Classifications

• • A—HUMAN NECESSITIES
  • A43—FOOTWEAR
  • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
  • A43B13/00—Soles; Sole-and-heel integral units
  • A43B13/02—Soles; Sole-and-heel integral units characterised by the material
  • A43B13/023—Soles with several layers of the same material
• • A—HUMAN NECESSITIES
  • A43—FOOTWEAR
  • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
  • A43B13/00—Soles; Sole-and-heel integral units
  • A43B13/02—Soles; Sole-and-heel integral units characterised by the material
  • A43B13/12—Soles with several layers of different materials
• • A—HUMAN NECESSITIES
  • A43—FOOTWEAR
  • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
  • A43B13/00—Soles; Sole-and-heel integral units
  • A43B13/14—Soles; Sole-and-heel integral units characterised by the constructive form
  • A43B13/141—Soles; Sole-and-heel integral units characterised by the constructive form with a part of the sole being flexible, e.g. permitting articulation or torsion
• • A—HUMAN NECESSITIES
  • A43—FOOTWEAR
  • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
  • A43B13/00—Soles; Sole-and-heel integral units
  • A43B13/14—Soles; Sole-and-heel integral units characterised by the constructive form
  • A43B13/22—Soles made slip-preventing or wear-resisting, e.g. by impregnation or spreading a wear-resisting layer
  • A43B13/24—Soles made slip-preventing or wear-resisting, e.g. by impregnation or spreading a wear-resisting layer by use of insertions
  • A43B13/26—Soles made slip-preventing or wear-resisting, e.g. by impregnation or spreading a wear-resisting layer by use of insertions projecting beyond the sole surface
• • A—HUMAN NECESSITIES
  • A43—FOOTWEAR
  • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
  • A43B17/00—Insoles for insertion, e.g. footbeds or inlays, for attachment to the shoe after the upper has been joined
  • A43B17/003—Insoles for insertion, e.g. footbeds or inlays, for attachment to the shoe after the upper has been joined characterised by the material
  • A43B17/006—Insoles for insertion, e.g. footbeds or inlays, for attachment to the shoe after the upper has been joined characterised by the material multilayered
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
  • B29D35/00—Producing footwear
  • B29D35/0054—Producing footwear by compression moulding, vulcanising or the like; Apparatus therefor
  • B29D35/0063—Moulds
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
  • B29D35/00—Producing footwear
  • B29D35/06—Producing footwear having soles or heels formed and joined on to preformed uppers using a moulding technique, e.g. by injection moulding, pressing and vulcanising
  • B29D35/08—Producing footwear having soles or heels formed and joined on to preformed uppers using a moulding technique, e.g. by injection moulding, pressing and vulcanising having multilayered parts
  • B29D35/085—Producing footwear having soles or heels formed and joined on to preformed uppers using a moulding technique, e.g. by injection moulding, pressing and vulcanising having multilayered parts by compression moulding, vulcanising or the like
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
  • B29D35/00—Producing footwear
  • B29D35/12—Producing parts thereof, e.g. soles, heels, uppers, by a moulding technique
  • B29D35/14—Multilayered parts
  • B29D35/142—Soles
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
  • B29D35/00—Producing footwear
  • B29D35/12—Producing parts thereof, e.g. soles, heels, uppers, by a moulding technique
  • B29D35/14—Multilayered parts
  • B29D35/148—Moulds or apparatus therefor

Definitions

• the present disclosure relates generally to an article of footwear and more particularly to a plate structure for an article of footwear.
• Articles of footwear conventionally include an upper and a sole structure.
• the upper may be formed from any suitable material(s) to receive, secure, and support a 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.
• Sole structures generally include a layered arrangement extending between a ground surface and the upper.
• a sole structure may include a midsole and an outsole.
• the midsole is generally disposed between the outsole and the upper and provides cushioning for the foot.
• the outsole provides abrasion-resistance and traction with the ground surface and may be formed from rubber or other materials that impart durability and wear-resistance, as well as enhance traction with the ground surface.
• sole structures adequately provide an article of footwear with cushioning and traction
• such sole structures are often bulky due to the materials incorporated into the sole structure as well as the requisite amount of material needed to provide a desired stiffness, cushioning, and/or rigidity to the sole structure.
• conventional sole structures may be designed and function well for a particular activity but adversely add to the overall weight of the article of footwear.
• FIG. 1 is a medial side perspective view of a plate structure for an article of footwear according to the present disclosure
• FIG. 2 is a top-front exploded perspective view of the plate structure of FIG. 1;
• FIG. 3 is a cross-sectional view of the plate structure of FIG. 1, taken along Line 3-3 in
• FIG. 1 A first figure.
• FIG. 4 is an example process for producing the plate structure of FIG. 1;
• FIG. 5 is an example process for producing the plate structure of FIG. 1;
• FIGS. 6A-6D illustrate an example process of forming the plate structure of FIG. 1;
• FIGS. 7A-7D illustrate an example process of forming a sole structure including the plate structure of FIG. 1;
• FIG. 8 is a lateral side perspective view of an article of footwear incorporating a plate structure according to the present disclosure
• FIG. 9 is a top-front exploded perspective view of a plate structure according to the present disclosure.
• FIG. 10 is a cross-sectional view of the plate structure of FIG. 9, taken across a width of the plate structure of FIG. 9 in a similar location as Line 3-3 of FIG. 1;
• FIG. 11 is a top-front exploded perspective view of a plate structure according to the present disclosure.
• FIG. 12 is a cross-sectional view of the plate structure of FIG. 11, taken across a width of the plate structure of FIG. 11 in a similar location as Line 3-3 of FIG. 1.
• 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 of ordinary skill in the art. Specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of configurations of the present disclosure. It will be apparent to those of ordinary skill in the art that specific details need not be employed, that example configurations may be embodied in many different forms, and that the specific details and the example configurations should not be construed to limit the scope of the disclosure.
• 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, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example configurations.
• a plate for an article of footwear includes a first film member, a second film member attached to the first film member to define an interior void between the first film member and the second film member, and a foam member disposed within and completely filling the interior void.
• the plate may include one or more of the following optional features.
• at least one of the first film member and the second film member may be formed from thermoplastic polyurethane (TPU).
• the foam member may be formed from TPU.
• at least two of the first film member, the second film member, and the foam member may be formed from the same material.
• the first film member may be attached to a first side of the foam member and the second film member may be attached to a second side of the foam member, the second side being disposed on an opposite side of the foam member than the first side.
• a first adhesive may be disposed between the first film member and the first side of the foam member and a second adhesive may be disposed between the second film member and the second side of the foam member. At least one of the first adhesive and the second adhesive may be a hot melt adhesive.
• At least one of the first film member and the second film member may define a rib.
• the foam member may extend into the rib within the interior void.
• a sole structure for an article of footwear may incorporate the plate described above.
• a plate for an article of footwear includes a first film member, a second film member attached to the first film member to define an interior void between the first film member and the second film member, and a foam member disposed within the interior void and being formed from the same material as at least one of the first film member and the second film member.
• the plate may include one or more of the following optional features.
• at least one of the first film member and the second film member may be formed from thermoplastic polyurethane (TPU).
• the foam member may be formed from TPU.
• the first film member may be attached to a first side of the foam member and the second film member may be attached to a second side of the foam member, the second side being disposed on an opposite side of the foam member than the first side.
• a first adhesive may be disposed between the first film member and the first side of the foam member and a second adhesive may be disposed between the second film member and the second side of the foam member. At least one of the first adhesive and the second adhesive may be a hot melt adhesive.
• At least one of the first film member and the second film member may define a rib.
• the foam member may extend into the rib within the interior void.
• a sole structure for an article of footwear may incorporate the plate described above [0035] Referring to FIG. 1, a plate structure 100 includes an upper surface 102 and a lower surface 104 formed on an opposite side of the plate structure 100 than the upper surface 102. A thickness Two of the plate structure 100 is defined by the distance between the upper surface 102 and the lower surface 104. The plate structure 100 may further include an anterior end 106 associated with a forward-most point of the plate structure 100, and a posterior end 108 corresponding to a rearward-most point of the plate structure 100.
• a longitudinal axis Awo of the plate structure 100 extends along a length of the plate structure 100 from the anterior end 106 to the posterior end 108 parallel to a ground surface, and generally divides the plate structure into a medial side 110 and a lateral side 112. Accordingly, the medial side 110 and the lateral side 112 respectively correspond with opposite sides of the plate structure 100, and extend from the anterior end 106 to the posterior end 108, while a lateral direction refers to the direction transverse to the longitudinal axis Awo and extending from the medial side 110 to the lateral side 112.
• the plate structure 100 may be divided into one or more regions.
• the regions may include a forefoot region 160, a mid-foot region 162, and a heel region 164.
• the forefoot region 160 may correspond with the phalanges and the metatarsal bones of the foot.
• the mid-foot region 162 may correspond with an arch area of the foot, and the heel region 164 may correspond with rear portions of the foot, including a calcaneus bone.
• the plate structure 100 may be further described as including a peripheral region 114 and an interior region 116, as indicated in FIG. 1.
• the peripheral region 114 is generally described as being a region between the interior region 116 and an outer perimeter (i.e., edge) of the plate structure 100.
• the peripheral region 114 extends from the forefoot region 160 to the heel region 164 along each of the medial side 110 and the lateral side 112, and wraps around each of the forefoot region 160 at the anterior end 106 and the heel region 24 at the posterior end 108.
• the interior region 116 is circumscribed by the peripheral region 114, and extends from the forefoot region 160, through the mid-foot region 162, to the heel region 164 along a central portion of the plate structure 100. Accordingly, each of the forefoot region 160, the mid-foot region 162, and the heel region 164 may be described as including the peripheral region 114 and the interior region 116.
• the plate structure 100 is configured to provide lightweight support and may have a variable stiffness.
• the upper surface 102 includes a foot cavity that defines a footbed of the plate structure 100, while the lower surface 104 may define a portion of a ground-engaging surface.
• the plate structure 100 may be formed to include one or more ribs 118 extending along the longitudinal axis Aioo within the interior region 106 of the mid-foot region 162.
• the one or more ribs 118 may be recessed from the upper surface 102 of the plate structure 100 and correspond to projections in the lower surface 104 of the plate structure 100.
• the one or more ribs 118 may create a corresponding spine 120 disposed between the one or more ribs 118 that likewise extends along the longitudinal axis Aioo within the interior region 106 of the mid-foot region 162 along the central portion of the plate structure 100.
• the spine 120 is a projection in the upper surface 102 of the plate structure 100 between the one or more ribs 118 and corresponds to a recess from the lower surface 104 of the plate structure 100.
• the one or more ribs 118 and corresponding spine 120 may provide increased stiffness and support in the plate structure 100.
• the plate structure 100 may further be formed to include a plurality of grooves 122 to provide increased flexibility in the plate structure 100.
• the plurality of grooves 122 may be formed in the interior region 106 of the forefoot region 160 and extend in a direction transverse to the longitudinal axis Aioo between the medial side 110 and the lateral side 112. As shown, the plurality of grooves 122 are recessed from the upper surface 102 of the plate structure 100. While FIG.
• the plurality of grooves 122 may extend fully between the medial side 110 (i.e., the medial edge) to the lateral side 112 (i.e., the lateral edge) of the peripheral region 106.
• FIG. 2 provides an exploded view of the plate structure 100.
• the plate structure 100 of the present disclosure is configured as a composite structure including a plurality of components joined together.
• the plate structure 100 includes a first film member or barrier member 124, a second film member or barrier member 126, and a foam member 128 disposedbetween the first barrier member 124 and the second barrier member 126.
• a foam member 128 including a foam cell structure between the barrier members 124, 128, the plate structure 100 may be significantly lighter than conventional plate structures that incorporate full density layers.
• the foam member 128 is a structural foam member having a higher rigidity than a form member conventionally used in a midsole. Accordingly, the foam member 128 provides the plate structure 100 with a degree of rigidity and strength.
• the first barrier member 124, the second barrier member 126, and the foam member 128 may be formed from the same material to minimize manufacturing waste. Suitable materials may include thermoplastic polyurethane (TPU), polyamide (PA), polyethylene (PE), or polypropylene (PP).
• TPU thermoplastic polyurethane
• PA polyamide
• PE polyethylene
• PP polypropylene
• the first barrier member 124, the second barrier member 126, and the foam member 128 may all be formed from TPU.
• at least one of the first barrier member 124 and the second barrier member 126 may be formed from a different material than the foam member 128.
• at least one of the first barrier member 124 and the second barrier member 124 may be formed from PA, while the foam member 128 may be formed from TPU or PE.
• the foam member 128 may be formed from an open cell foam. Alternatively, the foam member 128 is formed from a closed cell foam.
• the foam member 128 may further provide thermal insulation properties to the plate structure 100 when the plate structure 100 is
• the first barrier member 124, the second barrier member 126, and the foam member 128 are formed from different materials.
• the first barrier element 124 may be formed from PA
• the second barrier element 126 may be formed from TPU
• the foam member 128 may be formed from PP.
• any combination of TPU, PA, PE, and PP may be used.
• the plate structure 100 may be selectively contoured to accommodate material properties upon cooling.
• any of the first barrier member 124, the second barrier member 126, and the foam member 128 can be produced from a material that includes one or more thermoplastic polymers and/or one or more cross-linkable polymers.
• the material can include one or more thermoplastic materials, such as one or more thermoplastic polyurethane (TPU) copolymers, one or more ethylene-vinyl alcohol (EVOH) copolymers, and the like.
• TPU thermoplastic polyurethane
• EVOH ethylene-vinyl alcohol
• urethane groups can contain additional groups such as ester, ether, urea, allophanate, biuret, carbodiimide, oxazolidinyl, isocynaurate, uretdione, carbonate, and the like, in addition to urethane groups.
• suitable isocyanates for producing the polyurethane copolymer chains include diisocyanates, such as aromatic diisocyanates, aliphatic diisocyanates, and combinations thereof.
• suitable aromatic diisocyanates include toluene diisocyanate (TDI), TDI adducts with trimethyloylpropane (TMP), methylene diphenyl diisocyanate (MDI), xylene diisocyanate (XDI), tetramethylxylylene diisocyanate (TMXDI), hydrogenated xylene diisocyanate (HXDI), naphthalene 1,5 -diisocyanate (NDI), 1,5-tetrahydronaphthalene diisocyanate, para-phenylene diisocyanate (PPDI), 3,3' - dimethyldiphenyl-4, 4' -diisocyanate (DDDI), 4,4 '-dibenzyl diisocyanates,
• the polyurethane polymer chains are produced from diisocynates including HMDI, TDI, MDI, H12 aliphatics, and combinations thereof.
• the thermoplastic TPU can include polyester-based TPU, polyether-based TPU, polycaprolactone- based TPU, polycarbonate-based TPU, polysiloxane-based TPU, or combinations thereof.
• the polymeric layer can be formed of one or more of the following: EVOH copolymers, poly(vinyl chloride), polyvinylidene polymers and copolymers (e.g., polyvinylidene chloride), polyamides (e.g., amorphous polyamides), amide-based copolymers, acrylonitrile polymers (e.g., acrylonitrile-methyl acrylate copolymers), polyethylene terephthalate, polyether imides, polyacrylic imides, and other polymeric materials known to have relatively low gas transmission rates. Blends of these materials as well as with the TPU copolymers described herein and optionally including combinations of polyimides and crystalline polymers, are also suitable.
• the first barrier member 124 is further defined by a top surface 130, a bottom surface 132 formed on an opposite side of the first barrier member 124 than the top surface 132, and a peripheral side surface 134 extending between the top surface 130 and the bottom surface 132 and defining an outer periphery of the first barrier member 124.
• a thickness T124 of the first barrier member 124 is defined by the distance between the top surface 130 and the bottom surface 132.
• the second barrier member 126 is further defined by a bottom surface 136 corresponding to the lower surface 104 of the plate structure 100, a top surface 138 formed on an opposite side of the second barrier member 126 than the bottom surface 136, and a peripheral side surface 140 extending between the bottom surface 136 and the top surface 138 and defining an outer periphery of the second barrier member 126.
• a thickness T126 of the second barrier member 126 is defined by the distance between the bottom surface 136 and the top surface 138.
• the foam member 128 is further defined by a top surface 142, a bottom surface 144 formed on an opposite side of the foam member 128 than the top surface 142, and a peripheral side surface 146 extending between the top surface 142 and the bottom surface 144 and defining an outer periphery of the foam member 128.
• a thickness T128 of the foam member 128 is defined by the distance between the top surface 142 and the bottom surface 144.
• the first barrier member 124 and the second barrier member 126 can have thicknesses T124, T126 ranging from about 0.2 millimeters to about 0.4 millimeters.
• the foam member 128 can have a thickness T128 raging from about three millimeters to five millimeters.
• the thickness Two of the plate structure 100 has a maximum thickness of 3.5 millimeters.
• the thicknesses T124, T126 of the first barrier member 124 and the second barrier member 126 are different.
• the thicknesses T124, T126, T128 of the first barrier member 124, the second barrier member 126, and the foam member 128 are all different.
• the material thicknesses selected for the plate structure 100 may result in a variable stiffness. Specifically, the stiffness of the plate structure 100 may be tuned based on the respective thicknesses T124, T126, T128 of the first barrier member 124, the second barrier member 126, and the foam member 128.
• the thickness Two of the plate structure is increased, which results in a stiffer plate structure 100.
• the thickness T o of the plate structure is decreased, which results in a more flexible plate structure 100.
• the plate structure 100 includes the first barrier member 124 attached to the second barrier member 126 joined together at a peripheral edge 150 to define an interior void 148.
• the foam member 128 is disposed within and completely fills the interior void 148.
• the first barrier member 124, the second barrier member 126, and the foam member 128 are arranged in a layered configuration. Accordingly, the bottom surface 132 of the first barrier member 124 opposes and is attached to the top surface 142 of the foam member 128. Likewise, the top surface 138 of the second barrier member 126 opposes and is attached to the bottom surface 146 of the foam member 128.
• the foam member 128 shape generally corresponds to the shape of the first barrier element 124 and the second barrier element 126. Accordingly, the foam member 128 may be formed to extend within the one or more ribs 118, the corresponding spine 120, and the plurality of grooves 100.
• the layered configuration of the plate structure 100 may be a result of a simultaneous extrusion process 400.
• the simultaneous extrusion process 400 may include a plurality of hoppers 402a-402c that contain raw materials of each of the first barrier member 124, the second barrier member 126, and the foam member 128.
• Each material may be extruded through a corresponding extruder 404a-404c and enter a manifold 406 fit to a die 408.
• the die 408 subjects the extruded material to sufficient heat and/or pressure to fuse the first barrier member 124, the second barrier member 126, and the foam member 128 together as the materials exit the die 408.
• a cooling roll 410 receives the output material and cools the material to produce the layered configuration of the plate structure 100.
• additional layers such as adhesive are unnecessary to create the layered configuration, as the heat and/or pressure created by the simultaneous extrusion process 400 fuses the materials together.
• a chemical reaction to produce gas is activated in the foam member 128 extruder 404b as a result of a temperature reaching a threshold.
• the pressure within the manifold 406 and die 408 is higher than atmospheric, thereby compressing any activated gas within the manifold 406.
• the gas expands as the foam member 128 material exits the die 408.
• a physical foaming agent such as gas (i.e., nitrogen gas) is introduced into the hopper 404b of the extruder 404b, and is kept under pressure while within the die 408. This creates a significant pressure differential that acts on the gas as it exits the die 408 to expand as it enters atmospheric pressure.
• the layered configuration of the plate structure 100 may be the result of a calendering process 500. As shown in FIG. 5, each of the materials that form the first barrier member 124, the second barrier member 126, and the foam member 128 are separately extruded and cooled. The materials may then be processed through rolls 502 using heat and/or pressure to fuse the first barrier member 124, the second barrier member 126, and the foam member 128 together to form the layered configuration of the plate structure 100.
• the plate structure 100 may be shaped using a plate structure forming process 600.
• the plate structure forming process 600 may use a press 602 including an upper platen 604 having a contoured inside surface 608, and a lower platen 606 having a contoured inside surface 610.
• the upper platen 604 may be reciprocally movable relative to the lower platen 606 to operate the press 602 between an open position (e.g., FIG. 6A), when the upper platen 604 is the furthest away from the lower platen 606, and a closed position (e.g., FIG.
• the press 602 may further include a punching system 612 that operates to form a plurality of apertures 614 through the thickness Two of the plate structure 100 when in a punching position (FIG. 6C).
• FIG. 6 A shows step 600a, with the layered configuration of the plate structure 100 in a flat form, and the upper platen 604 of the press 602 in the open position.
• the upper platen 604 is lowered to meet with the lower platen 606 of the press 606 in the closed position (FIG. 6B).
• the inside surfaces 608, 610 of the press apply pressure to shape the flat form of the plate structure 100 into a formed structure.
• the punching system 612 is moved to the punching position to form a plurality of apertures 614 at step 600d.
• the formed structure of the plate structure 100 may exit the press 602 for further processing including an injection process 700.
• the formed structure of the plate structure 100 is incorporated into a chassis that is attached to an upper.
• the formed structure of the plate structure 100 may serve as a base for directly attaching traction elements 716 of a cleat structure 714.
• the injection process 700 may use a mold 702 including an upper plate 704 and a lower plate 706.
• the upper plate 704 may be rotatably movable relative to the lower plate 706 to operate the mold between an open position (e.g., FIG. 7A) when the upper plate 704 is rotated away from the lower plate 706 to a closed position (e.g., FIG. 7B) when the upper plate 704 is in direct contact with the lower plate 706. While in the closed position, an inside surface 708 of the upper plate 704 and an inside surface 710 of the upper plate 706 may oppose one another and form a cavity 712 for injection molding.
• FIG. 7A shows step 700a, with the formed structure of the plate structure 100 between the upper plate 704 and the lower plate 706 in the open position.
• the upper plate 704 is rotated toward the lower plate 706 in the closed position.
• the cleat structure 714 including a plurality of traction elements 716 is then injection molded onto the plate structure 100.
• the traction elements 716 of the cleat structure are directly molded onto the plate structure 100 through the plurality of apertures 614 formed by the punching system 612 (FIG. 7D).
• the upper plate 704 is rotated back to the open position and the plate structure 100 including the cleat structure 714 may exit the mold 702.
• the cleat structure 714 may define a profile of the ground-engaging surface and may at least partially cover the plate structure 100.
• an article of footwear 10 includes the plate structure 100, a cleat structure 714, and an upper 200 attached to the sole structure 100.
• the footwear 10 may further include an anterior end 12 associated with a forward-most point of the footwear 10, and a posterior end 14 corresponding to a rearward-most point of the footwear 10.
• a longitudinal axis Aw of the footwear 10 extends along a length of the footwear 10 from the anterior end 12 to the posterior end 14 parallel to a ground surface, and generally divides the footwear 10 into a medial side 16 and a lateral side 18. Accordingly, the medial side 16 and the lateral side 18 respectively correspond with opposite sides of the footwear 10 and extend from the anterior end 12 to the posterior end 14.
• a longitudinal direction refers to the direction extending from the anterior end 12 to the posterior end 14, while a lateral direction refers to the direction transverse to the longitudinal direction and extending from the medial side 16 to the lateral side 18.
• the article of footwear 10 may be divided into one or more regions.
• the regions may include a forefoot region 20, a mid-foot region 22, and a heel region 24.
• the forefoot region 20 may correspond with the phalanges and the metatarsal bones of a foot.
• the mid-foot region 22 may correspond with an arch area of the foot, and the heel region 24 may correspond with rear portions of the foot, including a calcaneus bone.
• the article of footwear 10 may be further described as including a peripheral region 26 and an interior region 28, as indicated in FIG. 1.
• the peripheral region 26 is generally described as being a region between the interior region 28 and an outer perimeter of the sole structure 100. Particularly, the peripheral region 26 extends from the forefoot region 20 to the heel region 24 along each of the medial side 16 and the lateral side 18, and wraps around each of the forefoot region 20 and the heel region 24.
• the interior region 28 is circumscribed by the peripheral region 26, and extends from the forefoot region 20 to the heel region 24 along a central portion of the sole structure 100. Accordingly, each of the forefoot region 20, the mid-foot region 22, and the heel region 24 may be described as including the peripheral region 26 and the interior region 28.
• the plate structure 100 may be incorporated into a chassis or be directly attached to the cleat structure 714 of an article of footwear 10.
• the upper 200 forms an enclosure having plurality of components that cooperate to define an interior void 202 and an ankle opening 204 in the heel region 24, which cooperate to receive and secure a foot for support on the plate structure 100.
• one or more fasteners 206 extend along the upper 200 to adjust a fit of the interior void 202 around the foot while concurrently accommodating entry and removal of the foot therefrom.
• the upper 200 may include apertures such as eyelets and/or other engagement features such as fabric or mesh loops that receive the fasteners 206.
• the fasteners 206 may include laces, straps, cords, hook-and-loop, or any other suitable type of fastener.
• the upper 200 may include a tongue portion 210 that extends between the interior void 202 and the fasteners 206.
• the upper 200 may be formed from one or more materials that are stitched or adhesively bonded together to define the interior void 202. Suitable materials of the upper 200 may include, but are not limited to, textiles, foam, leather, and synthetic leather.
• the example upper 200 may be formed from a combination of one or more substantially inelastic or non-stretchable materials and one or more substantially elastic or stretchable materials disposed in different regions of the upper 200 to facilitate movement of the article of footwear 10 between the tightened state and the loosened state.
• the one or more elastic materials may include any combination of one or more elastic fabrics such as, without limitation, spandex, elastane, rubber or neoprene.
• the one or more inelastic materials may include any combination of one or more of thermoplastic polyurethanes, nylon, leather, vinyl, or another material/fabric that does not impart properties of elasticity.
• a plate structure 100a is provided.
• like reference numerals are used hereinafter and in the drawings to identify like components while like reference numerals containing letter extensions are used to identify those components that have been modified.
• the plate structure 100a includes a first barrier member 124, a second barrier member 126 formed on opposite side of the plate structure 100a than the first barrier member 124, and a foam member 128 disposed between the first barrier member 124 and the second barrier member 126.
• the plate structure 100a further includes a first adhesive layer 125 disposed between the bottom surface 132 of the first barrier member 124 and the top surface 142 of the foam member 128, and a second adhesive layer 127 disposed between the bottom surface 144 of the foam member 128 and the top surface 138 of the second barrier member 126.
• the first adhesive layer 125 may further be defined by a top surface 152 and a bottom surface 154 formed on an opposite side of the first adhesive layer 125 than the top surface 152.
• a thickness T125 of the first adhesive layer 125 is defined by a distance between the top surface 152 and the bottom surface 154.
• the second adhesive layer 127 may further be defined by a top surface 156 and a bottom surface 158 formed on an opposite side of the second adhesive layer 127 than the top surface 156.
• a thickness T127 of the second adhesive layer 127 is defined by a distance between the top surface 156 and the bottom surface 158.
• the adhesive layers 125, 127 may be a hot meld adhesive, a cement, or the like. Accordingly, the adhesive layers 125, 127 operate to adhesively bond together the first barrier member 124, the second barrier member 126, and the foam member 128 to form the plate structure 100a. Like the thicknesses T 124, T 126 of the first barrier member 124 and the second barrier member 126, the thicknesses T125, T127 of the adhesive layers 125, 127 may be the same. Alternatively, one of the thicknesses T125, T127 of the adhesive layers 125, 127 may be different than the other of the adhesive layers 125, 127.
• the plate structure 100a includes the first barrier member 124 attached to the second barrier member 126 and joined together at a peripheral edge 150 to define an interior void 148.
• the foam member 128 is disposed within and completely fills the interior void 148.
• the first barrier member 124, the second barrier member 126, and the foam member 128 are arranged in a layered configuration. Accordingly, the bottom surface 132 of the first barrier member 124 opposes and is attached to the top surface 152 of the first adhesive layer 125. The bottom surface 154 of the first adhesive layer opposes and is attached to the top surface 142 of the foam member 128.
• the top surface 138 of the second barrier member 126 opposes and is attached to the bottom surface 158 of the second adhesive layer 127.
• the top surface 156 of the second adhesive layer 127 opposes and is attached to the bottom surface 146 of the foam member 128.
• the foam member 128 shape generally corresponds to the shape of the first barrier element 124 and the second barrier element 126.
• the plate structure 100a may further defined by thickness Twoa extending between the top surface 130 of the first barrier member 124 and the bottom surface 136 of the second barrier member 126.
• the respective thicknesses T124, T125, T128, T127, and T126 of the barrier member 124, the first adhesive layer 125, the foam member 128, the second adhesive layer 127, and the second barrier member 126 may further define the thickness Tiooa.
• the thicknesses T125, T127 of the adhesive layers is compressed into the foam member 128, resulting in a thickness Tiooa of the plate structure 100a that is substantially similar to the thickness Two of the plate structure 100.
• the adhesive layers 125, 127 may have a thickness that results in a thickness Tiooa of the plate structure 100a that is greater than the thickness T o of the plate structure 100.
• a plate structure 100b is provided.
• like reference numerals are used hereinafter and in the drawings to identify like components while like reference numerals containing letter extensions are used to identify those components that have been modified.
• the plate structure 100b includes additional foam members to reinforce the plate structure 100b.
• the plate structure 100b includes a first barrier member 124, a second barrier member 126 formed on opposite side of the plate structure 100a than the first barrier member 124, and a first foam member 166, a second foam member 168, a third foam member, a first adhesive layer 125, a second adhesive layer 127, a third adhesive layer 172, and a fourth adhesive layer 174 disposed between the first barrier member 124 and the second barrier member 126.
• the first foam member 166 may further be defined by a top surface 176 and a bottom surface 178 formed on an opposite side of the first foam member 166 than the top surface 176.
• a thickness Ti66 of the first foam member 166 is defined by a distance between the top surface 156 and the bottom surface 178.
• the second foam member 168 may be defined by a top surface 180 and a bottom surface 182 formed on an opposite side of the second foam member 168 than the top surface 180.
• a thickness Ties of the second foam member 168 is defined by a distance between the top surface 180 and the bottom surface 182.
• the third foam member 170 may be defined by a top surface 184 and a bottom surface 186 formed on an opposite side of the third foam member 170 than the top surface 184.
• a thickness Trio of the third foam member 170 is defined by a distance between the top surface 184 and the bottom surface 186.
• the third adhesive layer 172 may further be defined by a top surface 188 and a bottom surface 190 formed on an opposite side of the third adhesive layer 172 than the top surface 188.
• a thickness T172 of the third adhesive layer 172 is defined by a distance between the top surface 188 and the bottom surface 190.
• the fourth adhesive layer 174 may further be defined by a top surface 192 and a bottom surface 194 formed on an opposite side of the fourth adhesive layer 174 than the top surface 192.
• a thickness T174 of the fourth adhesive layer 174 is defined by a distance between the top surface 192 and the bottom surface 194.
• the plate structure 100b further includes the first barrier member 124 disposed on the first adhesive layer 125, the first adhesive layer 125 disposed on the first foam member 166, the first foam member 166 disposed on the third adhesive layer 172, the third adhesive layer 172 disposed on the second foam member 168, the second foam member 168 disposed on the fourth adhesive layer 174, the fourth adhesive layer 174 disposed on the third foam member 170, the third foam member 170 disposed on the second adhesive layer 127, and the second adhesive layer 127 disposed on the second barrier member 126.
• first barrier member 124, the first adhesive layer 125, the first foam member 166, the third adhesive layer 172, the second foam member 168, the fourth adhesive layer 174, the third foam member 170, the second adhesive layer 127, and the second barrier member 126 are arranged in a layered configuration.
• the adhesive layers 172, 174 may be a hot meld adhesive, a cement, or the like. Accordingly, the adhesive layers 125, 127, 172, 174 operate to adhesively bond together the first barrier member 124, the first foam member 166, the second foam member 168, the third foam member 170, and the second barrier member 126 to form the plate structure 100b. Like the thicknesses T125, T127 of the adhesive layers 125, 127, the thicknesses T172, T174 of the adhesive layers 172, 174 may be the same. Alternatively one of the thicknesses T125, T127, T172, T174 of the adhesive layers 125, 127, 172, 174 may be different than the other of the adhesive layers 125, 127, 172, 174.
• the plate structure 100b includes the first barrier member 124 attached to the second barrier member 126 and joined together at a peripheral edge 150 to define an interior void 148.
• the first foam member 166, the second foam member 168, and the third foam member 170 are disposed within and completely fill the interior void 148.
• the first barrier member 124, the first adhesive layer 125, the first foam member 166, the third adhesive layer 172, the second foam member 168, the fourth adhesive layer 174, the third foam member 170, the second adhesive layer 127, and the second barrier member 126 are arranged in a layered configuration.
• the first adhesive layer 125 is disposed between and attaches the bottom surface 132 of the first barrier member 124 to the top surface 176 of the first foam member 166
• the third adhesive layer 172 is disposed between and attaches the bottom surface 176 of the first foam member 166 to the top surface 180 of the second foam member 168
• the fourth adhesive layer 174 is disposed between and attaches the bottom surface 182 of the second foam member 168 and the top surface 184 of the third foam member 170
• the second adhesive layer 127 is disposed between and attaches the bottom surface 186 of the third foam member 170 to the top surface 138 of the second barrier member 126.
• a shape of the foam members 166, 168, 170 generally corresponds to the shape of the first barrier element 124 and the second barrier element 126.
• the plate structure 100b may further defined by thickness Tioob extending between the top surface 130 of the first barrier member 124 and the bottom surface 136 of the second barrier member 126.
• thickness Tioob extending between the top surface 130 of the first barrier member 124 and the bottom surface 136 of the second barrier member 126.
• the respective thicknesses T124, T125, Ti66, T172, Ties, T174, T170, T127, and T 126 of the first barrier member 124, the first adhesive layer 125, the first foam member 166, the third adhesive layer 172, the second foam member 168, the fourth adhesive layer 174, the third foam member 170, the second adhesive layer 127, and the second barrier member 126 may further define the thickness Twob.
• the thicknesses T125, T127, T172, T174, of the adhesive layers is compressed into the foam members 166, 168, 170, resulting in a thickness Twob of the plate structure 100a that is substantially similar to a thickness of barrier members 124, 126 and the foam members 166, 168, 170. Because the plate structure 100b includes more than one foam member 166, 168, 170, the thickness Twob of the plate structure 100b is greater than the thicknesses Two, Twoa of the plate structures 100, 100a.
• FIG. 11 shows the foam members 166, 168, 170 formed with the same thickness
• at least one of the foam members 166, 168, 170 is formed with a different thickness than the other of the foam members 166, 168, 170.
• the second foam member 168, disposed in the center of the plate structure 100b may include a greater thickness Ties than that of the first foam member 166 and the third foam member 170 to operate as a reinforcing layer for the plate structure 100b.
• a plate for an article of footwear comprising: a first film member; a second film member attached to the first film member to define an interior void between the first film member and the second film member; and a foam member disposed within and completely filling the interior void.
• Clause 2 The plate of Clause 1, wherein at least one of the first film member and the second film member is formed from thermoplastic polyurethane (TPU).
• TPU thermoplastic polyurethane
• Clause 4 The plate of any of the preceding Clauses, wherein at least two of the first film member, the second film member, and the foam member are formed from the same material.
• Clause 5. The plate of any of the preceding Clauses, wherein the first film member is attached to a first side of the foam member and the second film member is attached to a second side of the foam member, the second side being disposed on an opposite side of the foam member than the first side.
• Clause 6. The plate of Clause 5, further comprising a first adhesive disposed between the first film member and the first side of the foam member and a second adhesive disposed between the second film member and the second side of the foam member.
• Clause 7 The plate of Clause 6, wherein at least one of the first adhesive and the second adhesive is a hot melt adhesive.
• Clause 8 The plate of any of the preceding Clauses, wherein at least one of the first film member and the second film member defines a rib.
• a plate for an article of footwear comprising: a first film member; a second film member attached to the first film member to define an interior void between the first film member and the second film member; and a foam member disposed within the interior void and being formed from the same material as at least one of the first film member and the second film member.
• Clause 12 The plate of Clause 11, wherein at least one of the first film member and the second film member is formed from thermoplastic polyurethane (TPU).
• TPU thermoplastic polyurethane
• Clause 14 The plate of any of the preceding Clauses, wherein the first film member is attached to a first side of the foam member and the second film member is attached to a second side of the foam member, the second side being disposed on an opposite side of the foam member than the first side.
• Clause 15 The plate of Clause 14, further comprising a first adhesive disposed between the first film member and the first side of the foam member and a second adhesive disposed between the second film member and the second side of the foam member.
• Clause 16 The plate of Clause 15, wherein at least one of the first adhesive and the second adhesive is a hot melt adhesive.
• Clause 17 The plate of any of the preceding Clauses, wherein at least one of the first film member and the second film member defines a rib.
• Clause 18 The plate of Clause 17, wherein the foam member extends into the rib within the interior void.

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• Chemical & Material Sciences (AREA)
• Materials Engineering (AREA)
• Life Sciences & Earth Sciences (AREA)
• Wood Science & Technology (AREA)
• Laminated Bodies (AREA)

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• 2022
  • 2022-09-29 WO PCT/US2022/077294 patent/WO2023056381A1/en not_active Ceased
  • 2022-09-29 EP EP22794042.6A patent/EP4408231A1/de active Pending

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