CN114080168B

CN114080168B - Footwear sole structure and upper with embedded plates

Info

Publication number: CN114080168B
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: 2023-11-07
Anticipated expiration: 2040-09-18
Also published as: US20210085021A1; CN114080168A; WO2021055724A1; EP4030953A1

Abstract

An article of footwear includes an upper that includes a first upper portion that defines an ankle opening. An article of footwear includes a footwear plate that includes a composite material. The footwear panel includes a covered panel portion and an exposed panel portion coupled to the covered panel 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 panel. 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 embedded plates

Cross Reference to Related Applications

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

Technical Field

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

Background

This section provides background information related to the present disclosure, which 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 to receive, secure, and support 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 (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 materials that impart durability and wear resistance and enhance adhesion to the ground surface. The other layer of the sole structure includes a midsole 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 foot bed (foot bed) on an opposite side that may be contoured to conform to the contour of the bottom surface of the foot. The sole structure may also include a comfort-enhancing insole or sockliner that is positioned within the void proximate a bottom portion of the upper.

It is known that during running movements, the plantar-toe (MTP) joint of the foot absorbs energy as it bends by dorsiflexion. Since the foot does not move by plantarflexion until the foot steps off the ground surface, the MTP joint returns little of its absorbed energy to the running motion and is thus a source of energy expenditure during the running motion. Embedding a flat and rigid plate with a 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 site Bei Erban is on the last.

Fig. 10 is a schematic illustration of a footwear plate (bootweb 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 with a midsole disposed on top of a footwear plate according to aspects of the disclosure.

Fig. 12 is a schematic illustration of a cross-sectional view of an article of footwear, with a midsole disposed below a footwear plate, in accordance with aspects of the disclosure.

Description of the invention

The present disclosure describes an article of footwear that may be used with soccer (or known as soccer in the united states). In some aspects of the present disclosure, an article of footwear includes an upper that includes a first upper portion. The first upper portion defines an ankle opening. An article of footwear includes a footwear plate that includes a composite material. The footwear panel includes a covered panel portion and an exposed panel portion coupled to the covered panel 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 extends partially around the footwear. 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 panel portion is disposed on an interior upper surface of the second upper portion. In this way, the second vamp 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 coupled to the second upper portion to form a one-piece structure. The footwear plate may be oriented along a 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 panel portion may be in direct contact with an 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 structure may be referred to as a front cleat structure disposed at a forefoot region. The article of footwear may also include a rear cleat structure. A rear cleat structure is disposed at the heel area.

The front cleat 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 a ground-facing surface of the second upper portion at the heel region.

Each of the front and rear cleat structures may include a main outsole body and a plurality of traction elements directly coupled to the main 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 a 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 front cleat structure directly coupled to the second upper portion, the article of footwear further includes a rear cleat structure directly coupled to the second upper portion, and the front cleat structure is disposed at a forefoot region, the rear cleat structure is disposed at a heel region, each of the front cleat structure and the rear cleat structure includes a main outsole body and a plurality of traction elements directly coupled to the main 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 main 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 adhesion, 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 a 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 cleat structure may be disposed at a forefoot region. A rear cleat structure may be disposed at the heel area. The front cleat structure may define a first body opening and a second body opening, each sized to expose the footwear plate at a forefoot region. The front cleat structure may include an 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 Bei Erban disposed on the footwear sheet at the forefoot region.

The footwear panel defines an inner panel surface and a ground-engaging panel surface opposite the inner panel surface. The wicresoft Bei Erban can be in direct contact with the inner plate surface of the footwear panel. The strobel Bei Erban may be separately disposed at a forefoot region of the sole structure.

The present disclosure also describes a method of making 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 further 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 site Bei Erban on the last prior to placing the upper on the last. Further, the method may include coupling a strobel Bei Erban to the upper prior to inserting the footwear plate between the last and the upper at the heel region. Additionally, the method may include coupling the cleat structure to the second upper portion. The upper may be made entirely of textile, and the footwear panel may be made entirely of carbon fiber reinforced polymer. The cleat structures may be made of a polymeric material that is more rigid than the textile.

The above features and advantages and other features and advantages of the present teachings will be 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 the example configuration may be embodied in many different forms without the use of specific details, and that the specific details and example configuration should not be construed to limit the scope of the disclosure.

The terminology used herein is for the purpose of describing particular exemplary 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," "includes," and "including" 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. Unless specifically identified as an order of execution, the method steps, processes, and operations described herein should not be construed as necessarily requiring their execution in the particular order discussed or illustrated. 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 can 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" versus "directly between", "adjacent" versus "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 partially 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 forefoot portion 12, midfoot portion 14, and 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 the Metatarsophalangeal (MTP) joints of the foot. During use of article of footwear 10, midfoot portion 14 may correspond to an arch region of the foot and heel portion 16 may correspond to a rear portion of the foot that includes the calcaneus bone. Footwear 10 may include lateral side 18 and 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 defining interior void 102, and interior void 102 receives and secures a foot for support on sole structure 200 during use of article of footwear 10. Ankle opening 104 in heel portion 16 may provide access to interior void 102. For example, ankle opening 104 may receive a foot to secure the foot within interior void 102 and facilitate entry of the foot into interior void 102 and removal of the foot from 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 the entry of the foot into interior void 102 and the 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 (fabric or mesh loop) of fabric or mesh that receive fasteners 106. The fasteners 106 may include laces, straps, ropes, shackles, or any other suitable type of fastener. Upper 100 may also include a 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., upper materials) 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 durability, breathability, abrasion resistance, flexibility, and comfort properties.

In some embodiments, sole structure 200 may include cleat structures 210a, 210b and a laces Bei Erban 220 (fig. 6) disposed at forefoot region 12. The stoneware Bei Erban 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 end of forefoot portion 12 and a rearward end of heel portion 16.

In some embodiments, the outsole members 210a, 210b may define a spike structure that is operable to invade the ground surface to provide increased ground attachment force for the wearer/article of footwear 10. As such, the outsole member 210a may be referred to as a first outsole member or forefoot outsole member, or as a front cleat structure 210a. 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 210b.

Each of the cleat structures 210a, 210b includes a lower surface/ground engaging surface 212 and an opposite upper surface/inner surface 214. The cleat structures 210a, 210b generally provide wear resistance and adhesion to 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 enhance adhesion to the ground surface. For example, the cleat structures 210a, 210b may be formed from a polymeric material including 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 main outsole body 211 and one or more traction elements 215, such as cleats (cleats) or cleats (cleaning). In some examples, front cleat structures 210a are disposed entirely at forefoot portion 12, while rear cleat structures 210b are disposed entirely at heel portion 16 to enhance engagement with the ground surface during running motions.

In some examples, one or more traction elements 215 (e.g., cleats or cleats) extend directly from main outsole body 211 in a direction away from upper 100 to provide traction with a soft ground surface, 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 the main outsole body 211 of a cleat structure 210a, 210b and extend in a direction substantially perpendicular to the 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 may include a bottom surface/ground-facing surface 222 and an opposite upper surface/footbed surface 224. Strobel board 220 may be secured to upper 100, at least in part, through the use of stitching and/or adhesive that attaches strobel Bei Erban to upper 100. In some embodiments, at least a portion of the upper (e.g., a fabric in continuous relation to a sidewall of the upper) may extend around the site Bei Erban 220 such that it is located between the site Bei Erban and at least one of the front spike structure 210a or the rear spike 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 site Bei Erban 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 plate 300 may be referred to as a composite plate. As used herein, the term "composite" means a material made of two or more constituent materials having significantly different physical or chemical properties that, when combined, produce a material having characteristics different from the individual components that remain separate and independent in the finished structure, thereby distinguishing the composite from mixtures and solid solutions. Footwear plate 300 may be made, in whole or in part, from 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 when footwear 10 is rolled 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, the 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. Footwear plate 300 is oriented along a longitudinal axis L that extends longitudinally between a front end of forefoot portion 12 and a rear end of 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 serves as an insole and chassis (Chassis).

The length of the footwear plate 300 may be oriented along the longitudinal axis L between a first end 301 (fig. 5) and a second end 302 (fig. 5) of the 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, and 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.

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

Upper 100 includes a first upper portion or upper vamp portion 112 and a second upper portion or bottom vamp portion 114, second vamp portion or bottom vamp portion 114 extending from first vamp portion 112 around at least a portion of footwear form 300. First upper portion 112 may be the portion most commonly referred to as upper 100 and is the portion defining ankle opening 104 and interior void 102. Second upper portion 114 is an extension of first upper portion 112 and, as wrapped around at least a portion of footwear form 300, may be more appropriately considered a portion of sole structure 200. Second upper portion 114 may be integrally coupled to first upper portion 112 to form a one-piece structure. Thus, each of first upper portion 112 and second upper portion 114 are made, in whole or in part, from 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 spike structures 210a, 210b may be directly coupled to 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 the running motion. In other words, stitching 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 form 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 form 300 may extend between second upper portion 114 and at least one of front cleat structure 210a or rear cleat structure 210 b. Such a configuration may enable footwear form 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 slot, aperture, and/or gap, through which footwear plate 300 may pass. In this manner, a portion of footwear plate 300 extends through sole opening 122 to partially expose footwear plate 300 and thereby allow 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 when footwear 10 rolls during a 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 as footwear 10 rolls for engagement with the ground surface during running motions. Outsole member 210a also defines one or more body openings 213 that extend through main outsole body 211 to expose footwear plate 300, thereby allowing footwear plate 300 to directly contact the ground during running motions. 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 the running motion. Outsole member 210a may include an outsole web 217 that traverses body opening 213 to enhance adhesion at forefoot portion 12 of sole structure 200. In the depicted embodiment, outsole member 210a defines two body openings 213 separated by an outsole web 217. Two body openings 213 allow for exposure of the footwear plate 300. 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. Stitching 124 may extend only from heel region 16 to midfoot region 14 to allow exposure of footwear plate 300, thereby allowing footwear plate 300 to directly contact the ground during a running motion. The footwear plate 300 defines an inner plate surface 304 and a ground-engaging plate surface 306 opposite the inner plate surface 304.

Footwear panel 300 includes a covered panel portion 308 and an exposed panel portion 310 coupled to covered panel portion 308. The covered plate portion 308 may be directly coupled to the exposed plate portion 310 to enhance the structural integrity of the footwear plate 300. Covered panel portion 308 is disposed on an interior upper surface 119 of second upper portion 114. In this way, second upper portion 114 covers covered panel portion 308. Covered plate portion 308 may be in direct contact with interior upper surface 119 of second upper portion 114 to enhance the structural integrity of 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 body openings 213 are aligned with exposed plate portion 310 to expose 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) 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, foam, leather, and synthetic leather. The materials may be selected and positioned to impart durability, breathability, abrasion resistance, flexibility, and comfort properties. However, the 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 the stoneley Bei Erban 220 on a last 500, as shown in fig. 8. Last 500 is shaped as a human foot and span Bei Erban is placed at forefoot last region 502 of last 500. The method 400 then proceeds to block 404. At block 404, upper 100 is placed on last 500. When upper 100 is placed on last 500, forefoot last region 502 is inserted through sole opening 122, exposing laces Bei Erban 220, as shown in fig. 9. Next, the method 400 proceeds to block 406. Frame 406 entails coupling (e.g., stitching) upper 100 to strobel board 220 while upper 100 and strobel Bei Erban remain on last 500. The method 400 then continues to block 408. Frame 408 entails inserting footwear plate 300 between last 500 and upper 100 at heel region 16 of upper 100, and then continuing to move footwear plate 300 toward sole opening 122 until a portion of footwear plate 300 (i.e., exposed plate portion 310) is inserted through sole opening 122 at forefoot region 12 of upper 100, as shown in fig. 10. The method 400 then proceeds to block 410. At block 410, one or more outsole members 210a, 210b (e.g., cleat structures) are coupled to upper 100. Specifically, one or more outsole members 210a, 210b (e.g., cleat structures) are coupled to second upper portion 114. Front cleat structure 210a may be coupled to footwear form 300 and second upper portion 114 to secure footwear form 300 to second upper portion 114.

Referring to FIG. 11, sole structure 200 of article of footwear 10 may additionally include a midsole 202 for providing a cushion to the footwear user. To this end, 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 wearer of the footwear. An insole may also be provided on top of 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 the wearer of the footwear.

Referring to fig. 12, midsole 202 may be disposed below footwear plate 300 for providing cushioning when a footwear user performs an exercise (such as running, baseball, tennis, etc.) on a hard surface. To this end, 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 the wearer of the footwear.

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-shape fixture to substantially form an upper portion of the 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, the footwear plate 300 may be inserted through the opening in the textile such that a portion of the footwear plate 300 is inside the textile (and/or hidden from view from the exterior of the textile) and a portion of the footwear plate 300 is exposed and visible from the exterior of the textile. In one configuration, the heel portion of footwear plate 300 is inserted through the slit/opening and hidden from external view. After insertion, the footwear panel 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 assist and clarify the description of 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.

"article of footwear," "article of footwear," and "footwear" may be considered both machine and article of manufacture. The assembled ready-to-wear article of footwear (e.g., shoe, sandal, boot, etc.) and discrete components of the article of footwear (e.g., midsole, outsole, upper component, etc.) are considered to be, and may alternatively be referred to as, an "article of footwear" or "footwear" in the singular or plural before final assembly into the ready-to-wear article of footwear.

"a", "an", "the", "at least one" and "one or more" are used interchangeably to indicate at least one of the items is present. A plurality of such items may be present unless the context clearly indicates otherwise. Unless the context clearly or clearly indicates otherwise, all numerical values of parameters (e.g., amounts or conditions) in this specification (including the appended claims) should be understood to be modified in all instances by the term "about" whether or not "about" actually occurs before the numerical value. "about" indicates that the recited value allows some slight inaccuracy (some approximation of the accuracy of the value; approximately or moderately close to the value; almost). If the imprecision provided by "about" is not otherwise understood in the art in this general sense, then "about" as used herein at least indicates a variation that may be caused by the general methods of measuring and using these parameters. As used in the specification and the appended claims, a value is considered "approximate" to be equal to a stated value if it is not more than 5% of the stated value, nor less than 5% of the stated value, unless otherwise stated. In addition, disclosure of a range should be understood to specifically disclose all values and further divided ranges within the range.

The terms "comprises," "comprising," and "includes" 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 steps, processes, and operations may be changed where 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 to be understood as including any possible combination of the referenced claims of the appended claims, including "any one of the referenced claims.

For consistency and convenience, directional adjectives may be employed throughout this detailed description corresponding to the illustrated embodiments. Those of ordinary skill in the art will recognize that terms such as "above," "below," "upward," "downward," "top," "bottom," etc., are 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 the 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., the direction from the forefoot region toward the heel region. In some cases, a component may be identified with a longitudinal axis and a forward longitudinal direction and a rearward longitudinal direction along the axis. The longitudinal direction or longitudinal axis may also be referred to as a front-to-back direction or front-to-back axis.

The term "transverse" refers to a direction extending along the width of a 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 substantially perpendicular to both the lateral direction and the longitudinal direction. For example, in the case where the sole structure is placed flat on a ground surface, the vertical direction may extend upward from the ground surface. It will be appreciated that each of these directional adjectives may be applied to a separate component of the sole structure. The term "upward" or "upward" refers to a vertical direction that is directed toward the top of a component that may include the instep, fastening area, and/or throat of the upper. The term "downward" or "downward" refers to a vertical direction that is opposite the upward direction, pointing toward the bottom of the component, and may be directed generally toward the bottom of the sole structure of the article of footwear.

An "interior" of an article of footwear (such as a shoe) refers to the portion of the space occupied by the foot of the wearer when the article of footwear is worn. An "interior 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. "exterior side" or "exterior" of a component refers to a side or surface of the component that is oriented away from (or will be oriented away from) an interior of an 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 exterior to the assembled article of footwear. Furthermore, the terms "inwardly" and "inwardly" refer to directions toward the interior of a component or article of footwear (e.g., a shoe), and the terms "outwardly" and "outwardly" refer to directions toward the exterior of a component or article of footwear (e.g., a shoe). Furthermore, 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 from the center of the footwear component or further 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 as providing generally opposite terms to describe relative spatial positions.

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 in place 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. Further, many modifications and variations are possible 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 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 examples of the full scope of alternative embodiments that a person of ordinary skill would recognize, such alternative embodiments being implied by, being structurally and/or functionally equivalent to, or otherwise apparent based on, the inclusion and not limited to only those explicitly depicted and/or described embodiments.

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 covered 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 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, and the second upper portion defines a sole opening extending through the interior upper surface and the ground-facing surface;

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

wherein the covered plate portion is in direct contact with the interior upper surface of the second upper portion, the first upper portion being directly coupled to the second upper portion, the sole structure having a heel region, a forefoot region, and a midfoot region located between the forefoot region and the heel region, the sole structure including a cleat structure directly coupled to the second upper portion, the cleat structure being a rear cleat structure disposed at the heel region.

2. The 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 being oriented along a longitudinal axis, the second upper portion defining a first edge and a second edge, the first edge being coupled to the second edge along the longitudinal axis.

3. The article of footwear according to claim 2, wherein the article of footwear further includes a front cleat structure, and the front cleat structure is disposed at the forefoot region.

4. The article of footwear according to claim 3, wherein the front cleat structure defines a body opening that aligns with the exposed plate portion to expose the footwear plate at the forefoot region, the front cleat structure is directly coupled to the ground-facing surface of the second upper portion at the forefoot region, and the rear cleat 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 structure and the rear cleat structure includes a main outsole body and a plurality of traction elements directly coupled to the main outsole body.

6. The article of footwear according to claim 5, wherein each of the first upper portion and the second upper portion includes an upper material, the main 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 of claim 1, wherein the sole structure further includes a front cleat structure directly coupled to the second upper portion, and the front cleat structure is disposed at the forefoot region, each of the front cleat structure and the rear cleat structure includes a main outsole body and a plurality of traction elements directly coupled to the main 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 main 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 according to claim 1, wherein 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 1, wherein the sole structure further includes a laces Bei Erban disposed on the footwear plate at the forefoot region.

12. An article of footwear, comprising:

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,

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, and

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.

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

14. An article of footwear, comprising:

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 plate disposed on the footwear plate at the forefoot region, and

Wherein the footwear plate defines an inner plate surface and a ground-engaging plate surface opposite the inner plate surface, the strobel Bei Erban 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 located 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 site Bei Erban on the last prior to placing the upper on the last.

17. The method of claim 16, further comprising coupling the strobel Bei Erban to the upper prior to inserting the footwear plate between the last and the upper at the heel region.

18. The method of claim 16, further comprising coupling a spike 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 stud structure is made of a polymeric material that is more rigid than the textile.