CN116916782A

CN116916782A - Article of footwear with protruding members

Info

Publication number: CN116916782A
Application number: CN202280018342.9A
Authority: CN
Inventors: C·邓宁; P·S·多施
Original assignee: Puma SE
Current assignee: Puma SE
Priority date: 2021-01-15
Filing date: 2022-01-14
Publication date: 2023-10-20
Also published as: EP4277491A1; WO2022153252A1; JP2024503856A; US20220225737A1

Abstract

An article of footwear, comprising: an upper, a sole structure, and a cleat assembly coupled to the sole structure. The cleat assembly includes a plurality of protruding members extending from a base portion. Each protruding member includes a sidewall. The sidewall defines a first exterior angle and a second exterior angle relative to the base when viewed from one of a medial side or a lateral side of the footwear. The first external angle is greater than the second external angle.

Description

Article of footwear with protruding members

Cross Reference to Related Applications

The present application claims priority from U.S. provisional application Ser. No. 63/137,899 filed on 1/15 of 2021, the contents of which are incorporated herein by reference in their entirety and are considered to be part of the present application.

Technical Field

The present disclosure relates generally to an article of footwear including a cleat assembly (cleat assembly) having a protruding member extending from a base portion.

Background

Many conventional shoes or articles of footwear generally include an upper and a sole attached to a lower end of the upper. Conventional shoes also include an interior space, i.e., void or cavity, formed by the upper and the interior surface of the sole to accommodate the wearer's foot prior to securing the shoe to the foot. The sole is attached to a lower surface of the upper and is positioned between the upper and the ground. Thus, soles typically provide stability and cushioning to the wearer when the shoe is worn or in use. In some cases, the sole may include multiple components, such as an outsole, midsole, and insole. The outsole may provide traction to the bottom surface of the sole, and the midsole may be attached to the inner surface of the outsole and may provide cushioning and/or increased stability to the sole. For example, the sole may include a particular foam material that is capable of increasing stability for one or more desired locations along the sole, or may include a foam material that is capable of reducing stress or impact energy on the foot or leg when running, walking, or performing other activities.

The upper generally extends upwardly from the sole and defines an interior cavity that completely or partially encloses the foot. In most cases, the upper extends over and spans the medial and lateral sides of the instep and toe areas of the foot. Many articles of footwear may also include a tongue that extends through the instep area to bridge a gap between edges of the upper that defines an opening into the void. The tongue may also be disposed below a lacing system, which may be configured to allow adjustment of the tightness of the shoe, and may be manipulated by the user to allow the foot to enter or leave the interior space or void. In addition, the lacing system may allow the wearer to adjust certain dimensions of the upper and/or sole, thereby allowing the upper to accommodate a variety of foot types having different sizes and shapes.

Many shoe uppers may include a variety of materials that may be used to form the upper and selected for use based on one or more intended uses of the shoe. The upper may also include portions that include different materials for specific areas of the upper. For example, increased stability may be desired at the front of the upper or adjacent the heel area in order to provide a higher degree of resistance or stiffness. In contrast, other portions of the shoe may include soft woven fabrics to provide areas of stretch resistance, flexibility, breathability or moisture absorption characteristics.

However, in many cases, there is a need for articles of footwear having a more comfortable upper that fits the foot, as well as soles with improved structural features, such as cleat assemblies secured to the sole structure, to improve ground attachment forces.

Disclosure of Invention

As described herein, an article of footwear may have various configurations. An article of footwear may have an upper and a sole structure coupled with the upper.

Some embodiments of the present disclosure provide an article of footwear including an upper, a sole structure coupled to the upper, and a cleat assembly coupled to the sole structure. The cleat assembly may include a first protruding member extending from a first base. The first protruding member may define a first midfoot-facing portion and a forefoot-facing portion. The second protruding member may extend from the second base and may define a second midfoot-facing portion and a heel-facing portion. A first acute angle may be defined by the first base and the first midfoot-facing portion. A first obtuse angle may be defined by the first base and the forefoot-facing portion. A second acute angle may be defined by the second base and the second midfoot-facing portion. A second obtuse angle may be defined by the second base and the heel-facing portion.

In some embodiments, the article of footwear may include a first obtuse angle and a second obtuse angle, both of which are between 95 degrees and 145 degrees (including 95 degrees and 145 degrees).

In some embodiments, the article of footwear may include a first acute angle and a second acute angle, both of which are between 35 degrees and 85 degrees (including 35 degrees and 85 degrees).

In some embodiments, an article of footwear may include a first substrate formed by a forefoot portion of a cleat assembly. The forefoot portion of the cleat assembly may be at least partially disposed in a forefoot region of the article of footwear. The second base may be formed by a heel portion of the cleat assembly. The heel portion of the cleat assembly may be at least partially disposed in a heel region of the article of footwear.

In some embodiments, an article of footwear may include a first protruding member that is part of a plurality of first protruding members. The second protruding member is part of a plurality of second protruding members.

In some embodiments, the article of footwear may include at least one of a plurality of first protruding members or a plurality of second protruding members that include a ground-contacting surface that is parallel with the base portion.

In some embodiments, an article of footwear may include a plurality of first protruding members and a plurality of second protruding members. Each of the plurality of first protruding members and the plurality of second protruding members may be inclined toward a midfoot region of the article of footwear.

In some embodiments, an article of footwear may include a plurality of first protruding members integrally formed. The plurality of second protruding members may additionally or alternatively be integrally formed.

In some embodiments, an article of footwear may include one or more protruding members that include removable spike tips.

In some embodiments, the article of footwear may include one or more protruding members that are injection molded from scratch resistant polymers, such as polybenzimidazole, parylene, polyetheretherketone, polyimide, acrylonitrile butadiene styrene, coated polypropylene, or other additives added to polymers (e.g., polypropylene).

In some embodiments, the article of footwear may include a first protruding member that includes a tapered geometry such that a wider portion of the first protruding member is disposed proximate to the first substrate, and a second protruding member may include a tapered geometry such that a wider portion of the second protruding member is disposed proximate to the second substrate.

Some embodiments of the present disclosure provide an article of footwear that includes an upper, a sole structure coupled with the upper and defining a forefoot region, a midfoot region, and a heel region, and a cleat assembly secured to the sole structure. The cleat assembly may include a forefoot portion secured to the sole structure in a forefoot region. The forefoot portion may include a plurality of first protruding members extending from the first base. The plurality of first protruding members may be inclined toward the midfoot region. The heel portion of the cleat assembly may be secured to the sole structure in the heel region. The heel portion may include a plurality of second protruding members extending from a second base. The plurality of second protruding members may be inclined toward the midfoot region.

In some embodiments, an article of footwear may include a plurality of protruding members. Each of the plurality of protruding members may include a ground contacting surface. Each ground contacting surface may define a varying surface area between the protruding members. The surface area of the protruding member closest to the forefoot region of the article of footwear may be greater than the surface area of the protruding member closest to the forefoot region or the heel region of the article of footwear.

In some embodiments, an article of footwear may include a plurality of protruding members including removable cleat tips.

In some embodiments, an article of footwear may include a first base portion integrally formed with a first protruding member and a second base portion integrally formed with a second protruding member. Each base portion may be independent and different.

In some embodiments, the article of footwear may include a protruding member located in the forefoot region, which may define a midfoot-facing sidewall and a forefoot-facing sidewall (e.g., when viewed from a side of the article of footwear). The midfoot-facing side wall may form an acute angle with the base, and the forefoot-facing side wall may form an obtuse angle with the base. In general, the protruding member may extend downwardly from the base.

In some embodiments, an article of footwear may include a protruding member having midfoot-facing side walls and sole-facing side walls that are integrally formed with one another.

In some embodiments, the article of footwear may include a protruding member of the heel region that may define a midfoot-facing sidewall and a heel-facing sidewall (e.g., when viewed from a side of the article of footwear). The midfoot-facing side wall may form an acute angle with the base, and the heel-facing side wall may form an obtuse angle with the base. In general, the protruding member may extend downwardly from the base.

Some embodiments of the present disclosure provide a method of forming a cleat assembly for an article of footwear. The method may include injecting a first material into a mold cavity to form a cleat assembly. The mold cavity may include a plurality of stud recesses (stud recesses), each stud recess defining a respective stud recess base disposed along an inclined plane defining an acute angle with respect to a horizontal plane. The horizontal plane may be disposed outside the mold cavity. The method further includes removing the cleat assembly from the mold cavity at an angle substantially perpendicular to the horizontal plane.

In some embodiments, a method of forming a cleat assembly of an article of footwear may include securing the cleat assembly to a sole structure of the article of footwear.

Some embodiments of the present disclosure provide an article of footwear including an upper, a sole structure, and a cleat assembly coupled to the sole structure. The cleat assembly includes a plurality of protruding members extending from a base. Each protruding member includes a sidewall that defines a first exterior angle and a second exterior angle with respect to the base when viewed from one of a medial side or a lateral side of the article of footwear. The first external angle is greater than the second external angle.

In some embodiments, the present disclosure provides an article of footwear including an upper, a sole structure coupled to the upper, and a cleat assembly coupled to the sole structure. The cleat assembly may include a first protruding member extending from a first base. The first protruding member may define a first midfoot-facing portion and a forefoot-facing portion. The second protruding member may extend from the second base and may define a second midfoot-facing portion and a heel-facing portion. A first acute angle may be defined by the first base and the first midfoot-facing portion. A first obtuse angle may be defined by the first base and the forefoot-facing portion. A second acute angle may be defined by the second base and the second midfoot-facing portion. A second obtuse angle may be defined by the second base and the heel-facing portion.

Other aspects of the article of footwear, including its features and advantages, will become apparent to those of ordinary skill in the art upon review of the drawings and detailed description herein. Accordingly, all such aspects of the article of footwear are considered to be included in the detailed description of the present disclosure.

Drawings

FIG. 1 is a top side isometric view of an article of footwear configured as a left shoe, the article of footwear including a cleat assembly, according to an embodiment of the disclosure;

FIG. 2 is a side view of the article of footwear of FIG. 1;

FIG. 3 is a top view of the article of footwear of FIG. 1;

FIG. 4 is a schematic view of various layers of an upper of the article of footwear of FIG. 1;

FIG. 5 is a schematic view of a portion of a tongue of the article of footwear of FIG. 1;

FIG. 6 is a schematic view of a mold of a portion of the cleat assembly of FIG. 1;

FIG. 7 is a schematic view of a mold opening of the mold of FIG. 6;

FIG. 8 is a side view of a protruding member of the cleat assembly of FIG. 1;

FIG. 9 is a schematic outline view of a protruding member according to an embodiment of the present disclosure;

FIG. 10 is another schematic illustration of a profile of a protruding member according to an embodiment of the present disclosure;

FIG. 11 is a medial side view of a sole structure of an article of footwear including a cleat assembly according to an embodiment of the disclosure;

FIG. 12 is a bottom view of the sole structure of FIG. 11;

FIG. 13 is a side view of the sole structure of FIG. 11;

FIG. 14 is a cross-sectional side view of the sole structure of FIG. 12, taken along line A-A in FIG. 12;

FIG. 15 is a top view of the sole structure of FIG. 11;

FIG. 16 is a cross-sectional view of the sole structure of FIG. 12, taken along line B-B in FIG. 12;

FIG. 17 is a cross-sectional view of the sole structure of FIG. 12, taken along line C-C in FIG. 12;

FIG. 18 is a cross-sectional view of the sole structure of FIG. 12, taken along line D-D in FIG. 12;

FIG. 19 is a cross-sectional view of the sole structure of FIG. 12, taken along line E-E in FIG. 12;

FIG. 20 is a cross-sectional view of the sole structure of FIG. 12 taken along line F-F in FIG. 12;

FIG. 21 is a cross-sectional view of the sole structure of FIG. 12, taken along line G-G in FIG. 12; and

fig. 22 is a schematic view of a mold for a cleat assembly according to an embodiment of the present disclosure.

Detailed Description

The following discussion and the accompanying figures disclose various embodiments or configurations of a shoe that may include an upper and a sole structure. Although embodiments of the shoe or sole structure are disclosed with reference to athletic shoes (e.g., running shoes, tennis shoes, basketball shoes, etc.), concepts related to embodiments of the shoe or sole structure may be applied to a wide variety of footwear and footwear styles, including cross-training shoes, soccer shoes, golf shoes, hiking boots, ski boots, soccer shoes, and cleats, walking shoes, and track cleats, for example. The concepts of a shoe or sole structure may also be applied to articles of footwear that are considered to be non-athletic, including dress shoes, sandals, casual shoes, slippers, and high-heeled shoes. In addition to footwear, certain concepts described herein may also be applied to and incorporated into other types of apparel or other athletic equipment, including helmets, padding or protective padding, shin guards, and gloves. Still further, certain concepts described herein may be incorporated into mats, backpack straps, golf clubs, or other consumer or industrial products. Accordingly, the concepts described herein may be used in a variety of products.

The term "about" as used herein refers to the numerical changes that may occur, for example, by: typical measurement and manufacturing procedures by use with an article of footwear or other article of manufacture that may include embodiments of the disclosure herein; by inadvertent errors in these procedures; there are differences in the manufacture, source or purity of the components used to prepare the composition or mixture or to perform the method, among other things. The terms "about" and "approximately" as used in this disclosure refer to a range of + -5% of the numerical value following the term.

The terms "weight percent," wt-%, "percent by weight," "percent by weight," and variations thereof, as used herein, refer to the concentration of a substance or component, i.e., the weight of the substance or component divided by the total weight of a particular component of a composition, for example, and multiplied by 100. It should be understood that the terms "percent", "%" and the like as used herein may be synonymous with "weight percent" and "wt-%".

The present disclosure relates to an article of footwear and/or a particular component of an article of footwear, such as an upper and/or a sole or sole structure. The upper may include knitted components, woven fabrics, and/or non-woven fabrics. The knitted component may be knitted from knitting yarns, the knitted textile may be knitted from yarns, and the nonwoven textile may be formed by making a unitary nonwoven web. Knitted textiles include textiles formed by warp knitting, weft knitting, circular knitting, and/or other suitable knitting operations. For example, the knitted fabric may have a plain knit structure, a mesh knit structure, and/or a rib knit structure. Woven fabrics include, but are not limited to, textiles formed from a variety of weave forms, such as plain weave, twill weave, satin weave, multi-binge weave, jacquard weave, double knit, and/or double knit. Nonwoven fabrics include textiles made by air-laying and/or spin-laying processes. The upper may be composed of a variety of materials, such as first yarns, second yarns, and/or third yarns, that may have different characteristics or different visual characteristics.

Figures 1-3 depict an exemplary embodiment of an article of footwear 100 that includes an upper 102 and a sole structure 104. Upper 102 is coupled to sole structure 104 and cooperatively define an interior chamber 106 into which a foot may be inserted. For reference, the article of footwear 100 defines a forefoot region 108, a midfoot region 110, and a heel region 112. Forefoot region 108 generally corresponds with portions of article of footwear 100 surrounding the foot including the toes, the ball of the foot, and the joints connecting the metatarsals with the toes or phalanges. Midfoot region 110 is adjacent to and adjacent to forefoot region 108 and generally corresponds with the portion of article of footwear 100 surrounding the arch and foot bridge. Heel region 112 is adjacent to and abutting midfoot region 110 and generally corresponds with the portion of article of footwear 100 that wraps around the rear of the foot, including the heel or calcaneus, ankle, and/or achilles tendon.

Many conventional uppers are formed from multiple elements (e.g., textiles, polymer foam, polymer sheets, leather, and synthetic leather) that are joined together by gluing or stitching at seams. In particular, referring to fig. 4 and 5, upper 102 may be formed from first layer 114 and second layer 116. First layer 114 may include a plurality of recesses 118 configured to form apertures that enhance the breathability of upper 102. The second layer 116 may be at least partially transparent and pressed against the first layer 114. As shown in fig. 4, the second layer 116 is configured as a skin having a pattern such as dots or pixels. As shown in FIG. 5, tongue portion 120 of article of footwear 100 also includes a first layer 114 having a plurality of recesses 118 to further enhance the breathability of upper 102.

The article of footwear 100 also includes a medial side 122 and a lateral side 124 as shown in FIG. 3. Specifically, lateral side 124 corresponds with a lateral portion of article of footwear 100 and medial side 122 corresponds with a medial portion of article of footwear 100. Accordingly, the left and right articles of footwear have opposite lateral and medial sides, with medial side 122 being closest to each other when the article of footwear 100 is worn by a user and lateral side 124 being defined as the side furthest from each other when worn. Medial side 122 and lateral side 124 abut each other at opposite distal ends of article of footwear 100.

Unless otherwise indicated, forefoot region 108, midfoot region 110, heel region 112, medial side 122, and lateral side 124 are intended to define boundaries or regions of article of footwear 100. To this end, forefoot region 108, midfoot region 110, heel region 112, medial side 122, and lateral side 124 generally represent various portions of article of footwear 100. In addition, upper 102 and sole structure 104 may each be characterized as having portions located within forefoot region 108, midfoot region 110, heel region 112, and on medial side 122 and lateral side 124. Accordingly, upper 102 and sole structure 104 and/or portions of upper 102 and sole structure 104 may include portions disposed within forefoot region 108, midfoot region 110, heel region 112, and on medial side 122 and lateral side 124.

Sole structure 104 is attached or secured to upper 102 and extends between the user's foot and the ground when the user wears article of footwear 100. Sole structure 104 may include one or more components, which may include an outsole, a midsole, a heel, an upper, and/or an insole. For example, in some embodiments, the sole structure may include an outsole that provides structural integrity to the sole structure and provides traction to the user, a midsole that provides a cushioning system, and an insole that provides support to the arch of the user.

Referring again to fig. 1 and 2, sole structure 104 includes cleat assembly 130. Stud assembly 130 includes a forefoot portion 132 and a heel portion 134. The forefoot portion 132 includes a plurality of protruding members 136 and a base portion 138. A plurality of protruding members 136 extend from the base portion 138, with at least two different angles between the side wall 140 of each protruding member 136 and the base portion 138 from a side view.

In the illustrated embodiment, the sidewall 140 is configured as an outer surface of a cylinder. For example, as shown in fig. 1 and 2, the cylinder may be configured as a tapered cylinder (e.g., a truncated cone) with a wider portion thereof adjacent the base portion 138. In other embodiments, protruding member 136 may be multi-faceted (facet), and the sidewall may be just a single facet of the faceted outer surface of protruding member 136. Thus, a first sidewall defined by a first cut-out may define a first angle between the first cut-out and the base portion 138, while a second sidewall defined by a second cut-out of the same protruding member may define a second angle between the second cut-out and the base portion 138. The first angle may be different from the second angle.

The different angles of the protruding members 136 formed by the side walls 140 and the base portion 138 may vary between each protruding member 136 of the plurality of protruding members 136 when viewed in side elevation. Additional details of such different angles will be described below with reference to fig. 8-10. Likewise, heel portion 134 includes a plurality of protruding members 144 extending from a base portion 146. As with forefoot portion 132, one or more protruding members 144 of heel portion 134 may define at least two different angles between a sidewall 148 and a base portion 146 of each protruding member 144.

Each of the plurality of protruding members 136, 144 includes a respective ground contacting surface 150 generally defined by the respective side walls 140, 148. In embodiments where the plurality of protruding members 136, 144 includes a plurality of tangential surfaces, the ground contacting surface may be generally defined by the tangential surfaces. Each protruding member 136 of forefoot portion 132 may include a ground-contacting surface 150 of a different size (e.g., surface area). For example, the ground contacting surface 150 of the protruding member 136 proximate the foot region 110 in the article of footwear 100 may be larger than the ground contacting surface 150 of the protruding member 136 proximate the forefoot region 108. Likewise, the surface area of ground-contacting surface 150 may vary with the location of protruding members 136 relative to medial side 122 and lateral side 124 of article of footwear 100. In the illustrated embodiment, the ground-contacting surface 150 is generally planar. However, in other embodiments, the protruding member may include a ground-contacting surface having a generally convex or concave geometry.

Generally, both forefoot portion 132 and heel portion 134 of cleat assembly 130 may be formed by injection molding. For example, in some embodiments, an injection mold, such as mold 160 shown in fig. 6, may be used to form forefoot portion 132 of cleat assembly 130. The mold 160 is configured as a two-piece rigid mold including a mold cavity 162 having a plurality of recesses corresponding to the geometry of the plurality of protruding members 136. The mold cavity 162 is formed in an angled portion 164 of the mold 160. The angled portion 164 relative to the mold cavity 162 may facilitate successful removal of the forefoot portion 132 of the cleat assembly 130 from the mold 160 and eliminate the undercut feature (undercut features) of the cleat assembly 130.

In certain embodiments, during manufacture, preformed spike tips may be added to the mold cavity 162 and inserted into the plurality of recesses prior to injection molding. The preformed spike tip may be formed of a material different from the injection molding material forming cleat assembly 130. For example, the spike tip may be formed of a relatively wear or scratch resistant material as compared to an injection molded material (which may be a polymer injection molded material). Further, in some embodiments, cleat assembly 130 may include removable cleat tips. For example, the spike may be secured to the forefoot portion 132 and the heel portion 134 by threaded fasteners.

As shown in fig. 7, the portion of the mold 160 corresponding to the ground-contacting surface 150 of the protruding member 136 is generally parallel (e.g., at an acute angle or substantially parallel) to the angled portion 164 of the mold 160. This geometry further reduces the undercut features formed in the cleat assembly 130. The corresponding mold and mold features shown in fig. 6 and 7 may be used to produce heel portion 134 of cleat assembly 130.

Fig. 8 shows a single protruding member 136A of the forefoot portion 132 of the cleat assembly 130. It should be understood that protruding member 136A is merely illustrative and may correspond to any one of one or more of protruding members 136, 144. In particular, the reference line shown in fig. 8 may generally correspond to any one of the protruding members 136, 144, regardless of the relative angle with respect to an axis (e.g., axis 170) that extends along the base portion 138 adjacent to one of the plurality of protruding members 136 in a bottom side view. In this regard, the reference lines (e.g., lines 172, 174) may correspond to the various sidewalls of the protruding members 134, 144, and may intersect the base reference axis (e.g., line 170) at various angles.

In the illustrated embodiment, the protruding member 136A defines an axis 170 extending along the base portion 138. A first portion of the sidewall 140 is disposed at least partially along a first line 172 and a second portion of the sidewall 140 is disposed along a second line 174. The first line 172 intersects the axis 170 at a first external angle 176 and the second line 174 intersects the axis 170 at a second external angle 178. First exterior angle 176 is an obtuse angle (i.e., greater than 90 degrees) and faces forefoot region 108 of article of footwear 100 (e.g., see fig. 1 and 2). The second exterior angle 178 is acute (i.e., less than 90 degrees) and faces the midfoot region 110 of the article of footwear 100. Generally, the angles shown in FIG. 8 facilitate removal from an injection mold while providing sufficient ground contact surface area and strength during use.

Each protruding member 144 of heel portion 134 may correspondingly define a first external angle formed by a sidewall 148 portion facing heel region 112 of article of footwear 100 and a base portion 146. Further, each protruding member 144 of heel portion 134 may correspondingly define a second exterior angle formed by a sidewall 148 portion and a base portion 146 facing midfoot region 110 of article of footwear 100. As with protruding member 136A, the first outer angle of protruding member 144 of heel portion 134 is an obtuse angle and the second outer angle of protruding member 144 of heel portion 134 is an acute angle.

In general, the first outer angle 176 may be between about 95 degrees and 145 degrees. Further, the second exterior angle 178 may be between about 35 degrees and 85 degrees. Accordingly, each outer angle of protruding members 136, 144 facing the outer end of article of footwear 100 (i.e., forefoot region 108 or heel region 112) may be between approximately 95 degrees and 145 degrees. Additionally or alternatively, each outer angle of the protruding members 136, 144 facing the foot region 110 in the article of footwear 100 may be between approximately 45 degrees and 85 degrees.

Fig. 9 and 10 illustrate other geometries of protruding members according to some embodiments of the present disclosure. For example, fig. 9 shows a protruding member 200 extending from a base surface 202 and including a side wall 204 and a ground contacting surface 206. One side of sidewall 204 facing the end of the article of footwear (i.e., the forefoot region or the heel region) forms a first included angle 208 with base surface 202. A second side of sidewall 204 facing the midfoot region of the article of footwear forms a second included angle 210 with base surface 202. In the illustrated example, the first included angle 208 is about 110 degrees and the second included angle 210 is about 70 degrees.

Fig. 10 shows protruding member 220 extending from base surface 222, the protruding member 220 comprising a side wall 224 and a ground-contacting surface 226. The side of the sidewall 224 facing the end of the article of footwear forms a first included angle 228 with the base surface. A second side of sidewall 224 facing the midfoot region of the article of footwear forms a second included angle 230 with base surface 222. In the illustrated example, the first included angle 228 is approximately 110 degrees and the second included angle 230 is approximately 80 degrees.

The ground-contacting surfaces 206, 226 shown in fig. 9 and 10, respectively, are generally parallel to the corresponding base surfaces 202, 222. However, in other embodiments, one or more ground contacting surfaces of the cleat assembly may be inclined relative to the base portion. Each protruding member 200, 220 provides an exemplary geometry that may be used by one or more of the plurality of protruding members 136, 144 of the cleat assembly 130.

Figures 11-21 depict an exemplary embodiment of a sole structure 240 according to an embodiment of the present application. Similar to sole structure 104, sole structure 240 is configured to attach to an upper and cooperatively define an interior void into which a foot may be inserted. For reference, sole structure 240 defines a forefoot region 248, a midfoot region 250, and a heel region 252. Forefoot region 248 generally corresponds with portions of an article of footwear (e.g., article of footwear 100) that wrap around portions of the foot, including the toes, the ball of the foot, and the joints connecting the metatarsals with the toes or phalanges. Midfoot region 250 is adjacent to and abuts forefoot region 248 and generally corresponds with the portion of the article of footwear surrounding the arch and foot bridge. Heel region 252 is adjacent to and abuts midfoot region 250 and generally corresponds with the portion of the article of footwear that wraps around the rear of the foot, including the heel or calcaneus, ankle, and/or achilles tendon.

Sole structure 240 also includes a medial side 256, shown in fig. 11, and a lateral side 258, shown in fig. 13. Specifically, lateral side 258 corresponds with a lateral portion of the article of footwear, and medial side 256 corresponds with a medial portion of the article of footwear. Thus, the left and right articles of footwear have opposite lateral and medial sides, the medial side being defined as the side closest to each other when the article of footwear is worn by a user, and the lateral side being defined as the side furthest from each other when worn. Medial side 256 and lateral side 258 abut each other at opposite distal ends of the article of footwear.

Similar to sole structure 104, sole structure 240 includes cleat assembly 260. Cleat assembly 260 includes a forefoot portion 262 and a heel portion 264. Forefoot portion 262 includes a plurality of protruding members 266 and a base portion 268. A plurality of protruding members 266 extend from the base portion 268 and may define a first outer angle 270 and a second outer angle 272 relative to the base portion 268. Likewise, heel portion 264 includes a plurality of protruding members 274 extending from base portion 276. As with forefoot portion 262, one or more protruding members 274 of heel portion 264 may define a first outer corner 278 and a second outer corner 280.

In some embodiments, the forefoot portion 262 may include a unitary body such that the plurality of protruding members 266 and the base portion 268 are integrally formed. Likewise, heel portion 264 may comprise a unitary body such that at least one of the plurality of protruding members 274 is integrally formed with base portion 274. In other embodiments, forefoot portion 262 and heel portion 264 may include one or more base portions 268, 274, respectively.

As shown in fig. 11 and 13, each first exterior corner 270, 278 faces the outer end of sole structure 240 (i.e., forefoot region 248 or heel region 252) and each second exterior corner 272, 280 faces the center of sole structure 240 (i.e., midfoot region 250). The first outer angles 270, 278 are between about 95 degrees and 145 degrees. The second outer angle 280 is approximately between 35 degrees and 85 degrees.

Referring now to fig. 16-21, a plurality of protruding members 266, 274 extend generally perpendicularly downwardly from the respective base portions 268, 276 when viewed from the toe or heel end of the article of footwear. In addition, each protruding member 266, 274 may further include a cleat member 282 that extends beyond the respective protruding member 266, 274, forming a ground-contacting surface 284. As shown in fig. 16 and 21, some of the ground contacting surfaces 284 of cleat assembly 260 may be disposed on substantially the same plane. Further, as shown in fig. 17, some of the ground contacting surfaces 284 of cleat assembly 260 may be disposed on different planes.

Figure 22 illustrates a mold 300 for a sole structure, such as sole structure 104. Similar to sole structure 104, mold 300 may include a forefoot portion 302 and a heel portion 304. In general, the mold 300 defines a space that includes a plurality of cleat pockets 308 (e.g., cleat pockets 308A-D). Each of the plurality of cleat pockets 308 defines a respective base 310 (e.g., bases 310A-D). Each of the plurality of bases 310 in the forefoot portion 302 is generally disposed along the inclined surface 312. For example, a first cleat recess 308A of the plurality of cleat recesses 308 defines a first base 308A disposed along a first incline, a second cleat recess 308B defines a second base 310B disposed along a second incline, and a third cleat recess 308C defines a third base 308C disposed along a third incline.

In the illustrated embodiment, the first, second, and third sloped surfaces have the same slope direction as the overall sloped surface 312. Further, in the illustrated embodiment, the first sloped portion of the first substrate 310A is slightly sloped (e.g., less than 30 degrees) relative to the total sloped surface 312, and the third sloped portion of the third substrate 310C is slightly sloped (e.g., less than 10 degrees) relative to the total sloped surface 312. Further, as shown, the overall incline 312 and each of the first incline, the second incline, and the third incline form an acute angle with respect to the horizontal 318. A fourth cleat recess 308D formed in heel portion 304 defines a fourth base 308D disposed along a slope having an opposite slope to the overall slope 312 of forefoot portion 302.

The inclination of each base 310 of the plurality of cleat recesses 308 allows the sole structure to be removed from mold 300 substantially perpendicular to horizontal plane 318. The general inclination of each of forefoot portion 302 and heel portion 304 (e.g., inclined surface 312) allows the formation of cleats in a corresponding plurality of cleat recesses 308 to define a linear centerline 320 that is generally perpendicular to horizontal plane 318 when material is injected into mold 300 to form a sole structure. In addition, the overall inclination of each of forefoot portion 302 and heel portion 304 may prevent undercuts from being created in mold 300 that would lock the sole structure in mold 300.

In general, the protruding members described above, such as protruding members 136, 144, 200, 220, 266, 274, provide a structure for a cleat assembly in which each cleat member is generally inclined toward the midfoot portion of an article of footwear. Also, the mold 300 described above provides a mold for a sole structure in which the cleat assembly is generally inclined toward the midfoot portion of the article of footwear. Such cleat assemblies may provide positive style to improve traction. Furthermore, the geometry of such a cleat assembly facilitates the injection molding process, overcoming the complexity of undercut without introducing unnecessary parting lines.

Any of the embodiments described herein may be modified to include any structure or method disclosed in connection with the different embodiments. Furthermore, the present disclosure is not limited to articles of footwear of the type specifically illustrated. Aspects of the articles of footwear of any of the embodiments disclosed herein may be modified for use with any type of footwear, apparel, or other athletic equipment.

As previously mentioned, those skilled in the art will appreciate that while the present disclosure has been described above in connection with particular embodiments and examples, the application is not so limited, and the appended claims are intended to cover numerous other embodiments, examples, uses, and modifications and variations related to the embodiments, examples, and uses. The entire disclosure of each patent and publication cited herein is incorporated by reference as if each such patent or publication were individually incorporated by reference. Various features and advantages of the application are set forth in the following claims.

INDUSTRIAL APPLICABILITY

Many modifications of the disclosure will be apparent to those skilled in the art in view of the above description. Accordingly, the description is to be construed as illustrative only and is for the purpose of describing the methods and apparatus for enabling those skilled in the art to make and use the disclosure. The exclusive rights to all modifications which come within the scope of the appended claims are reserved.

Claims

1. An article of footwear, comprising:

a vamp;

a sole structure associated with the upper; and

a cleat assembly associated with the sole structure, the cleat assembly comprising:

a first protruding member extending from the first base, the first protruding member defining a first midfoot-facing portion and a forefoot-facing portion;

a second protruding member extending from the second base, the second protruding member defining a second midfoot-facing portion and a heel-facing portion;

a first acute angle defined by the first base and the first midfoot-facing portion;

a first obtuse angle defined by the first base and the forefoot-facing portion;

a second acute angle defined by the second base and the second midfoot-facing portion; and

a second obtuse angle defined by the second base and the heel-facing portion.

2. The article of footwear of claim 1, wherein each of the first obtuse angle and the second obtuse angle is between a range of 95 degrees and 145 degrees.

3. The article of footwear of claim 1, wherein each of the first acute angle and the second acute angle is between a range of 35 degrees and 85 degrees.

4. The article of footwear of claim 1, wherein the first base is formed by a forefoot portion of the cleat assembly disposed at least partially in a forefoot region of the article of footwear, and the second base is formed by a heel portion of the cleat assembly disposed at least partially in a heel region of the article of footwear.

5. The article of footwear of claim 1, wherein the first protruding member is part of a plurality of protruding members and the second protruding member is part of a plurality of second protruding members.

6. The article of footwear according to claim 5, wherein at least one of the plurality of first protruding members or the plurality of second protruding members includes a ground-contacting surface that is parallel with a portion corresponding to the first substrate or the second substrate.

7. The article of footwear according to claim 5, wherein each of the plurality of first protruding members and the plurality of second protruding members is inclined toward a midfoot portion of the article of footwear.

8. The article of footwear according to claim 5, wherein the plurality of first protruding members are integrally formed and the plurality of second protruding members are integrally formed.

9. The article of footwear according to claim 1, wherein each of the first projecting member and the second projecting member includes a first removable spike tip and a second removable spike tip, respectively.

10. The article of footwear of claim 1, wherein each of the first protruding member and the second protruding member comprises a scratch resistant injection molded polymeric material.

11. The article of footwear of claim 1, wherein the first protruding member includes a tapered geometry such that a wider portion of the first protruding member is disposed proximate the first substrate and the second protruding member includes a tapered geometry such that a wider portion of the second protruding member is disposed proximate the second substrate.

12. An article of footwear, comprising:

a vamp;

a sole structure associated with the upper, the sole structure defining a forefoot region, a midfoot region, and a heel region; and

a cleat assembly secured to the sole structure, the cleat assembly comprising:

a forefoot portion secured to the sole structure at the forefoot region and including a plurality of first protruding members extending from the first base, the plurality of first protruding members being inclined toward the midfoot region; and

a heel portion secured to the sole structure at the heel region and including a plurality of second protruding members extending from a second base, the plurality of second protruding members being inclined toward the midfoot region.

13. The article of footwear of claim 12, wherein each protruding member of the plurality of first protruding members defines a respective ground-contacting surface, and

wherein the surface area of the respective ground contacting surfaces of the plurality of first protruding members proximate the midfoot region is greater than the surface area of the ground contacting surfaces of the plurality of first protruding members proximate the forefoot region.

14. The article of footwear according to claim 12, wherein each of the plurality of first protruding members and the plurality of second protruding members includes a respective removable spike tip.

15. The article of footwear according to claim 12, wherein at least a portion of the first substrate is integrally formed with at least one of the plurality of first protruding members by injection molding, and

wherein at least a portion of the second substrate is integrally formed with at least one of the plurality of second protruding members by injection molding.

16. The article of footwear of claim 12, wherein at least one of the plurality of first protruding members defines a midfoot-facing sidewall and a forefoot-facing sidewall, the midfoot-facing sidewall forming an acute angle with the first base, the forefoot-facing sidewall forming an obtuse angle with the first base.

17. The article of footwear of claim 16, wherein the midfoot-facing sidewall is integrally formed with the forefoot-facing sidewall.

18. The article of footwear of claim 12, wherein at least one of the plurality of second protruding members defines a midfoot-facing sidewall and a heel-facing sidewall, the midfoot-facing sidewall forming an acute angle with the second base, the heel-facing sidewall forming an obtuse angle with the second base.

19. A method of forming a cleat assembly, the method comprising:

injecting a first material into a mold cavity to form a cleat assembly, the mold cavity comprising a plurality of cleat pockets, each cleat pocket defining a corresponding cleat pocket base, the bases being arranged along an inclined plane defining an acute external angle relative to a horizontal plane; and

the cleat assembly is removed from the mold cavity at an angle substantially perpendicular to the horizontal.

20. The method of claim 19, further comprising:

the cleat assembly is secured to the sole structure of an article of footwear.