US20220087362A1

US20220087362A1 - Footwear sole structure and upper with an embedded plate

Info

Publication number: US20220087362A1
Application number: US17/403,199
Authority: US
Inventors: Alex Bardini; Michael Wallans
Original assignee: Nike Inc
Current assignee: Nike Inc
Priority date: 2020-09-18
Filing date: 2021-08-16
Publication date: 2022-03-24
Also published as: EP4213675A1; WO2022060502A1; CN116157038A

Abstract

A sole structure includes an outsole defining an inner outsole surface and an outer outsole surface opposite the inner outer surface. The inner outsole surface is spaced apart from the outer outsole surface along a first direction. The sole structure further includes a midsole disposed on the outsole and a footwear plate is directly coupled to the midsole. The footwear plate includes a composite material and includes a first plate portion, a second plate portion is connected to the first plate portion, and a third plate portion is connected to the second plate portion. The second plate portion is connected between the first plate portion and the third plate portion. The second plate portion is obliquely angled relative to the first plate portion and the third plate portion so that the first plate portion is spaced apart from the third plate portion along the first direction.

Description

The application claims priority, and the benefit of, U.S. Provisional Patent Application No. 63/080,283, filed on Sep. 18, 2020.

TECHNICAL FIELD

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

BACKGROUND

This section provides background information related to the present disclosure which is not necessarily prior art.
Articles of footwear 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. A bottom portion of the upper, proximate to a bottom surface of the foot, attaches to the sole structure.
Sole structures include a layered arrangement extending between a ground surface and the upper. One layer of the sole structure includes an outsole that provides abrasion-resistance and traction with the ground surface. The outsole may be formed from rubber or other materials that impart durability and wear-resistance, as well as enhancing traction with the ground surface. Another layer of the sole structure includes a midsole disposed between the outsole and the upper. The midsole provides cushioning for the foot and is at least partially formed from a polymer foam material that compresses resiliently under an applied load to cushion the foot by attenuating ground-reaction forces. The midsole may define a bottom surface on one side that opposes the outsole and a footbed on the opposite side that may be contoured to conform to a profile of the bottom surface of the foot. Sole structures may also include a comfort-enhancing insole or a sockliner located within a void proximate to the bottom portion of the upper.
The metatarsophalangeal (MTP) joint of the foot is known to absorb energy as it flexes through dorsiflexion during running movements. As the foot does not move through plantarflexion until the foot is pushing off of a ground surface, the MTP joint returns little of the energy it absorbs to the running movement and, thus, is the source of an energy drain during running movements. Embedding flat and rigid plates having longitudinal stiffness within a sole structure increases the overall stiffness thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic illustration in lateral side view of an article of footwear in accordance with an embodiment of the present disclosure.

FIG. 2 is a schematic illustration in lateral side view of an article of footwear in accordance with another aspect of the present disclosure.

FIG. 3 is a schematic illustration in lateral side view of an article of footwear in accordance with another aspect of the present disclosure, wherein the midsole is configured as a drop-in midsole and is only disposed at the heel region of the sole structure.

FIG. 4 is a schematic illustration in lateral side view of an article of footwear in accordance with another aspect of the present disclosure, wherein the midsole is configured as a drop-in midsole and extends through the heel region, the midfoot region, and the forefoot region of the sole structure.

FIG. 5 is is a schematic illustration in lateral side view of an article of footwear in accordance with another aspect of the present disclosure, wherein the midsole is configured as a drop-in midsole and includes two discrete midsole parts spaced apart from each other.

FIG. 6 is a schematic illustration in lateral side view of an article of footwear in accordance with another aspect of the present disclosure, wherein the midsole is configured as a drop-in midsole and is only disposed at the forefoot region of the sole structure.

FIG. 7 is a flowchart of a method for manufacturing an article of footwear.

DESCRIPTION

The present disclosure describes an article of footwear, which may be used for football (or soccer as known in the United States), running, basketball, and or other sports.
In an aspect of the present disclosure, a sole structure includes an outsole defining an inner outsole surface and an outer outsole surface opposite the inner outer surface. The inner outsole surface is spaced apart from the outer outsole surface along a first direction. The sole structure further includes a midsole disposed on the outsole and a footwear plate is directly coupled to the midsole. The footwear plate includes a composite material. The footwear plate includes a first plate portion, a second plate portion is connected to the first plate portion, and a third plate portion is connected to the second plate portion. The second plate portion is connected between the first plate portion and the third plate portion. The second plate portion is obliquely angled relative to the first plate portion and the third plate portion so that the first plate portion is spaced apart from the third plate portion along the first direction to enhance stability of the sole structure while minimizing energy loss as the sole structure contacts a ground surface.
The midsole includes a midsole material. The composite material has a first stiffness. The midsole material has a second stiffness, and the first stiffness may be greater than the second stiffness.
The midsole defines an inner midsole surface and an outer midsole surface opposite the inner midsole surface. The inner midsole surface faces the upper. The outer midsole surface faces away from the upper. The midsole defines a midsole thru-hole extending from the inner midsole surface to the outer midsole surface of the midsole. The second plate portion is disposed inside the midsole thru-hole of the midsole. The first plate portion is disposed in the forefoot region of the sole structure. The third plate portion is disposed in the heel region of the sole structure. The second plate portion is disposed in the midfoot region of the sole structure.
The third plate portion is disposed on top of the midsole. The second plate portion is disposed between the inner midsole surface and the outer midsole surface of the midsole. The midsole thru-hole is obliquely angled relative to the inner midsole surface and the outer midsole surface.
The midsole defines a midsole longitudinal recess in communication with the midsole thru-hole, the midsole longitudinal recess is adjacent the outsole. The midsole longitudinal recess is disposed in the forefoot region of the sole structure. The first plate portion is at least partially disposed in the midsole longitudinal recess to maximize energy return during toe off. The first plate portion is spaced apart from the second plate portion along a second direction. The second direction is perpendicular to the first direction. The outsole is elongated along the second direction.
The outsole defines an inner outsole surface and an outer outsole surface opposite the inner outsole surface. The inner outsole surface faces the upper. The outer outsole surface faces away from the upper. The third plate portion is in direct contact with the inner outsole surface of the outsole. The midsole longitudinal recess is elongated along a second direction. The second direction is perpendicular to the first direction.
The midsole defines an inner midsole surface and an outer midsole surface opposite the inner midsole surface. The inner midsole surface faces the upper. The outer midsole surface faces away from the upper. The midsole defines a midsole opening extending from the inner midsole surface into the midsole. The midsole opening does not extend through an entirety of a thickness of the midsole. The second plate portion is disposed inside the midsole opening of the midsole, and the third plate portion is disposed on top of the inner midsole surface at the heel region of the sole structure.
The first plate portion is disposed at the forefoot region of the sole structure, the first plate portion is disposed inside the midsole, and the first plate portion is closer to the inner midsole surface than to the outer midsole surface of the midsole.
The midsole is configured as a drop-in midsole, the midsole is entirely disposed inside the interior void of the upper, the third plate portion is disposed inside the midsole, and the first plate portion is disposed inside the outsole.
The midsole is only disposed at the heel region of the sole structure. The midsole extends through the heel region, the midfoot region, and the forefoot region. The midsole includes a first midsole part and a second midsole part spaced apart from each other along the longitudinal axis to define a gap therebetween, and the gap receives the second plate portion of the footwear plate.
In an aspect of the present disclosure, an article of footwear includes an upper defining an interior void and an ankle opening in communication with the interior void. The article of footwear further includes a sole structure coupled to the upper. The sole structure includes a forefoot region, a midfoot region, and a heel region, the midfoot region is disposed between the forefoot region and the heel region. The sole structure includes an outsole defining an inner outsole surface and an outer outsole surface opposite the inner outer surface. The inner outsole surface is spaced apart from the outer outsole surface along a first direction. The sole structure further includes a midsole disposed on the outsole and a footwear plate is coupled to the midsole. The footwear plate includes a composite material and includes a first plate portion, a second plate portion directly connected to the first plate portion, and a third plate portion directly connected to the second plate portion. The second plate portion is connected between the first plate portion and the third plate portion. The second plate portion is obliquely angled relative to the first plate portion and the third plate portion so that the first plate portion is spaced apart from the third plate portion along the first direction to enhance stability of the sole structure while minimizing energy loss of the sole structure as the article of footwear contacts a ground surface.
The midsole defines an inner midsole surface and an outer midsole surface opposite the inner midsole surface. The inner midsole surface faces the upper. The outer midsole surface faces away from the upper. The midsole defines a midsole thru-hole extending from the inner midsole surface to the outer midsole surface of the midsole. The second plate portion is disposed inside the midsole thru-hole of the midsole. The first plate portion is disposed in the forefoot region of the sole structure. The third plate portion is disposed in the heel region of the sole structure. The second plate portion is disposed in the midfoot region of the sole structure.
The third plate portion is disposed on top of the midsole, the second plate portion is disposed between the inner midsole surface and the outer midsole surface of the midsole. The midsole thru-hole is obliquely angled relative to the inner midsole surface and the outer midsole surface.
The midsole defines a midsole longitudinal recess in communication with the midsole thru-hole. The midsole longitudinal recess is adjacent the outsole, the midsole longitudinal recess is disposed in the forefoot region of the sole structure. The first plate portion is at least partially disposed in the midsole longitudinal recess to maximize energy return during toe off.
The outsole defines an inner outsole surface and an outer outsole surface opposite the inner outsole surface. The inner outsole surface faces the upper. The outer outsole surface faces away from the upper. The third plate portion is in direct contact with the inner outsole surface of the outsole. The midsole longitudinal recess is elongated along a second direction. The second direction is perpendicular to the first direction.
The midsole defines an inner midsole surface and an outer midsole surface opposite the inner midsole surface, the inner midsole surface faces the upper. The outer midsole surface faces away from the upper. The midsole defines a midsole opening extending from the inner midsole surface into the midsole, the midsole opening does not extend through an entirety of a thickness of the midsole, and the second plate portion is disposed inside the midsole opening of the midsole, and the third plate portion is disposed on top of the inner midsole surface at the heel region of the sole structure.
The first plate portion is disposed at the forefoot region of the sole structure, the first plate portion is disposed inside the midsole, and the first plate portion is closer to the inner midsole surface than to the outer midsole surface of the midsole.
The midsole is configured as a drop-in midsole, the midsole is entirely disposed inside the interior void of the upper. The third plate portion is disposed inside the midsole, and the first plate portion is disposed inside the outsole. The midsole may only be disposed at the heel region of the sole structure. The midsole extends through the heel region, the midfoot region, and the forefoot region. The midsole includes a first midsole part and a second midsole part spaced apart from each other along the longitudinal axis to define a gap therebetween. The gap receives the second plate portion of the footwear plate.
The present disclosure also describes a method of manufacturing an article of footwear. The method includes inserting a footwear plate through an opening of a midsole to directly couple the footwear plate to the midsole. The opening of the midsole is a thru-hole extending along an entirety of a thickness of the midsole. Alternatively, the opening of the midsole extends along a portion of a thickness of the midsole. The footwear plate includes a composite material. The footwear plate includes a first plate portion, a second plate portion is connected to the first plate portion, and a third plate portion is connected to the second plate portion. The second plate portion is connected between the first plate portion and the third plate portion. The second plate portion is obliquely angled relative to the first plate portion and the third plate portion so that the first plate portion is spaced apart from the third plate portion along a first direction. The method further includes attaching the midsole to the outsole. The outsole is elongated along a longitudinal axis. The first direction is perpendicular to the longitudinal axis. The sole structure includes the midsole and the outsole. The sole structure has a forefoot region, a heel region, and a midfoot region between the forefoot region and the heel region. The opening of the midsole is disposed at the midfoot region of the sole structure. The method further includes attaching an upper to the sole structure.
The above features and advantages and other features and advantages of the present teachings are readily apparent from the following detailed description of the modes for carrying out the present teachings when taken in connection with the accompanying drawings.
Example configurations will now be described more fully with reference to the accompanying drawings. Example configurations are provided so that this disclosure will be thorough, and will fully convey the scope of the disclosure to those 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.
The terminology used herein is for the purpose of describing particular exemplary configurations only and is not intended to be limiting. As used herein, the singular articles “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of features, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. Additional or alternative steps may be employed.
When an element or layer is referred to as being “on,” “engaged to,” “connected to,” “attached to,” or “coupled to” another element or layer, it may be directly on, engaged, connected, attached, or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” “directly attached to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.
The terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections. These elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, 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.
Referring to FIG. 1, an article of footwear 10 includes an upper 100 and a sole structure 200 coupled to the upper 100. The article of footwear 10 (and its components, such as the upper 100 and the sole structure 200) may be divided into one or more portions. The portions may include a forefoot region 12, a midfoot region 14, and a heel region 16. The forefoot region 12 may correspond with toes and joints connecting metatarsal bones with phalanx bones of a foot during use of the footwear 10. The forefoot region 12 may correspond with the metatarsophalangeal (MTP) joint of the foot. The midfoot region 14 may correspond with an arch area of the foot. The heel region 16 may correspond with rear portions of the foot, including a calcaneus bone, during use of the article of footwear 10. The midfoot region 14 is therefore between the forefoot region 12 and the heel region 16. The footwear 10 may include lateral and medial sides, respectively, corresponding with opposite sides of the footwear 10 and extending through the portions 12, 14, 16.
The upper 100 includes interior surfaces that define an interior void 102 that receives and secures a foot for support on the sole structure 200 during use of the article of footwear 10. An ankle opening 104 in the heel region 16 may provide access to the interior void 102. For example, the ankle opening 104 may receive a foot to secure the foot within the void 102 and facilitate entry and removal of the foot to and from the interior void 102. In some examples, one or more fasteners, such as laces, extend along the upper 100 to adjust a fit of the interior void 102 around the foot while concurrently accommodating entry and removal of the foot therefrom. The upper 100 may include apertures 106 such as eyelets and/or other engagement features such as fabric or mesh loops that receive the fasteners 107. The fasteners 107 may include laces, straps, cords, hook-and-loop, or any other suitable type of fastener 107. The upper 100 may also include a heel cup at the heel region 16 to support the heel of the footwear user.
The upper 100 may include a tongue portion 110 that extends between the interior void 102 and the apertures 106. The upper 100 may be formed from one or more materials (i.e., the upper material) that are stitched or adhesively bonded together to form the interior void 102. Suitable materials of the upper may include, but are not limited to, textiles, fabrics, foam, leather, and synthetic leather. The materials may be selected and located to impart properties of durability, air-permeability, wear-resistance, flexibility, and comfort.
In some implementations, the sole structure 200 may include an outsole 204 configured to contact the ground. The sole structure 200 is oriented (e.g., elongated) along a longitudinal axis L that extends lengthwise between a forward terminal end 13 of the forefoot region 12 and a rearward terminal end 15 of the heel region 16. The outsole 204 may be a one-piece structure to enhance its structural integrity or a plurality of discrete outsole members to enhance traction at specific, discrete locations of the sole structure 200.
The outsole 204 generally provides abrasion-resistance and traction with the ground during use of the article of footwear 10 and includes a main outsole body 210. The main outsole body 210 includes a lower/ground-engaging surface 212 and an opposite upper/inner surface 214. The outsole 204 further includes one or more traction elements 215, such as spikes, cleats, and/or treads, each configured to enhance the traction of the article of footwear 10 when the outsole 204 contacts the ground. The outsole 204 may be formed from one or more materials that impart durability and wear-resistance, as well as enhance traction with the ground surface. For example, the outsole 204 may be formed from a polymeric material including at least one of a rubber, a polyurethane, an ionomer, and/or an engineering plastic. For example, at least a portion of the outsole 204 may comprise a rubber.
In some examples, one or more traction elements 215 (e.g., spike, treads, and/or cleats) extend directly from the main outsole body 210 in a direction away from the upper 100 to provide traction with ground surfaces, such as grass, and enhance the structural integrity of the outsole 204. For instance, in some embodiments, each traction element 215 may attach to the main outsole body 210 of the outsole 204 and extend in a vertical direction V that is perpendicular or least substantially perpendicular to the longitudinal axis L of the sole structure 200. The longitudinal axis L is parallel to the longitudinal direction LG. The longitudinal direction LG is perpendicular to the vertical direction V. The vertical direction V may be referred to as the first direction, and the longitudinal direction LG may be referred to as the second direction. In the example shown, the traction elements 215 extend through the heel region 16, the midfoot region 14, and the forefoot region 12 of the sole structure 200 to provide traction along the entire sole structure 200. It is envisioned, however, that the traction elements 215 may be disposed at spaced apart locations along the outsole 204 to provide traction at high wear areas of the sole structure 200.
The sole structure 200 may include a midsole 206 for providing cushioning to the footwear user. To this end, the midsole 206 may be made of a polymeric material, such as rubber or foam. As a non-limiting example, the midsole 206 may be wholly or partially made of an ethylene-vinyl acetate (EVA) foam to enhance cushioning of the sole structure 200. The midsole 206 may continuously extend along the forefoot region 12, the midfoot region 14, and the heel region 16 to provide cushioning along the entire foot of the footwear wearer. The midsole 206 is disposed over the outsole 204 and includes a midsole body 208 having an inner midsole surface 209 and an outer midsole surface 211 opposite the inner midsole surface 209. It is contemplated that the midsole 206 may be secured to the outsole 204 and is exposed outside of the sole structure 200. As a non-limiting example, adhesives, stitching, and/or thermal bonds may be used to secure the midsole 206 to the outsole 204.
The sole structure 200 may further include a strobel board 220 disposed over the midsole 206. The strobel board 220 may include a bottom/ground-facing surface 222 and an opposite upper/footbed surface 224. The strobel board 220 may be secured to the upper 100, at least in part through the use of stitching and/or adhesives that attach the strobel board 220 to the upper 100. In some embodiments, at least a portion of the upper 100 (e.g., a fabric that is continuous with a sidewall of the upper 100) may extend around the strobel board 220 such that it lies between the strobel board 220 and the outsole 204.
The sole structure 200 may further include a footwear plate 300 directly connected to the midsole 206 to provide energy-return properties to the sole structure 200. By directly connecting the footwear plate 300 to the midsole 206, the energy can be easily transferred from the footwear plate 300 to the midsole 206. For instance, the footwear plate 300 may be in direct contact the midsole 206. Specifically, at least a portion of the footwear plate 300 may be disposed between the midsole 206 and the strobel board 220. The footwear plate 300 may be partly or wholly made of a composite material, such as a carbon fiber composite, to enhance the stiffness of the article of footwear 10. For this reason, the footwear plate 300 may be referred to as the composite plate. As used herein, the term “composite material” means a material made from two or more constituent materials with significantly different physical or chemical properties that, when combined, produce a material with characteristics different from the individual components, while the individual components remain separate and distinct within the finished structure, differentiating composites from mixtures and solid solutions. The footwear plate 300 may be wholly or partly made of a plate material, such as carbon fiber-reinforced polymer, that is stiffer than an upper material forming the upper 100, a midsole material forming the midsole 206, and than the outsole material forming the outsole 204 to enhance the stability of the sole structure 200. In other words, the stiffness of the plate material is greater than the stiffness of the upper material of the upper 100, the stiffness of the midsole material forming the midsole 206, and than the stiffness of the outsole material forming the outsole 204 to enhance the stability of the sole structure 200, while providing the sole structure 200 with energy-return properties. The footwear plate 300 is part of the sole structure 200 to reduce energy loss at the MTP joint while enhancing rolling of the foot as the footwear 10 rolls for engagement with a ground surface during a running motion. The footwear plate 300 may define a length extending through at least a portion of the length of the sole structure 200. In some examples, the length of the plate 300 extends through the forefoot, midfoot, and heel portions 12, 14, 16 of the sole structure 200 to enhance the structural integrity of the sole structure 200. The footwear plate 300 is oriented along the longitudinal axis L that extends lengthwise between the forward terminal end 13 of the forefoot region 12 and the rearward terminal end 15 of the heel region 16. In other examples, the length of the plate 300 extends through the forefoot region 12 and the midfoot region 14, and is absent from the heel region 16. The footwear plate 300 can function as an innersole and a chassis. The footwear plate 300 may have a thickness extending along the vertical direction V and a width extending between the lateral side and the medial side of the sole structure 200.
The footwear plate 300 may include a forefoot or first plate portion 302, a midfoot or second plate portion 304 directly connected to the first plate portion 302, and a heel or third plate portion 306 directly connected to the second plate portion 304. The first plate portion 302 may be entirely disposed in the forefoot region 12 of the sole structure 200. The second plate portion 304 may be entirely disposed in the midfoot region 14 of the sole structure 200. The third plate portion 306 may be entirely disposed in the heel region 16 of the sole structure 200. The third plate portion 306 is entirely disposed inside the interior void 102 at the heel region 12 of the sole structure 200 to attenuate the impact to the foot of the footwear wearer during a heel strike. The first plate portion 302 and the second plate portion 304 may be exposed so that the footwear plate 300 is at least partially visible. The second plate portion 304 may be obliquely angled relative to the first plate portion 302 and the third plate portion 304. As such, the first plate portion 302 is spaced apart from the third plate portion 306 along the vertical direction V (i.e., the first direction) to enhance the stability of the sole structure 200 while minimizing energy loss as the article of footwear contacts a ground surface GS.
The midsole 206 defines a thru-hole 216, such as a slit, entirely disposed in the midfoot region 14 to receive the second plate portion 304 of the footwear plate 300 As such, the thru-hole 216 extends from the inner midsole surface 209 to the outer midsole surface 211 of the midsole body 208. The second plate portion 304 may be entirely disposed inside the thru-hole 216 of the midsole 206. To receive the second plate portion 304, the thru-hole 216 may be obliquely angled relative to the inner midsole surface 209 and the outer midsole surface 211. The third plate portion 306 is disposed on top of the midsole 206 at the heel region 16 to minimize energy loss during a heel strike. The second plate portion 304 is disposed between the inner midsole surface 209 and the outer midsole surface 211.
The midsole 206 defines a midsole longitudinal recess 218 in communication with the midsole thru-hole 216. The midsole longitudinal recess 218 is adjacent the outsole 204 and is elongated along the longitudinal direction LG (i.e., the second direction). The midsole longitudinal recess 218 may be only disposed at the forefoot region 12 of the sole structure 200 to maximize energy return during toe off. The first plate portion 302 is at least partially disposed in the midsole longitudinal recess 218 to maximize energy return during toe off. The outsole 204 has an inner outsole surface 226 facing the upper 100 and an outer outsole surface 228 facing away from the upper 100. The first plate portion 302 may be in direct contact with the inner outsole surface 226 of the outsole 204 to maximize energy return during toe off.
FIG. 2 shows an article of footwear 10 that is substantially identical to the article of footwear 10 described above with respect to FIG. 1, except for the features described below. Instead of the thru-hole 216, the midsole 206 defines a midsole opening 207 extending from the inner midsole surface 209 toward (but not through) the outer midsole opening 211. In other words the midsole opening 207 does not extend through the entire thickness of the midsole 206. The second plate portion 304 is disposed inside the midsole opening 207. The third plate portion 306 is disposed on top of the inner midsole surface 209 to absorb energy during the heel strike. As discussed above, the first plate portion 302 is disposed at the forefoot region 12 of the sole structure 200. The first plate portion 302 may be entirely disposed inside the midsole 206 and may be closer to the inner midsole surface 209 than to the outer midsole surface 211 of the midsole 206 to absorb energy during toe off.
FIG. 3 shows an article of footwear 10 that is substantially identical to the article of footwear 10 described above with respect to FIG. 1, except for the features described below. The midsole 206 is configured as a drop-in midsole. Therefore, the midsole 206 is entirely disposed inside the interior void 102. Further, the midsole 206 is only disposed at the heel region 16 of the sole structure 200. The third plate portion 306 may be entirely disposed inside the midsole 206, and the first plate portion 302 may be entirely disposed inside the outsole 204. The configuration of the sole structure 200 as described above facilitates energy absorption at the heel region 16 during a heel strike and maximizes energy return during toe off while minimizing parts counts of the sole structure 200.
FIG. 4 shows an article of footwear 10 that is substantially identical to the article of footwear 10 described above with respect to FIG. 3, except for the features described below. The midsole 206 is configured as a drop-in midsole. Therefore, the midsole 206 is entirely disposed inside the interior void 102. Further, the midsole 206 extends continuously through, the heel region 16, the midfoot region 14, and then forefoot region 12 of the sole structure 200. The third plate portion 306 may be entirely disposed inside the midsole 206, and the first plate portion 302 may be entirely disposed inside the outsole 204. The configuration of the sole structure 200 as described above facilitates energy absorption at the heel region 16 during a heel strike and maximizes energy return at the forefoot region 12 during toe off while providing cushioning throughout the entire length of the sole structure 200.
FIG. 5 shows an article of footwear 10 that is substantially identical to the article of footwear 10 described above with respect to FIG. 3, except for the features described below. The midsole 206 is configured as a drop-in midsole. Therefore, the midsole 206 is entirely disposed inside the interior void 102. However, the midsole 206 includes two discrete parts (i.e., the first midsole part 206 a and the second midsole part 206 b). The first midsole part 206 a and the second midsole part 206 b are spaced apart from each other along the longitudinal axis L to define a gap G therebetween. The gap G is located at the midfoot region 14 of the sole structure 200 to receive the second plate portion 304. The first midsole part 206 a extends along the entire heel region 16, and the second midsole part 206 b extends along the entire forefoot region 12. The third plate portion 306 may be entirely disposed inside the midsole 206, and the first plate portion 302 may be entirely disposed inside the outsole 204. The configuration of the sole structure 200 as described above facilitates energy absorption at the heel region 16 during a heel strike and maximizes energy return at the forefoot region 12 during toe off while providing cushioning at the heel region 16 and the forefoot region 12 of the sole structure 200.
FIG. 6 shows an article of footwear 10 that is substantially identical to the article of footwear 10 described above with respect to FIG. 3, except for the features described below. The midsole 206 is configured as a drop-in midsole. Therefore, the midsole 206 is entirely disposed inside the interior void 102. Further, the midsole 206 is only disposed at the forefoot region 12 of the sole structure 200. The first plate portion 302 may be entirely disposed inside the midsole 206, and the third plate portion 306 may be entirely disposed inside the outsole 204. The configuration of the sole structure 200 as described above facilitates energy absorption at the forefoot region 12 during toe off and maximizes energy return during a heel strike while minimizing parts counts of the sole structure 200.
FIG. 7 illustrates a flowchart of a method 400 for manufacturing the article of footwear 10. The method 400 begins at block 402. At block 402, the footwear plate 300 is inserted through an opening (e.g., thru-hole 216 or midsole opening 207) of the midsole 206. This opening may extend through a portion or the entire thickness of the midsole 206. This opening is disposed at the midfoot region 14 of the midsole 206. It is envisioned that the upper 100 may be wrapped around the footwear plate 300. After block 402, the method 400 continues to block 404. At block 404. The midsole 206 is attached to the outsole 204. As discussed above, the outsole 204 is elongated along the longitudinal axis LG or the second direction LG. To do so, the midsole 206 may be stitched, glued, and/or thermally bonded to the outsole 204. Alternatively, the midsole 206 may be a drop-in midsole. In this case, the midsole 206 is simply placed on top (but not secured to) the outsole 204. At block 404, the strobel board 204 may be disposed on top of the midsole 206. The method 400 then continues to block 406. At block 406, the upper 100 is connected to the sole structure 200. To do so, the upper 100 may be stitched, glued, and/or thermally bonded to the sole structure 200.
To assist and clarify the description of various embodiments, various terms are defined herein. Unless otherwise indicated, the following definitions apply throughout this specification (including the claims). Additionally, all references referred to are incorporated herein in their entirety.
An “article of footwear”, a “footwear article of manufacture”, and “footwear” may be considered to be both a machine and a manufacture. Assembled, ready to wear footwear articles (e.g., shoes, sandals, boots, etc.), as well as discrete components of footwear articles (such as a midsole, an outsole, an upper component, etc.) prior to final assembly into ready to wear footwear articles, are considered and alternatively referred to herein in either the singular or plural as “article(s) of footwear” or “footwear”.
“A”, “an”, “the”, “at least one”, and “one or more” are used interchangeably to indicate that at least one of the items is present. A plurality of such items may be present unless the context clearly indicates otherwise. All numerical values of parameters (e.g., of quantities or conditions) in this specification, unless otherwise indicated expressly or clearly in view of the context, including the appended claims, are to be understood as being modified in all instances by the term “about” whether or not “about” actually appears before the numerical value. “About” indicates that the stated numerical value allows some slight imprecision (with some approach to exactness in the value; approximately or reasonably close to the value; nearly). If the imprecision provided by “about” is not otherwise understood in the art with this ordinary meaning, then “about” as used herein indicates at least variations that may arise from ordinary methods of measuring and using such parameters. As used in the description and the accompanying claims, unless stated otherwise, a value is considered to be “approximately” equal to a stated value if it is neither more than 5 percent greater than nor more than 5 percent less than the stated value. In addition, a disclosure of a range is to be understood as specifically disclosing all values and further divided ranges within the range.
The terms “comprising”, “including”, and “having” are inclusive and therefore specify the presence of stated features, steps, operations, elements, or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, or components. Orders of steps, processes, and operations may be altered when possible, and additional or alternative steps may be employed. As used in this specification, the term “or” includes any one and all combinations of the associated listed items. The term “any of” is understood to include any possible combination of referenced items, including “any one of” the referenced items. The term “any of” is understood to include any possible combination of referenced claims of the appended claims, including “any one of” the referenced claims.
For consistency and convenience, directional adjectives may be employed throughout this detailed description corresponding to the illustrated embodiments. Those having ordinary skill in the art will recognize that terms such as “above”, “below”, “upward”, “downward”, “top”, “bottom”, etc., may be used descriptively relative to the figures, without representing limitations on the scope of the invention, as defined by the claims.
The term “longitudinal” refers to a direction extending along a length of a component. For example, a longitudinal direction of an article of footwear extends between a forefoot region and a heel region of the article of footwear. The term “forward” or “anterior” is used to refer to the general direction from a heel region toward a forefoot region, and the term “rearward” or “posterior” is used to refer to the opposite direction, i.e., the direction from the forefoot region toward the heel region. In some cases, a component may be identified with a longitudinal axis as well as a forward and rearward longitudinal direction along that axis. The longitudinal direction or axis may also be referred to as an anterior-posterior direction or axis.
The term “transverse” refers to a direction extending along a width of a component. For example, a transverse direction of an article of footwear extends between a lateral side and a medial side of the article of footwear. The transverse direction or axis may also be referred to as a lateral direction or axis or a mediolateral direction or axis.
The term “vertical” refers to a direction generally perpendicular to both the lateral and longitudinal directions. For example, in cases where a sole structure is planted flat on a ground surface, the vertical direction may extend from the ground surface upward. It will be understood that each of these directional adjectives may be applied to individual components of a sole structure. The term “upward” or “upwards” refers to the vertical direction pointing towards a top of the component, which may include an instep, a fastening region and/or a throat of an upper. The term “downward” or “downwards” refers to the vertical direction pointing opposite the upwards direction, toward the bottom of a component and may generally point towards the bottom of a sole structure of an article of footwear.
The “interior” of an article of footwear, such as a shoe, refers to portions at the space that is occupied by a wearer's foot when the article of footwear is worn. The “inner side” of a component refers to the side or surface of the component that is (or will be) oriented toward the interior of the component or article of footwear in an assembled article of footwear. The “outer side” or “exterior” of a component refers to the side or surface of the component that is (or will be) oriented away from the interior of the article of footwear in an assembled article of footwear. In some cases, other components may be between the inner side of a component and the interior in the assembled article of footwear. Similarly, other components may be between an outer side of a component and the space external to the assembled article of footwear. Further, the terms “inward” and “inwardly” refer to the direction toward the interior of the component or article of footwear, such as a shoe, and the terms “outward” and “outwardly” refer to the direction toward the exterior of the component or article of footwear, such as the shoe. In addition, the term “proximal” refers to a direction that is nearer a center of a footwear component, or is closer toward a foot when the foot is inserted in the article of footwear as it is worn by a user. Likewise, the term “distal” refers to a relative position that is further away from a center of the footwear component or is further from a foot when the foot is inserted in the article of footwear as it is worn by a user. Thus, the terms proximal and distal may be understood to provide generally opposing terms to describe relative spatial positions.
While various embodiments have been described, the description is intended to be exemplary, rather than limiting and it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible that are within the scope of the embodiments. Any feature of any embodiment may be used in combination with or substituted for any other feature or element in any other embodiment unless specifically restricted. Accordingly, the embodiments are not to be restricted except in light of the attached claims and their equivalents. Also, various modifications and changes may be made within the scope of the attached claims.
While several modes for carrying out the many aspects of the present teachings have been described in detail, those familiar with the art to which these teachings relate will recognize various alternative aspects for practicing the present teachings that are within the scope of the appended claims. It is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and exemplary of the entire range of alternative embodiments that an ordinarily skilled artisan would recognize as implied by, structurally and/or functionally equivalent to, or otherwise rendered obvious based upon the included content, and not as limited solely to those explicitly depicted and/or described embodiments.

Claims

What is claimed is:

1. A sole structure, comprising:

an outsole defining an inner outsole surface and an outer outsole surface opposite the inner outsole surface, and the inner outsole surface is spaced apart from the outer outsole surface along a first direction;

a midsole disposed on the outsole;

a footwear plate is directly coupled to the midsole, wherein the footwear plate includes a composite material and includes a first plate portion, a second plate portion is connected to the first plate portion, and a third plate portion is connected to the second plate portion, and the second plate portion is connected between the first plate portion and the third plate portion; and

wherein the second plate portion is obliquely angled relative to the first plate portion and the third plate portion so that the first plate portion is spaced apart from the third plate portion along the first direction to enhance stability of the sole structure while minimizing energy loss as the sole structure contacts a ground surface.

2. The sole structure of claim 1, wherein the midsole includes a midsole material, the composite material has a first stiffness, the midsole material has a second stiffness, and the first stiffness is greater than the second stiffness.

3. The sole structure of claim 1, wherein the midsole defines an inner midsole surface and an outer midsole surface opposite the inner midsole surface, the midsole defines a midsole thru-hole extending from the inner midsole surface to the outer midsole surface of the midsole, the second plate portion is disposed inside the midsole thru-hole of the midsole, the first plate portion is disposed at a forefoot region of the sole structure, the third plate portion is disposed at a heel region of the sole structure, and the second plate portion is disposed in a midfoot region of the sole structure, the third plate portion is disposed on top of the midsole, the second plate portion is disposed between the inner midsole surface and the outer midsole surface of the midsole, and the midsole thru-hole is obliquely angled relative to the inner midsole surface and the outer midsole surface, the first plate portion is spaced apart from the second plate portion along a second direction, the second direction is perpendicular to the first direction, and the outsole is elongated along the second direction.

4. The sole structure of claim 3, wherein the midsole defines a midsole longitudinal recess in communication with the midsole thru-hole, the midsole longitudinal recess is adjacent the outsole, the midsole longitudinal recess is disposed in the forefoot region of the sole structure, and the first plate portion is at least partially disposed in the midsole longitudinal recess to maximize energy return during toe off.

5. The sole structure of claim 4, wherein the outsole defines an inner outsole surface and an outer outsole surface opposite the inner outsole surface the third plate portion is in direct contact with the inner outsole surface of the outsole, the midsole longitudinal recess is elongated along the second direction, and the second direction is perpendicular to the first direction.

6. The sole structure of claim 1, wherein the midsole defines an inner midsole surface and an outer midsole surface opposite the inner midsole surface, the midsole defines a midsole opening extending from the inner midsole surface into the midsole, the midsole opening does not extend through an entirety of a thickness of the midsole, and the second plate portion is disposed inside the midsole opening of the midsole, and the third plate portion is disposed on top of the inner midsole surface at a heel region of the sole structure.

7. The sole structure of claim 6, wherein the first plate portion is disposed at a forefoot region of the sole structure, the first plate portion is disposed inside the midsole, and the first plate portion is closer to the inner midsole surface than to the outer midsole surface of the midsole.

8. The sole structure of claim 1, wherein the midsole is configured as a drop-in midsole, the midsole is entirely disposed inside an interior void of an upper, the third plate portion is disposed inside the midsole, and the first plate portion is disposed inside the outsole.

9. The sole structure of claim 8, wherein the midsole is only disposed at a heel region of the sole structure.

10. The sole structure of claim 8, wherein the midsole extends through a heel region, a midfoot region, and a forefoot region of the sole structure.

11. The sole structure of claim 8, wherein the midsole includes a first midsole part and a second midsole part spaced apart from each other along a longitudinal axis of the sole structure to define a gap therebetween, and the gap receives the second plate portion of the footwear plate.

12. An article of footwear, comprising:

an upper defining an interior void and an ankle opening in communication with the interior void;

a sole structure coupled to the upper, wherein the sole structure includes a forefoot region, a midfoot region, and a heel region, the midfoot region is disposed between the forefoot region and the heel region, and the sole structure includes:

a midsole disposed on the outsole;

a footwear plate is coupled to the midsole, wherein the footwear plate includes a composite material and includes a first plate portion, a second plate portion directly connected to the first plate portion, and a third plate portion directly connected to the second plate portion, and the second plate portion is connected between the first plate portion and the third plate portion; and

wherein the second plate portion is obliquely angled relative to the first plate portion and the third plate portion so that the first plate portion is spaced apart from the third plate portion along the first direction to enhance stability of the sole structure while minimizing energy loss of the sole structure as the article of footwear contacts a ground surface.

13. The article of footwear of claim 12, wherein the midsole defines an inner midsole surface and an outer midsole surface opposite the inner midsole surface, the inner midsole surface faces the upper, the outer midsole surface faces away from the upper, the midsole defines a midsole thru-hole extending from the inner midsole surface to the outer midsole surface of the midsole, the second plate portion is disposed inside the midsole thru-hole of the midsole, the first plate portion is disposed in the forefoot region of the sole structure, the third plate portion is disposed in the heel region of the sole structure, and the second plate portion is disposed in the midfoot region of the sole structure.

14. The article of footwear of claim 13, wherein the third plate portion is disposed on top of the midsole, the second plate portion is disposed between the inner midsole surface and the outer midsole surface of the midsole, and the midsole thru-hole is obliquely angled relative to the inner midsole surface and the outer midsole surface.

15. The article of footwear of claim 14, wherein the midsole defines a midsole longitudinal recess in communication with the midsole thru-hole, the midsole longitudinal recess is adjacent the outsole, the midsole longitudinal recess is disposed in the forefoot region of the sole structure, and the first plate portion is at least partially disposed in the midsole longitudinal recess to maximize energy return during toe off.

16. The article of footwear of claim 15, wherein the outsole defines an inner outsole surface and an outer outsole surface opposite the inner outsole surface, the inner outsole surface faces the upper, the outer outsole surface faces away from the upper, the third plate portion is in direct contact with the inner outsole surface of the outsole, the midsole longitudinal recess is elongated along a second direction, and the second direction is perpendicular to the first direction.

17. The article of footwear of claim 12, wherein the midsole defines an inner midsole surface and an outer midsole surface opposite the inner midsole surface, the inner midsole surface faces the upper, the outer midsole surface faces away from the upper, the midsole defines a midsole opening extending from the inner midsole surface into the midsole, the midsole opening does not extend through an entirety of a thickness of the midsole, and the second plate portion is disposed inside the midsole opening of the midsole, and the third plate portion is disposed on top of the inner midsole surface at the heel region of the sole structure.

18. The article of footwear of claim 17, wherein the first plate portion is disposed at the forefoot region of the sole structure, the first plate portion is disposed inside the midsole, and the first plate portion is closer to the inner midsole surface than to the outer midsole surface of the midsole.

19. The article of footwear of claim 12, wherein the midsole is configured as a drop-in midsole, the midsole is entirely disposed inside the interior void of the upper, the third plate portion is disposed inside the midsole, and the first plate portion is disposed inside the outsole.

20. The article of footwear of claim 19, wherein the midsole is only disposed at the heel region of the sole structure.

21. The article of footwear of claim 19, wherein the midsole extends through the heel region, the midfoot region, and the forefoot region.

22. The article of footwear of claim 19, wherein the midsole includes a first midsole part and a second midsole part spaced apart from each other along a longitudinal axis of the sole structure to define a gap therebetween, and the gap receives the second plate portion of the footwear plate.

23. A method of manufacturing an article of footwear, comprising:

inserting a footwear plate through an opening of a midsole to directly couple the footwear plate to the midsole, wherein the footwear plate includes a composite material, the footwear plate includes a first plate portion, a second plate portion is connected to the first plate portion, and a third plate portion is connected to the second plate portion, and the second plate portion is connected between the first plate portion and the third plate portion, and the second plate portion is obliquely angled relative to the first plate portion and the third plate portion so that the first plate portion is spaced apart from the third plate portion along a first direction;

attaching the midsole to the outsole, wherein the outsole is elongated along a longitudinal axis, the first direction is perpendicular to the longitudinal axis, a sole structure includes the midsole and the outsole, the sole structure has a forefoot region, a heel region, and a midfoot region between the forefoot region and the heel region, and the opening of the midsole is disposed at the midfoot region; and

attaching an upper to the sole structure.

24. The method of claim 23, wherein the opening of the midsole is a thru-hole extending along an entirety of a thickness of the midsole.

25. The method of claim 23, wherein the opening of the midsole extends along a portion of a thickness of the midsole.