 16 to provide cushioning to the entire foot of a footwear wearer.

In another embodiment, a method for manufacturing an article of footwear may begin by lasting (last) one or more layers of textile around a foot-shaped fixture to substantially form an upper portion of a shoe. In this embodiment, the first edge 118 and the second edge 120 may then be joined while the textile is still on the fixture. Subsequently, footwear plate 300 may be inserted through the opening in the textile such that a portion of footwear plate 300 is inside the textile (and/or hidden from view from outside the textile), and a portion of footwear plate 300 is exposed and visible from outside the textile. In one configuration, the heel portion of the footwear plate 300 is inserted through the slit/opening and is hidden from external view. After insertion, the footwear plate may be bonded to at least a portion of the textile to form a portion of the sole structure. Finally, the cleat structure may be bonded to an outer surface of the sole structure (i.e., textile and/or footwear plate 300).

To facilitate and clarify the description of the various embodiments, various terms are defined herein. The following definitions apply throughout this specification (including the claims) unless otherwise indicated. Furthermore, all references mentioned are incorporated herein in their entirety.

"articles of footwear," "articles of footwear," and "footwear" may be considered both machines (machines) and articles of manufacture. Assembled ready-to-wear articles of footwear (e.g., shoes, sandals, boots, etc.) and discrete components of the articles of footwear (e.g., midsoles, outsoles, upper components, etc.) are considered in the singular or plural and may alternatively be referred to as "articles of footwear" or "footwear" prior to final assembly into a ready-to-wear article of footwear.

"a", "an", "the", "at least one" and "one or more" may be used interchangeably to indicate that there is at least one of the items. There may be a plurality of such items unless the context clearly indicates otherwise. Unless otherwise expressly or clearly indicated by the context, all numbers expressing quantities or conditions of parameters (e.g., amounts or conditions) used in this specification, including the appended claims, are to be understood as being modified in all instances by the term "about" whether or not "about" actually appears before the number. "about" indicates that the numerical value allows some slight imprecision (with some approach to exactness in the value; about or reasonably close to the value; nearly). If the imprecision provided by "about" is not otherwise understood in the art with this ordinary meaning, then "about" as used herein indicates at least variations that may result from ordinary methods of measuring and using the parameters. As used in the specification and the appended claims, unless otherwise indicated, a value is considered "approximate" to be equal to the recited value if it is no more than 5% of the recited value and no less than 5% of the recited value. Additionally, disclosure of ranges should be understood to specifically disclose all values within the range and further divided ranges.

The terms "comprising", "including" and "having" are inclusive and therefore specify the presence of stated features, steps, operations, elements, or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, or components. The order of the steps, processes, and operations may be altered when possible and additional or alternative steps may be employed. As used in this specification, the term "or" includes any and all combinations of the associated listed items. The term "any" is understood to include any possible combination of the referenced items, including "any one of the referenced items. The term "any" is understood to include any possible combination of the recited claims of the appended claims, including "any one of the recited claims.

Directional adjectives may be employed throughout this detailed description corresponding to the illustrated embodiments for consistency and convenience. Those of ordinary skill in the art will recognize that terms such as "above," "below," "upward," "downward," "top," "bottom," and the like can be used descriptively with respect to the figures, and do not represent limitations on the scope of the invention, as defined by the claims.

The term "longitudinal" refers to a direction extending along the length of a component. For example, a longitudinal direction of the article of footwear extends between a forefoot region and a heel region of the article of footwear. The terms "forward" or "forward" are used to refer to a general direction from the heel region toward the forefoot region, and the terms "rearward" or "rearward" are used to refer to the opposite direction, i.e., from the forefoot region toward the heel region. In some cases, a component may be identified with a longitudinal axis and forward and rearward longitudinal directions along the axis. The longitudinal direction or longitudinal axis may also be referred to as an anterior-posterior direction or an anterior-posterior axis.

The term "transverse" refers to a direction extending along the width of the component. For example, a lateral direction of the article of footwear extends between a lateral side and a medial side of the article of footwear. The lateral direction or axis may also be referred to as a lateral direction or axis or a medial direction or axis.

The term "vertical" refers to a direction that is generally perpendicular to both the lateral and longitudinal directions. For example, where the sole structure is flat resting on a ground surface, the vertical direction may extend upward from the ground surface. It will be understood that each of these directional adjectives may be applied to a separate component of the sole structure. The terms "upward" or "upwardly" refer to a vertical direction pointing toward the top of a component that may include the instep, fastening area, and/or throat of an upper. The terms "downward" or "downward" refer to a vertical direction opposite the upward direction, pointing toward the bottom of the component and may generally point toward the bottom of the sole structure of the article of footwear.

The "interior" of an article of footwear (such as a shoe) refers to the portion of the space occupied by the wearer's foot when the article of footwear is worn. An "inner side" of a component refers to a side or surface of the component that is oriented toward (or will be oriented toward) the component or the interior of the article of footwear in the assembled article of footwear. The "outer side" or "outer" of a component refers to the side or surface of the component that is oriented away from (or will be oriented away from) the interior of the article of footwear in the assembled article of footwear. In some cases, other components may be located between the interior side of the component and the interior in the assembled article of footwear. Similarly, other components may be located between the exterior side of the component and the space outside the assembled article of footwear. Further, the terms "inwardly" and "inwardly" refer to a direction toward the interior of a component or article of footwear (e.g., a shoe), and the terms "outwardly" and "outwardly" refer to a direction toward the exterior of a component or article of footwear (e.g., a shoe). Further, the term "proximal" refers to a direction that is closer to the center of the footwear component or closer to the foot when the foot is inserted into the article of footwear when the article of footwear is worn by a user. Likewise, the term "distal" refers to a relative position that is further away from the center of the footwear component or further away from the foot when the foot is inserted into the article of footwear when the article of footwear is worn by a user. Thus, the terms proximal and distal may be understood to provide generally opposite terms to describe relative spatial locations.

While various embodiments have been described, the description is intended to be exemplary, rather than limiting and it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible that are within the scope of the embodiments. Any feature of any embodiment may be used in combination with or instead of any other feature or element in any other embodiment, unless specifically limited. Accordingly, the embodiments are not to be restricted except in light of the attached claims and their equivalents. Also, various modifications and changes may be made within the scope of the appended claims.

While several modes for carrying out many aspects of the present teachings have been described in detail, those familiar with the art to which these teachings relate will recognize various alternative aspects for practicing the present teachings that are within the scope of the appended claims. It is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and exemplary of the full scope of alternative embodiments as would be recognized by a person of ordinary skill, such alternative embodiments being implied by, structurally and/or functionally equivalent to, or otherwise evident from, the contained content and not merely being limited to those explicitly depicted and/or described.

Claims

1. An article of footwear comprising:

an upper including a first upper portion, wherein the first upper portion defines an ankle opening;

a footwear plate comprising a composite material, wherein the footwear plate comprises a covered plate portion and an exposed plate portion coupled to the exposed plate portion;

a sole structure including a second upper portion, wherein the second upper portion is an extension of the first upper portion, the second upper portion extending partially around the footwear plate, the second upper portion defining a ground-facing surface and an interior upper surface opposite the ground-facing surface, and the second upper portion defining a sole opening extending through the interior upper surface and the ground-facing surface; and is

Wherein the covered plate portion is disposed on the interior upper surface of the second upper portion such that the second upper portion covers the covered plate portion and the exposed plate portion is aligned with the sole opening to expose the exposed plate portion.

2. An article of footwear according to claim 1, wherein the first upper portion is integrally coupled to the second upper portion to form a single-piece structure, the footwear plate is oriented along a longitudinal axis, the second upper portion defines a first edge and a second edge, the first edge is coupled to the second edge along the longitudinal axis, and the sole structure includes a cleat structure that is directly coupled to the second upper portion.

3. The article of footwear according to claim 2, wherein the covered plate portion is in direct contact with the interior upper surface of the second upper portion, the first upper portion is directly coupled to the second upper portion, the sole structure has a heel region, a forefoot region, and a midfoot region between the forefoot region and the heel region, the cleat structure is a front cleat structure disposed at the forefoot region, the article of footwear further includes a rear cleat structure, and the rear cleat structure is disposed at the heel region.

4. The article of footwear according to claim 3, wherein the forward stud structure defines a body opening that is aligned with the exposed plate portion to expose the footwear plate at the forefoot region, the forward stud structure is directly coupled to the ground-facing surface of the second upper portion at the forefoot region, and the rearward stud structure is directly coupled to the ground-facing surface of the second upper portion at the heel region.

5. The article of footwear according to claim 4, wherein each of the front cleat structures and the rear cleat structures includes a primary outsole body and a plurality of traction elements directly coupled to the primary outsole body.

6. The article of footwear of claim 5, wherein each of the first upper portion and the second upper portion includes an upper material, the primary outsole body and the plurality of traction elements include an outsole material, and the outsole material is more rigid than the upper material to enhance traction.

7. The article of footwear of claim 1, further comprising a midsole disposed below the footwear plate.

8. The article of footwear according to claim 1, wherein the sole structure includes a heel region, a forefoot region, and a midfoot region between the forefoot region and the heel region, the sole structure including a front stud structure directly coupled to the second upper portion, the article of footwear further including a rear stud structure directly coupled to the second upper portion, and the front stud structure being disposed at the forefoot region, the rear stud structure being disposed at the heel region, each of the front stud structure and the rear stud structure including a primary outsole body and a plurality of traction elements directly coupled to the primary outsole body, the footwear plate including a carbon fiber reinforced polymer, each of the first upper portion and the second upper portion including an upper material, the primary outsole body and the plurality of traction elements include an outsole material, and the outsole material is more rigid than the upper material to enhance traction, and the carbon fiber reinforced polymer is more rigid than the upper material and the outsole material to enhance stability of the sole structure.

9. The article of footwear of claim 1, further comprising a midsole disposed on top of the footwear plate.

10. The article of footwear of claim 1, wherein the sole structure includes a heel region, a forefoot region, and a midfoot region between the forefoot region and the heel region, and the footwear plate extends through the heel region, the midfoot region, and the forefoot region of the sole structure to enhance stability of the article of footwear.

11. The article of footwear of claim 10, wherein the footwear plate is oriented along a longitudinal axis, the second upper portion defines a first edge and a second edge, and the first edge is stitched to the second edge from the heel region of the sole structure to the midfoot region of the sole structure.

12. The article of footwear according to claim 11, wherein the sole structure includes a front cleat structure coupled to the second upper portion, the article of footwear further including a rear cleat structure coupled to the second upper portion, the front cleat structure disposed at the forefoot region, the rear cleat structure disposed at the heel region, the front cleat structure defining a first body opening and a second body opening, the first body opening and the second body opening each sized to expose the footwear plate at the forefoot region, and the front cleat structure including an outsole web separating the first body opening from the second body opening.

13. The article of footwear of claim 1, wherein the sole structure includes a heel region, a forefoot region, and a midfoot region between the forefoot region and the heel region, the sole structure further including a strobel board disposed on the footwear board at the forefoot region.

14. The article of footwear of claim 13, wherein the footwear plate defines an inner plate surface and a ground-engaging plate surface opposite the inner plate surface, the strobel plate is in direct contact with the inner plate surface of the footwear plate, and the strobel plate is disposed only at the forefoot region of the sole structure.

15. A method for manufacturing an article of footwear, comprising:

placing an upper on a last, wherein the upper has a first upper portion and a second upper portion extending from the first upper portion, the first upper portion defining an ankle opening, the second upper portion partially defining a sole structure of the article of footwear, the sole structure having a forefoot region, a heel region, and a midfoot region between the forefoot region and the heel region, and the second upper portion defining a sole opening; and

inserting a footwear plate between the last and the upper at the heel region and continuing to move the footwear plate toward the sole opening until a portion is inserted through the sole opening at the forefoot region.

16. The method of claim 15, further comprising placing a strobel board on the last prior to placing the upper on the last.

17. The method according to claim 16, further comprising coupling the strobel board to the upper prior to inserting the footwear board between the last and the upper at the heel region.

18. The method according to claim 16, further including coupling a cleat structure to the second upper portion.

19. The method according to claim 18, wherein the upper is made entirely of textile and the footwear plate is made entirely of carbon fiber reinforced polymer.

20. The method according to claim 19, wherein the cleat structure is made of a more rigid polymer material than the textile.