Composite panels for articles of footwear

Abstract

The present application relates to a composite plate for an article of footwear. A sewn article includes a substrate and a first strand portion formed of a fiber bundle. The substrate includes a first region and a second region. The first strand portion is attached to the substrate in the first region and the second region via a series of stitches formed with thread and forms a first layer on the substrate. The article has a first stitch density in the first region along a first length segment of the first strand portion, and has a second stitch density different from the first density in the second region along a second length segment of the first strand portion.

Description

[0001] This application is a divisional application of an application filed on January 23, 2019, with application number 201980019924.7 and invention name “Composite panel for footwear articles”.

[0002] CROSS-REFERENCE TO RELATED APPLICATIONS

[0003] This application claims priority to U.S. non-provisional patent application No. 16 / 254,975, filed on January 23, 2019, which claims priority under 35 U.S.C. §119(e) to U.S. Provisional Application Serial No. 62 / 621,193, filed on January 24, 2018, the disclosure of which is incorporated herein by reference in its entirety. Technical Field

[0004] The present disclosure relates generally to articles of footwear, and more particularly, the present disclosure relates to making composite panels for use in articles of footwear. Background Art

[0005] This section provides background information related to the present disclosure but is not necessarily prior art.

[0006] Areas of the composite that accommodate flexion - such as in the flexion areas of the toes and joints connecting the metatarsal bones to the phalanges of the foot - are more susceptible to crack propagation and fracture due to repeated bending / flexing of the composite during use. Therefore, in composite articles, fiber density is often reduced in these flexion areas in order to reduce stiffness to allow for flexion, at the expense of reducing the overall strength of the composite article. Summary of the invention

[0007] This application provides the following:

[0008] 1) A plate for footwear, comprising:

[0009] Sewn articles, including:

[0010] a substrate having a first region and a second region; and

[0011] a first strand portion formed by a first fiber bundle,

[0012] wherein (i) a first fiber strand is attached to a substrate in a first region and a second region via a series of stitches formed with a first thread, (ii) the first fiber strand forms a first layer on the substrate, and (iii) the sewn article has a first stitch density in the first region along a first length of the strand portion and a second stitch density different from the first density in the second region along a second length of the first strand portion; and

[0013] The resin composition is solidified into fibers of at least a first fiber bundle of the end strand portion.

[0014] 2) The board as described in 1), wherein the resin composition solidifies fibers of at least the first fiber bundle of the strand portion, fibers and / or yarns of the substrate, and threads of the sewn article.

[0015] 3) The board as described in any one of 1) to 2), wherein the pin crosses over the first strand portion and penetrates the substrate at a first attachment position spaced apart from the strand portion.

[0016] 4) A plate as described in any one of 1) to 3), wherein the first length segment extends in a direction between an inner side of the substrate and an outer side of the substrate.

[0017] 5) The plate as described in 4), wherein the second length segment extends in a direction between the inner side of the base plate and the outer side of the base plate.

[0018] 6) A board as described in any one of 1) to 5), wherein the first density is greater than the second density.

[0019] 7) A board as described in any one of 1) to 6), wherein a first average distance between stitches in the first region is greater than a second average distance between stitches in the second region.

[0020] 8) A board as described in any one of 1) to 7), wherein the first fiber bundle includes at least one of carbon fiber, boron fiber, glass fiber and synthetic polymer fiber.

[0021] 9) A plate as described in any one of 1) to 8), wherein the sewn article includes a second strand portion formed by a second fiber bundle, and the second strand portion is attached to the base plate in the first area and the second area via a series of stitches formed with a second thread.

[0022] 10) The plate as described in 9), wherein the first fiber bundle comprises carbon fibers and the second fiber bundle comprises glass fibers.

[0023] 11) A board as described in any one of 1) to 10), wherein the substrate is a fabric comprising a first polymer composition, which includes one or more first polymers, and the thread comprises a second polymer composition, which includes one or more second polymers.

[0024] 12) The panel according to 11), wherein both the first polymer composition of the fabric and the second polymer composition of the threads are thermoplastic compositions.

[0025] 13) A plate as described in 11), wherein the one or more first polymers of the first polymer composition of the fabric and the one or more second polymers of the second polymer composition of the thread both comprise polyurethane, or polyester, or polyether, or polyamide, or polyolefin.

[0026] 14) The plate as described in 11), wherein the melting temperature of the second polymer composition of the thread is at least 20 degrees Celsius higher than the melting temperature of the first polymer composition of the substrate.

[0027] 15) The board as described in any one of 1) to 14) further includes a plurality of traction elements attached to one side of the board.

[0028] 16) A method of forming a plate for an article of footwear, the method comprising:

[0029] Positioning substrate;

[0030] arranging a strand portion formed of a fiber bundle on a substrate; and

[0031] The strand portion is attached to the base plate via a series of stitches formed with thread such that a first area of ​​the sewn article has a first stitch density and a second area of ​​the sewn article has a second stitch density, wherein the first stitch density is at least ten percent greater than the second stitch density.

[0032] 17) The method as described in 16), wherein the method further comprises placing the sewn article in a mold;

[0033] disposing a liquid resin composition between and around a plurality of fibers of a fiber bundle sewn to a substrate;

[0034] solidifying the liquid resin composition to consolidate the plurality of fibers with the solid resin composition and form a composite plate for an article of footwear; and

[0035] The composite panel is removed from the mold.

[0036] 18) The method of 17), further comprising placing at least one traction element in the mold before placing the liquid resin composition; and

[0037] The traction elements are attached to the composite panel before the composite panel is removed from the mold.

[0038] 19) A method of forming a composite panel for an article of footwear, the method comprising:

[0039] Positioning a sewn article in a mold, the sewn article comprising a strand portion of a fiber bundle sewn to a base plate with thread, wherein a first region of the sewn article has a first stitch density and a second region of the sewn article has a second stitch density, wherein the first stitch density is at least ten percent greater than the second stitch density;

[0040] while the sewn article is positioned in the mold, disposing a resin composition between and around a plurality of fibers of the fiber bundle sewn to the base plate, consolidating the plurality of fibers with the resin composition and forming a composite plate for an article of footwear, the composite plate comprising a first region and a second region, the second region comprising a flex region having greater flexibility than the first region; and

[0041] The composite panel is removed from the mold.

[0042] 20) The method of 19), wherein the method further comprises forming the sewn article before positioning the sewn article in the mold. BRIEF DESCRIPTION OF THE DRAWINGS

[0043] The drawings described herein are for illustrative purposes only of selected configurations and are not intended to limit the scope of the present invention; the selected embodiments are not all possible implementations.

[0044] Figure 1 is a perspective view of an article of footwear according to the principles of the present disclosure;

[0045] Figure 2 yes Figure 1 an exploded view of an article of footwear showing an upper and a generally rigid three-dimensional shoe plate including a composite component secured to a foot bed surface of the upper;

[0046] Figure 3 Yes Figure 1 A top perspective view of a composite component shoe plate showing an inner surface of the shoe plate having a shape that conforms to the surface contour of the bottom surface of the foot;

[0047] Figure 4 It is used to form Figure 1 A top view of a base plate of a composite shoe plate of an article of footwear;

[0048] Figure 5A and 5B Each provides a top view of a bundle of strands consisting of a portion of a Figure 4 The fiber bundle of the substrate is formed and a first layer is formed on the substrate;

[0049] Fig. 6A yes Figure 5A-5B a close-up view of a fiber bundle of the invention, the fiber bundle being attached to a base plate in a heel region via stitching having a first density;

[0050] Figure 6B It is along Fig. 6A A cross-sectional view taken along line 6B-6B of FIG. 1 showing stitching penetrating the substrate to attach the fiber bundle to the top surface of the substrate, and the fibers include non-polymer fibers and polymer fibers;

[0051] Figure 7 yes Figure 5A-5B a close-up view of a fiber bundle of the base plate attached to the base plate in the midfoot region via stitching having a second density greater than a first density of stitching in the heel region;

[0052] Figure 8 yes Figure 5A-5B a close-up view of a fiber bundle of the invention, the fiber bundle being attached to the base plate in the forefoot region via stitching having a third density that is greater than a second density of stitching in the midfoot region;

[0053] Fig. 9 is a close-up view of a fiber bundle attached to a substrate via stitching that increases in density across the width of the substrate in accordance with the principles of the present disclosure;

[0054] Fig.10 is a top view of respective layers of a shoe plate formed from fiber bundles having distal ends proximate a flexure zone in a forefoot region of the shoe plate in accordance with the principles of the present disclosure;

[0055] Fig.11 is a top view of respective layers of a shoe plate formed from fiber bundles extending along the length of the shoe plate and having a curved orientation proximate a flexure zone in a forefoot region of the shoe plate in accordance with the principles of the present disclosure;

[0056] Fig.12 is a top view of respective layers of a shoe plate formed from fiber bundles extending along the length of the shoe plate and having a curved orientation proximate a flexure zone in a forefoot region of the shoe plate in accordance with the principles of the present disclosure;

[0057] Figure 13-15 Each shows a method for forming a corresponding shoe plate according to the principles of the present disclosure. Fig.11 The fiber bundle strands and individual layers of the fiber bundle;

[0058] Fig.16 is a perspective view of a mold for forming a shoe panel according to the principles of the present disclosure, the mold being shown in conjunction with a fiber stack prior to being formed into a shoe panel; and

[0059] Fig.17 is a perspective view of a mold for forming a shoe panel according to the principles of the present disclosure, the mold being shown in conjunction with the shoe panel being formed.

[0060] Corresponding reference numerals indicate corresponding parts throughout the drawings. DETAILED DESCRIPTION

[0061] The present disclosure relates to a sewn article having one or more fiber bundles supported by a substrate. The fiber bundles can be attached to the substrate via stitching to fix the bundles to the substrate in a desired position and / or in a desired pattern. The density of the stitching used to attach the bundles to the substrate can be varied at different locations of the substrate to provide the substrate (e.g., once formed into a shoe plate) with different properties. For example, in areas where the board is expected to flex and bend, the density of the stitching can be increased relative to other areas of the substrate to locally increase the flexibility of the formed board while resisting rupture.

[0062] One aspect of the present disclosure provides a sewn article. The sewn article includes a substrate having a first region and a second region. The sewn article also includes a first strand portion formed by a first fiber bundle, the first strand portion being attached to the substrate in the first region and the second region via a series of stitches formed with a first thread and forming a first layer on the substrate. The article has a first stitch density in the first region along a first length segment of the strand portion, and has a second stitch density different from the first density in the second region along a second length segment of the strand portion.

[0063] Embodiments of the present disclosure may include one or more of the following optional features. In some embodiments, the pin spans the strand portion and penetrates the substrate at a first attachment location spaced apart from the strand portion. The pin may also penetrate the strand portion. Optionally, the first length segment may extend in a direction between a medial side of the substrate and a lateral side of the substrate. Here, the second length segment extends in a direction between a medial side of the substrate and a lateral side of the substrate.

[0064] In some examples, the first density is greater than the second density. The first density may be at least 10% greater than the second density, may be 10% to 50% greater than the second density, or may be 20% to 40% greater than the second density. Optionally, the first average distance between stitches in the first region may be greater than the second average distance between stitches in the second region. Here, the first average distance between stitches may be at least 10% greater than the second average distance between stitches, may be 10% to 50% greater than the second average distance between stitches, or may be 20% to 40% greater than the second average distance between stitches.

[0065] In some configurations, the second density is greater than the first density. The second density may be at least 10% greater than the first density, 10% to 50% greater than the first density, or 20% to 40% greater than the first density. Additionally or alternatively, the second average distance between stitches in the first region may be greater than the first average distance between stitches in the second region. Here, the second average distance between stitches may be at least 10% greater than the first average distance between stitches, 10% to 50% greater than the first average distance between stitches, or 20% to 40% greater than the first average distance between stitches.

[0066] In some embodiments, the substrate is a fabric comprising fibers and / or yarns, and the fibers and / or yarns are formed by a first polymer composition comprising one or more first polymers. The stitches may include a second polymer composition, which includes one or more second polymers. The substrate may be a fabric comprising a first polymer composition, which includes one or more first polymers, wherein at least one of the one or more first polymers of the first polymer composition of the substrate is the same as at least one of the one or more second polymers of the second polymer composition of the stitches. Here, the fabric may be a non-woven fabric. In some examples, the fiber bundle includes at least one of carbon fibers, boron fibers, glass fibers, and synthetic polymer fibers. The synthetic polymer fibers may be high-tenacity synthetic polymer fibers, such as aramid fibers.

[0067] In some configurations, the sewn article includes a second strand portion formed by a second fiber bundle, the second strand portion being attached to the substrate in the first region and the second region via a series of stitches formed with a second thread. The first fiber bundle may include carbon fibers. The second fiber bundle may include glass fibers. The density of the first fiber bundle in the first region is at least five weight percent greater than the density of the first fiber bundle in the second region. Additionally or alternatively, the density of the second fiber bundle in the second region is at least five weight percent greater than the density of the second fiber bundle in the first region. Here, the melting temperature of the second polymer composition of the thread may be at least 15°C higher than the melting temperature of the first polymer composition of the substrate.

[0068] In some examples, a series of stitches spans the strand portion. Optionally, the second region may define a flexure region having greater flexibility than the first region. The flexibility of the second region may be at least five percent greater than the flexibility of the first region, or may be at least ten percent greater than the flexibility of the first region. The second density may be greater than the first density.

[0069] In some embodiments, the sewn article is a component of an article of footwear, an article of apparel, or an article of sporting equipment. The component of the article of footwear may be a component of a plate of the article of footwear.

[0070] Another aspect of the present disclosure provides a sewn article. The sewn article includes a substrate having a first side and a second side. The sewn article also includes a strand portion formed by a fiber bundle, the strand portion being attached to the substrate via a series of stitches formed with thread, forming a first layer on the substrate, and including a first length segment extending in a direction between the first side and the second side and a second length segment extending in a direction between the first side and the second side. The stitches have a different density along the first length segment than along the second length segment.

[0071] Embodiments of this aspect may include one or more of the following optional features. In some configurations, the pins span the strand portion and penetrate the substrate at a first attachment location spaced apart from the strand portion. The pins may also penetrate the strand portion. The substrate may include a first end and a second end, the first length segment being closer to the first end than the second length segment and having a greater pin density than the second length segment. Here, the substrate may include a flexure region at the first length segment, the flexure region having greater flexibility than other regions of the substrate.

[0072] In some examples, the substrate is a fabric comprising a first polymer composition comprising one or more first polymers, and the thread comprises a second polymer composition comprising one or more second polymers. In this example, at least one of the one or more first polymers is the same type of polymer as at least one of the one or more second polymers. Examples of polymer types suitable for use as the substrate and the first and second polymers of the suture include polyurethanes, polyethers, polyesters, polyamides, and polyolefins.

[0073] In some configurations, the fiber bundle includes at least one of carbon fiber, boron fiber, glass fiber, and synthetic polymer fiber. The thread forming the stitches may be formed by a polymer composition. Alternatively, the suture may be formed by a polymer composition comprising one or more polymers of the same type as the substrate. In addition, the polymer composition included in the thread may have a higher melting point than the substrate. A series of stitches formed by the suture may also span the strand portion.

[0074] Another aspect of the present disclosure provides a sewn article. The sewn article includes a substrate having a first side and a second side. The sewn article includes a strand portion formed by a fiber bundle, the strand portion is attached to the substrate via a series of stitches formed with thread, a first layer is formed on the substrate, and includes a first length segment extending in a direction between the first side and the second side and a second length segment extending in a direction between the first side and the second side. The density of the stitches varies between the first side and the second side along at least one of the first length segment and the second length segment.

[0075] This aspect of the disclosure may include one or more of the following optional features. In some examples, the pin spans the strand portion and penetrates the substrate at a first attachment location spaced apart from the strand portion. The pin may also penetrate the strand portion.

[0076] In some embodiments, the substrate includes a first end and a second end, the first length segment is closer to the first end than the second length segment, and has a greater stitch density than the second length segment. Here, the substrate may include a flexure region at the first length segment, and the flexure region has greater flexibility than other regions of the substrate. The substrate may be a fabric including a first polymer composition, the first polymer composition including one or more first polymers, and the thread may include a second polymer composition, the second polymer composition including one or more second polymers. Here, at least one of the one or more first polymers is the same as at least one of the one or more second polymers.

[0077] In some configurations, the fiber bundle includes at least one of carbon fiber, boron fiber, glass fiber, and synthetic polymer fiber. The thread forming the stitches may be formed by a polymer composition. Alternatively, the suture may be formed by a polymer composition comprising one or more polymers of the same type as the substrate. In addition, the polymer composition included in the thread may have a higher melting point than the substrate. A series of stitches formed by the suture may also span the strand portion.

[0078] Another aspect of the present disclosure provides a sewn article. The sewn article includes a substrate having a first region and a second region. The sewn article also includes a strand portion formed by a fiber bundle, the strand portion being attached to the substrate via a series of stitches formed with thread, forming a first layer on the substrate, and including a plurality of length segments having a longitudinal axis extending in a direction between the first region and the second region and a distal end terminating at a corresponding position on the substrate, the corresponding position being spaced apart from an edge of the substrate to define a flexure region of the substrate at the distal end. The flexure region has greater flexibility than other regions of the substrate.

[0079] Implementations of this aspect of the disclosure may include one or more of the following optional features. In some implementations, the distal ends cooperate to form a transition line that extends across the width of the substrate between a first side of the substrate and a second side of the substrate. Here, the transition line is arcuate, or the transition line is straight. Optionally, the transition line may extend from the first side to the second side. Additionally or alternatively, the substrate may be exposed between the transition line and the edge.

[0080] In some configurations, the base plate is exposed between the distal end and the edge. The pin may span the strand portion and penetrate the base plate at a first attachment location spaced apart from the strand portion. The pin may also penetrate the strand portion.

[0081] In some examples, the density of stitches along at least one of the plurality of length segments is different from the density of stitches along another of the plurality of length segments. In this example, the density of stitches varies along at least one of the plurality of length segments. In other examples, the density of stitches varies along at least one of the plurality of length segments.

[0082] In some embodiments, the substrate is a fabric comprising a first polymer composition comprising one or more first polymers, and the thread comprises a second polymer composition comprising one or more second polymers. Here, at least one of the one or more first polymers is the same as at least one of the one or more second polymers.

[0083] In some configurations, the fiber bundle includes at least one of carbon fiber, boron fiber, glass fiber, and synthetic polymer fiber. The thread forming the stitches may be formed by a polymer composition. Alternatively, the suture may be formed by a polymer composition comprising one or more polymers of the same type as the substrate. In addition, the polymer composition included in the thread may have a higher melting point than the substrate. A series of stitches formed by the suture may also span the strand portion.

[0084] Another aspect of the present disclosure provides a sewn article. The sewn article includes a substrate having a first area and a second area. The sewn article also includes a strand portion formed by a fiber bundle, the strand portion being attached to the substrate via a series of stitches formed with thread, forming a first layer on the substrate, and including a flexure region having greater flexibility than other areas of the substrate. The length of the strand portion in the flexure region has a greater density than in other areas of the substrate.

[0085] Aspects of the present disclosure may include one or more of the following optional features. In some configurations, the flexure region defines a transition line that extends across the width of the substrate between a first side of the substrate and a second side of the substrate. The transition line may be arched, or the transition line may be straight. Additionally, the transition line may extend from the first side to the second side. Optionally, the substrate may be exposed between the transition line and an edge of the substrate.

[0086] In some examples, the stitch crosses the strand portion and penetrates the substrate at a first attachment location spaced apart from the strand portion. Additionally or alternatively, the stitch may penetrate the strand portion. Furthermore, the substrate may be a fabric comprising a first polymer composition comprising one or more first polymers, and the thread may comprise a second polymer composition comprising one or more second polymers. At least one of the one or more first polymers and at least one of the one or more second polymers may be the same.

[0087] In some configurations, the fiber bundle includes at least one of carbon fiber, boron fiber, glass fiber, and synthetic polymer fiber. The thread forming the stitches may be formed by a polymer composition. Alternatively, the suture may be formed by a polymer composition comprising one or more polymers of the same type as the substrate. In addition, the polymer composition included in the thread may have a higher melting point than the substrate. A series of stitches formed by the suture may also span the strand portion.

[0088] Another aspect of the present disclosure provides a method for forming a sewn article. The method includes positioning a substrate and arranging a strand portion formed by a fiber bundle on the substrate. The method also includes attaching the strand portion to the substrate via a series of stitches formed with thread, so that a first area of ​​the sewn article has a first stitch density and a second area of ​​the sewn article has a second stitch density, wherein the first stitch density is at least ten percent greater than the second stitch density. Optionally, the sewn article can be a sewn article according to any system or method disclosed herein.

[0089] Another aspect of the present disclosure provides a method for forming a composite article. The method includes placing a sewn article in a mold, the sewn article including a strand portion of a fiber bundle sewn to a substrate with a thread. When the sewn article is placed in the mold, the method also includes consolidating the substrate, the strand portion and the stitches via a resin composition to form the composite article. The method also includes removing the composite article from the mold. The composite article includes a first region and a second region. The second region includes a flexure region having greater flexibility than the first region.

[0090] Embodiments of the present disclosure may include one or more of the following optional features. In some embodiments, the method includes forming the sewn article before positioning the sewn article in a mold. Forming the sewn article may include placing a strand portion formed by a fiber bundle on a substrate, and attaching the strand portion to the substrate via a series of stitches formed with thread in a first region and a second region, wherein the first region has a first stitch density and the second region has a second stitch region greater than the first stitch density.

[0091] In some examples, consolidating the substrate, strands, and stitching includes applying a resin composition to the substrate, strands, and stitching when the sewn article is in a mold. Applying the resin composition may include combining the first and second reactive compositions to form a liquid resin composition, and applying the liquid composition to the sewn article. The liquid resin composition may be a liquid epoxy resin composition.

[0092] In some configurations, the method includes curing the resin composition before the composite article is removed from the mold. Alternatively, the resin composition can be a thermoplastic resin composition contained in at least one of the substrate, strand portion, and thread of the sewn article. The substrate, strand portion, and thread consolidation can include allowing the resin composition to flow and penetrate into the fibers of the strand portion, and then allowing the resin composition to re-solidify before the composite article is removed from the mold. The method can further include trimming the periphery of the composite article.

[0093] In some embodiments, the composite article is a component of an article of footwear, an article of apparel, or an article of sporting equipment. When the composite article is a component of an article of footwear, the method further comprises incorporating the component for the article of footwear into the article of footwear.

[0094] In some configurations, arranging the strand portion on the substrate includes positioning the strand portion in a plurality of length segments having a longitudinal axis extending in a direction between a first region and a second region. The plurality of length segments may have distal ends terminating at respective locations on the substrate, the respective locations being spaced apart from an edge of the substrate to define a flexure zone. Optionally, arranging the strand portion on the substrate may include positioning the strand portion in a plurality of length segments having a first substantially straight portion within a first region and an arcuate portion within a second region defining a flexure zone. Here, the method may include aligning the arcuate portions of adjacent length segments to define a flexure zone.

[0095] In some examples, attaching the strand portion via a series of stitches formed with the thread includes passing the stitches across the strand portion and penetrating the substrate at a first attachment location spaced from the strand portion. Additionally or alternatively, attaching the strand portion via a series of stitches formed with the thread includes passing the stitches through the strand portion.

[0096] Another aspect of the present disclosure provides a method for manufacturing an article of footwear, an article of apparel, or an article of sporting equipment. The method includes positioning a composite article. The composite article includes a sewn article having a strand portion of a fiber bundle sewn to a substrate with a thread. The fibers are consolidated by a resin composition. The composite article is a component of the article of footwear, an article of apparel, or an article of sporting equipment. The method also includes fixing the composite article and a second component to each other. The second component is a second component of the article of footwear, an article of apparel, or an article of sporting equipment.

[0097] Implementations of this aspect of the disclosure may include one or more of the following optional features. In some implementations, the composite article is a component of an article of footwear and the second component is a second component of the article of footwear. Alternatively, the composite article may be a plate for an article of footwear.

[0098] Further areas of applicability will become apparent from the description provided herein.The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

[0099] Example configurations will now be described more fully with reference to the accompanying drawings. Example configurations are provided so that this description will be thorough and fully convey the scope of the present disclosure to those skilled in the art. Specific details are set forth, such as examples of specific components, devices, and methods, in order to provide a thorough understanding of the configurations of the present disclosure. It will be apparent to those skilled in the art that specific details need not be used, that the example configurations may be embodied in many different forms, and that the specific details and example configurations should not be construed as limiting the scope of this specification.

[0100] The terms used herein are for the purpose of describing specific example configurations and are 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 text expressly indicates otherwise. The terms "comprises", "comprising", "including", and "having" are inclusive and therefore indicate the presence of the features, steps, operations, elements, and / or parts, but do not exclude the presence or addition of one or more other features, steps, operations, elements, parts, and / or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring them to be performed in the particular order discussed or shown, unless specifically stated in an order of execution. Additional or alternative steps may be utilized.

[0101] When an element or layer is referred to as being "on," "engaged to," "connected to," "attached to," or "coupled to," it may be directly on, engaged, connected, attached to, or coupled to that other element or layer, or intervening elements or layers may be present. Conversely, when an element is referred to as being "directly on," "directly engaged to," "directly connected to," "directly attached to," or "directly coupled to," there may be no intervening elements or layers. Other words used to describe relationships between elements should be understood in the same manner (e.g., "between" versus "directly between," "adjacent" versus "directly adjacent," etc.). As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items.

[0102] The terms first, second, third, etc. may be used herein to describe each element, component, region, layer and / or part. These elements, components, regions, layers and / or parts should not be limited by these terms. These data may only be used to distinguish an element, component, region, layer or part from another region, layer or part. Terms such as "first", "second" and other numerical terms do not imply order or sequence unless this article clearly indicates. Thus, the first element, component, region, layer or part discussed below may be referred to as the second element, component, region, layer or part, without departing from the teaching of the example construction.

[0103] refer to Figure 1-9 In some embodiments, article of footwear 10 includes an upper 100 and a plate 200 attached to upper 100 . Figure 1 A front perspective view of a shoe 10 is provided that is divided into one or more portions. The portions may include a forefoot portion 12, a midfoot portion 14, and a heel portion 16. The forefoot, midfoot, and heel portions 12, 14, 16 may be alternatively referred to as forefoot, midfoot, and heel regions 12, 14, 16, respectively. The forefoot portion 12 may correspond to the joints and toes that connect the metatarsal bones of the foot to the phalanges. The midfoot portion 14 may correspond to the arch region of the foot, and the heel portion 16 may correspond to the rear portion of the foot, including the calcaneus. The shoe 10 may include a lateral side 18 and a medial side 20, respectively, that correspond to opposite sides of the shoe 10 and extend through the portions 12, 14, 16.

[0104] The upper 100 includes an inner surface defining an interior cavity 102, which is configured to receive and secure a foot supported on the sole structure 200. An ankle opening 104 located in the heel portion 16 may provide access to the interior cavity 102. For example, the ankle opening 104 may accommodate a foot to secure the foot in the void 102 and facilitate entry and removal of the foot from the interior cavity 102. In some examples, one or more fasteners 106 extend along the upper 100 to adjust the fit of the interior cavity 102 around the foot while accommodating entry and removal of the foot therefrom. The upper 100 may include holes and / or other engagement features for receiving the fasteners 106, such as eyelets, and other engagement features such as fabric or mesh loops. The fasteners 106 may include laces, straps, cords, hooks and loops, or any other suitable type of fasteners.

[0105] The upper 100 may include a tongue portion 110 extending between the interior cavity and the fastener 106. The upper 100 may be formed of one or more materials that are stitched or bonded together to form the interior cavity 102. Suitable materials for the upper may include, but are not limited to, fabrics, foams, leather, and synthetic leather. The materials may be selected and positioned to impart durability, breathability, wear resistance, flexibility, and comfort.

[0106] Reference Figure 2 , Figure 1 10 shows a footbed surface 222 disposed between plate 200 and upper 100 for receiving a bottom surface of a foot (e.g., the sole) within interior cavity 102. In some configurations, footbed surface 222 may be integrally formed with upper 100, or in other configurations, footbed surface 222 may correspond to a separately formed layer attached to upper 100. In some examples, the contour of footbed surface 222 is configured to conform to the contour of the sole of a foot. Additionally or alternatively, an insole or sock may be disposed on footbed surface 222 under the foot within at least a portion of interior cavity 102 of upper 100 to enhance the comfort of shoe 10.

[0107] Shoe plate 200 defines a longitudinal axis L that extends through forefoot portion 12, midfoot portion 14, and heel portion 16. Plate 200 is attached to upper 100 and may impart features provided by a traditional outsole. Figure 3 A top perspective view of the embroidered plate 200 is provided, showing the plate 200 having a ground engaging surface 212 and an opposing inner surface 214 opposing a footbed surface 222. In some examples, an outsole material such as rubber is attached to the ground engaging surface 212 to provide traction with the ground surface. The contour of the inner surface 214 can be configured to conform to the contour of the bottom surface (e.g., the sole) of the foot within the interior cavity 102. In some examples, the sidewall 220 extends around the perimeter of the plate 200 between the ground engaging surface 212 and the inner surface 214. When the interior cavity 102 receives a foot therein, the sidewall 220 and the inner surface 214 of the plate 200 can cooperate to hold and support the foot on the plate 200. For example, the sidewall 220 can define a rim around the perimeter of the contoured inner surface 214 to hold the foot during use of the shoe 10 while walking, running, and / or lateral movements are performed. In some embodiments, portions of sidewall 220 extend around upper 100 and are attached to an outer surface of upper 100 at one or more locations to secure plate 200 to upper 100. Adhesive may be used to secure plate 200 to upper 100.

[0108] In some examples, one or more protruding elements 215 (e.g., cleats) extend from ground engaging surface 212 in a direction away from plate 200 and upper 100 to provide traction on soft ground surfaces, such as grass. For example, a cleat shaft 217 associated with each protruding element 215 can be attached to ground engaging surface 212 of plate 200 and extend in a direction substantially perpendicular to a longitudinal axis L of plate 200.

[0109] In some embodiments, the shoe plate 200 is substantially rigid and is formed of one or more composite materials. Compared to conventional composite plates formed by unidirectional tapes that provide only directional stiffness properties, the shoe plate 200 is formed by one or more bundle strand portions 300 arranged in a selected pattern to impart anisotropic stiffness and gradient load paths throughout the plate 200. Each bundle strand portion 300 may refer to a bundle, monofilament, spun yarn, or polymer pre-impregnated bundle of multiple fibers 350 of a ribbon or strip of a unidirectional tape. Unless otherwise indicated, the present disclosure refers to each bundle strand portion 300 as a corresponding bundle 300 of a fiber 350. As used herein, the term "bundle" refers to a bundle (i.e., multiple) of filaments (e.g., fibers 350) that may be twisted or untwisted, and each bundle may be specified as a size associated with the number of fibers 350 contained in the corresponding bundle 300. For example, the size range of the at least one bundle 300 forming the shoe plate 200 may range from about 1,000 fibers per bundle to about 48,000 fibers per bundle.

[0110] In some configurations, the fibers 350 associated with the at least one bundle 300 include at least one of carbon fibers, glass fibers, boron fibers, and synthetic polymer fibers. The synthetic polymer fibers may include high-tenacity synthetic polymer fibers, such as aramid fibers. In addition, at least a portion of the fibers 350 associated with the at least one bundle 300 may be formed of a first thermoplastic material. Fibers such as carbon fibers, aromatic fibers, and boron fibers may provide high modulus, while glass fibers (e.g., fiberglass) and polymer fibers (e.g., nylon or polyester fibers) may provide medium modulus. Additionally or alternatively, fibers or yarns formed from a thermoplastic composition may be mixed with the fibers 350 of the one or more bundles 300 to help melt / inject the embroidery preform during vacuum molding or compression molding.

[0111] In some embodiments, the resin composition is used to consolidate the fibers of the strands to form a composite article. In some examples, in addition to consolidating the fibers to the strands, the resin composition also consolidates the fibers of the substrate in the composite article, or the fibers of the suture, or the fibers of both the substrate and the suture. The resin composition can be applied to the sewing article as a liquid, and the liquid penetrates into the fibers of the sewing article and surrounds the fibers. Then, while in contact with the fibers, the liquid resin composition is cured, so that the fibers are consolidated in the solid resin composition in the composite article. In one example, the liquid resin composition is cured into a thermosetting resin composition, and the composite article includes the fibers consolidated by the thermosetting resin composition. The thermosetting resin composition can be formed by combining the first and second reactive compositions. Alternatively or additionally, the thermosetting resin composition can be formed by exposing the liquid resin composition to actinic radiation (for example, by being exposed to light or heat or both). The liquid resin composition can include one or more epoxy polymers, or one or more precursors of epoxy polymers. In another example, the liquid resin composition is cured into a thermoplastic resin composition, and the composite article includes fibers consolidated by the thermoplastic resin composition. The thermoplastic resin composition may include one or more thermoplastic polyurethanes, one or more thermoplastic polyesters, one or more thermoplastic polyethers, one or more thermoplastic polyamides, one or more thermoplastic polyolefins, or any combination thereof.

[0112] In some examples, the fiber density per unit area varies within a single bundle 300 of fibers 350. Additionally or alternatively, the type of fibers 350 forming the respective bundles 300 can vary across the plate 200 between the forefoot region 12 and the heel region 16 and between the lateral side 18 and the medial side 20. In doing so, the plate 200 can be designed to have a stiffness gradient based on the anatomical features of the foot so that the plate 200 flexes in a manner that matches the natural flexion of the foot during walking, running, or other motions. For example, the stiffness of the plate 200 can increase along the length of the plate 200 from the forefoot portion 12 to the heel portion 14, and / or the stiffness of the plate 200 can decrease to define a flexure zone, such as where the toes and joints connect the metatarsal bones to the phalanges of the foot to allow the plate 200 to bend / flex while reducing crack propagation in the flexure zone. In some examples, the pattern for each bundle 300 of fibers 350 provides a stiffness gradient between the lateral side 18 and the medial side 20 of the plate 200 through at least one of the portions 12, 14, 16. Thus, the one or more bundles of fibers 350 may include a path having multiple bends to change direction in the load path of the plate 200 to accommodate anatomical features and enhance the performance of the shoe 10 for its intended use. In addition, to increase interlaminar fracture toughness at localized areas of the plate 200 (e.g., flexure areas), the bundles 300 of fibers 350 may be attached to the base plate 400 ( Figure 4 ) of the stitching portion 304 ( Figure 6A-9 ) can be higher in the flexure region of the panel 200, and / or additional embroidery stitching can be placed on top of the bundles 300 of fibers 350 that have been sewn down immediately adjacent to the flexure region. Here, the spacing of the stitching and / or embroidery stitching can be reduced in the flexure region of the panel 200, thereby increasing the stitching density (i.e., density) to thereby increase the interlaminar fracture toughness in the flexure region, where flexure / bending of the panel 200 repeatedly occurs during use of the panel 200. In some embodiments, the panel 200 is formed by embroidering at least two bundles 300 of fibers 350 in a layered configuration, while being secured to the same base plate 400 (via stitching). Figure 13-15 ). In other embodiments, the panel is formed by fixing at least two bundles 300 of fibers 350 to respective substrates, respectively, and stacking the substrates so that the at least two bundles 300 of fibers 350 are embroidered in a layered configuration.

[0113] As used herein, substrate 400 refers to any one of a covering, a carrier or a lining, where at least one bundle 300 of fibers 350 is fixed and combined. Substrate 400 can be formed of a thermosetting polymer material or a thermoplastic polymer material, and can be a fabric (e.g., knitted, woven or non-woven), an injection molded article or a thermoformed article. The polymer material of the substrate can include one or more polyurethanes, one or more polyethers, one or more polyesters, one or more polyamides, one or more polyolefins and combinations thereof. For example, polyurethane can be a polyester-polyurethane copolymer. Polyester can be polyethylene terephthalate or polybutylene terephthalate. Polyamide can be nylon 6, nylon 66 or nylon 11.

[0114] The stitching 304 for attaching the bundle 300 of fibers 350 to the substrate 400 can be formed of the same material as the substrate 400. For example, the stitching 304 can include a thread formed of a polymer composition, which includes some of the same polymers as the polymer composition of the substrate 400. The polymer material of the stitching can include one or more polyurethanes, one or more polyethers, one or more polyesters, one or more polyamides, one or more polyolefins, and combinations thereof. For example, the polyurethane can be a polyester-polyurethane copolymer. The polyester can be polyethylene terephthalate or polybutylene terephthalate. The polyamide can be nylon 6, nylon 66, or nylon 11.

[0115] In some examples, the substrate 400 (e.g., a fabric) may include a first polymer composition having one or more first polymers, and the thread of the stitching may include a second polymer composition having one or more second polymers, at least one of the one or more second polymers being of the same polymer type as at least one of the one or more first polymers. For example, both the first polymer composition and the second polymer may include polyurethane, or both the first polymer composition and the second polymer may include polyester, or both the first polymer composition and the second polymer may include polyamide, etc. Additionally or alternatively, the thread of the stitching may include a second polymer composition having a melting temperature higher than the melting temperature of the first polymer composition of the substrate. More specifically, the thermoplastic composition present in the thread of the stitching or forming a majority of its mass may have a melting temperature at least 20 degrees Celsius higher than the melting temperature of the polymer composition present in the substrate 400. For example, the thread of the stitching may include a polymer composition having a melting temperature at least 20 degrees Celsius higher than the first polymer composition included in the substrate 400, or be composed of the first polymer composition forming a majority of the weight of the substrate 400.

[0116] Typically, it is difficult to manufacture a composite panel that is non-flat (e.g., curved / contoured) and substantially rigid in a final state from an initially rigid and flat-shaped preform panel. Embodiments herein are directed to an embroidery preform that fixes the one or more bundles 300 of fibers 350 to the same substrate 400 or different substrates 400, reduces the tortuous path of the bundles 300 of fibers 350 and / or the density of the bundles 300 of fibers 350 in the localized area associated with the flexure region, increases the density / density of the stitching used to fix the bundles of fibers 350 to the substrate (one or more) 400 in the localized area to increase interlaminar fracture toughness, and applies heat to mold the embroidery preform to form a shoe plate 200 having a desired shape and curvature. Thereafter, the plate 200 may be cured to impart structural rigidity. That is, the substrate (one or more) 400 and each bundle 300 of fibers 350 are thin and flexible to allow the embroidery preform to be positioned in a mold to form a three-dimensionally shaped panel 200 having structural rigidity. In some examples, manufacturing the plate 200 includes injecting a liquid thermoplastic material into an embroidery preform (e.g., one or more bundles 300 of fibers 350 fixed to a substrate 400), and using vacuum molding and / or compression molding techniques to form the plate 200. The liquid thermoplastic material may include at least one of a polymerizable composition or a prepolymer material. Additional polymers / tougheners (e.g., softer polymers, rubbers, and / or block copolymers) may be added to the liquid thermoplastic material to reduce the brittleness of the plate 200.

[0117] In other examples, the substrate 400 or a portion thereof is formed of a thermosetting polymer material and / or a thermoplastic polymer material. The thermoplastic polymer material includes a melting point lower than the melting point or degradation temperature of the fibers 350 of the bundle 300. Here, in addition to or in place of the liquid thermoplastic material injected into the embroidery preform, a thermoplastic material and / or a thermosetting polymer material can be incorporated into the substrate 400 to melt / inject into the embroidery preform during a vacuum molding process and / or a compression molding process. Additionally or alternatively, a thermoplastic composition yarn can be mixed with the fibers 350 of the one or more bundles 300 to help melt / inject into the embroidery preform during vacuum molding or compression molding. Optionally, the embroidery preform can be powder coated with a thermosetting and / or thermoplastic polymer material, or an injection molding technique can be used to overmold and / or impregnate the embroidery preform with a thermosetting and / or thermoplastic polymer material.

[0118] Figure 4 A top view of an exemplary substrate 400 for forming a shoe plate 200 is provided. The substrate 400 can be substantially thin, flat, and flexible. As described above, the substrate 400 or at least a portion thereof can be formed of a thermosetting polymer material or a thermoplastic polymer material. In some configurations, the substrate 400 includes a fabric, which can be knitted, woven, or non-woven. The substrate 400 can also optionally be formed of an injection molded article or a thermoformed article. The substrate 400 can be cut into a desired shape defined by a peripheral edge 402.

[0119] Figure 5A and 5B Each provides a top view of a bundle 300 of fibers 350 attached to Figure 4 The top surface 410 of the substrate 400 is formed on the substrate 400 to form a first layer on the substrate 400. The bundle 300 (i.e., the bundle strand portion) includes a plurality of segments 302 that extend continuously between two different locations along the peripheral edge 402 of the substrate 400 to form a first layer covering the substrate 400 (i.e., the segments 302 extend across the substrate between the outer and inner sides 18, 20). The segments 302 can be arranged adjacent to each other and substantially parallel. In the example shown, the segments 302 extend in a direction that converges with the longitudinal axis of the substrate 400. In other examples, the segments 302 can extend generally parallel to the longitudinal axis of the substrate 400, or extend in other directions that converge with the longitudinal axis of the substrate 400. Figure 5A Each segment is shown terminating at a corresponding loop portion inside the peripheral edge 402 of the base plate 400 . Figure 5B Each segment is shown to also terminate at a corresponding loop portion outside the peripheral edge 402 of the base plate 400. Thus, Figure 5BThe loop portions of the segments 302 extending outside the peripheral edge 402 of the substrate 400 may be removed (eg, by cutting) to eliminate the presence of pinch points when the bundle 300 and fibers 300 and substrate 400 are subjected to heat and pressure during the manufacturing process.

[0120] The bundle of fibers 350 may be attached to the substrate 400 via a series of stitches 304. Figure 6A-8 , heel area 16( Fig. 6A ), midfoot area 14( Figure 7 ) and forefoot area 12( Figure 8 ) each shows a corresponding length segment / portion of a bundle 300 of fibers 350 attached to a substrate 400 via a stitching 304. The bundle 300 is arranged on a top surface 410 of the substrate 400, and the stitching 304 spans (e.g., zigzags) over the bundle 300 and penetrates the substrate 400 at an attachment location 305 spaced apart from the bundle 300. Additionally or alternatively, a portion of the stitching 304 may extend through the bundle 300 of fibers 350. The substrate 400 and the stitching 304 may be formed of a thermoplastic polymer material that melts during a heat treatment. The stitching 304 may be formed of a first thermoplastic polymer material, and the substrate 400 may be formed of a second thermoplastic polymer material having a lower melting temperature than the first thermoplastic polymer material. Therefore, when the substrate 400 begins to melt during a heat treatment, the stitching 304 holds the bundle 300 of fibers 350 in place without melting. In some examples, the stitching 304 or at least a portion thereof is formed of a resin. The stitching 304 may also include a material that matches an optional injection polymer for compression molding and / or vacuum molding. The fibers 350 associated with the bundle 300 may include non-polymer fibers 352 and polymer fibers 354. For example, the non-polymer fibers 352 may include carbon fibers, glass fibers, and / or boron fibers. The synthetic polymer fibers may include high-tenacity synthetic polymer fibers, such as aramid fibers. On the other hand, the polymer fibers 354 may include thermoplastic polymer fibers having a higher melting temperature than the thermoplastic polymer material used to form the substrate 400 and / or the stitching 304. In addition, the thermoplastic polymer material used to form the substrate 400 may include a melting temperature lower than the degradation temperature associated with the non-polymer fibers 352 (e.g., carbon fibers).

[0121] The density of stitching 304 may be greater in some localized areas of the plate 200 (or other sewn article) for increasing interlaminar fracture toughness, while other areas where increased fracture toughness is not required may include stitching 304 of a lower density suitable for attaching bundles 300 of fibers 350 to the base plate 400. In addition, areas associated with a lower density of stitching 304 reduce manufacturing time when attaching bundles 300 of fibers 350 to the base plate 400. In some examples, localized areas that benefit from increased fracture toughness include flexure areas where flexure / bending of the formed plate 200 (or other article) occurs repeatedly during use of the plate 200. In some examples, the midfoot region 14 includes a higher density of stitching 304 than the heel region 16, and the forefoot region 12 includes a higher density of stitching 304 than the midfoot region 14. In some embodiments, a higher density of stitching 304 may be provided by applying stitching 304 as an embroidery piece to substrate 400 but not across bundle 300, whereby the density of stitching 304 is increased to increase interlaminar fracture toughness in localized areas.

[0122] refer to Fig. 6A , the bundle 300 of fibers 350 is attached to the base plate 400 in the heel region 16 via a first series of stitches 304 formed with a thread and having a first density along a first length segment of the bundle 300 of fibers 350. The first length segment of the bundle 300 may correspond to one of the segments 302 in the heel region 16, which extends in a direction between the lateral side 18 of the base plate 400 and the medial side 20 of the base plate 400 (i.e., converging with the longitudinal axis L of the base plate 400). In the example shown, the first density / thickness of the stitches 304 is proportional to the first length segment L1 that separates adjacent attachment locations 305 arranged on the same side of the bundle 300. For example, the stitching 304 may span the bundle 300 from a first attachment location 305-1 on one side of the bundle 300 to a second attachment location 305-2 on the other side of the bundle, and then return again to the other side of the bundle 300 by spanning the bundle 300 from the second attachment location 305-2 to a third attachment location 305-3. Here, the first length segment L1 separates adjacent first attachment location 305 - 1 and third attachment location 305 - 3 arranged on the same side of the bundle 300 .

[0123] Figure 6B Provides along Fig. 6A 6B-6B of FIG. 4, which shows a stitch 304 attaching the bundle 300 of fibers 350 to the top surface 410 of the substrate 400. The stitch 304 can penetrate the surfaces 410, 412 of the substrate 400 and zigzag across the bundle 300 between the first attachment locations 305. The non-polymer fibers 352 (e.g., carbon fibers) and the polymer fibers 354 (e.g., thermoplastic polymer fibers) can include circular cross-sections intermixed with each other throughout the entire length of the bundle 300.

[0124] refer to Figure 7 , the bundle 300 of fibers 350 is attached to the base plate 400 in the midfoot region 14 via a second series of stitches 304 formed with thread and having a second density along a second length segment of the bundle 300 of fibers 350. Here, the second density / thickness of the stitches 304 along the second length segment of the bundle 300 in the midfoot region 14 is greater than that in Fig. 6A 16. The first and second series of stitches 304 may be continuous or discontinuous. The second length segment of the bundle 300 may correspond to one of the segments 302 in the midfoot region 14 that extends in a direction between the lateral side 18 of the base plate 400 and the medial side 20 of the base plate 400 (i.e., converging with the longitudinal axis L of the base plate 400). As with the first density / thickness of the stitching 304 in the heel region 16 along the first length segment, the second density / thickness of the stitching 304 in the midfoot region 14 along the second length segment of the bundle 300 may be proportional to the second length segments L2 that separate adjacent attachment locations 305 that are arranged on the same side of the bundle 300. In the example shown, the second length segments L2 that separate adjacent attachment locations 305 associated with the second length segment of the bundle 300 are shorter than the first length segments L1 that separate adjacent attachment locations 305 associated with the first length segment of the bundle 300. Thus, the stitched article (eg, bundle 300 and base plate 400 ) has a higher density / thickness of stitching 304 in midfoot region 14 along the second length of bundle 300 than in heel region 16 along the first length of bundle 300 .

[0125] In some embodiments, the second density is ten percent (10%) greater than the first density. In some examples, the second density may be ten percent (10%) to fifty percent (50%) greater than the first density. The second density may be twenty percent (20%) to forty percent (40%) greater than the first density. Although these examples show that the second density of stitching 304 in midfoot region 14 is greater than the first density of stitching 304 in heel region 16, in other examples, the first density of stitching in heel region 16 may be greater than the second density of stitching 304 in midfoot region 14.

[0126] The stitching 304 in the heel region 16 along the first length segment of the bundle 300 may include a first average distance between adjacent stitches, and the stitching 304 in the midfoot region 14 along the second length segment of the bundle 300 may include a second average distance between adjacent stitches. In some examples, the second average distance between the stitches in the midfoot region 14 may be greater than the first average distance between the stitches in the heel region 16. For example, the second average distance between the stitches 304 may be at least ten percent (10%) greater than the first average distance. In some configurations, the second average distance may be ten percent (10%) to fifty percent (50%) greater than the first average distance. In some configurations, the second average distance may be twenty percent (20%) to forty percent (40%) greater than the first average distance.

[0127] refer to Figure 8 , the bundle 300 of fibers 350 is attached to the base plate 400 in the forefoot region 12 via a third series of stitches 304 formed with thread and having a third density along a third length segment of the bundle 300 of fibers 350. Here, the third density / thickness of the stitches 304 along the third length segment of the bundle 300 in the forefoot region 12 is greater than Figure 7 The second density / thickness of stitches 304 along a second length of bundle 300 in midfoot region 14 (and Fig. 6A The lines forming the third series of stitches 304 may be continuous or discontinuous with the lines forming the first and / or second series of stitches 304. The third length segment of the bundle 300 may correspond to one of the segments 302 in the forefoot region 12, which extends in a direction between the lateral side 18 of the base plate 400 and the medial side 20 of the base plate 400 (i.e., converging with the longitudinal axis L of the base plate 400). In the example shown, the third density / thickness of the stitching 304 in the forefoot region 12 along the third length segment of the bundle 300 is proportional to the third length segment L3 separating adjacent attachment locations 305 arranged on the same side of the bundle 300. Here, the third length segment L3 separating adjacent attachment locations 305 associated with the third length segment of the bundle 300 is proportional to the third length segment L3 separating adjacent attachment locations 305 arranged on the same side of the bundle 300. Figure 7 The second length segment L2 separating the adjacent attachment positions 305 and Fig. 6AThe stitched article (e.g., bundle 300 and base plate 400) includes a stitching density / thickness in the forefoot region 12 along the third length segment of bundle 300 that is higher than both the stitching in the midfoot region 14 along the second length segment of bundle 300 and the stitching in the heel region 16 along the first length segment of bundle 300. The density / thickness of stitching 304 may also be increased by incorporating embroidery stitching that secures and penetrates base plate 400 but does not span or otherwise act to attach / secure bundle 300 of fibers 350 to base plate 400. The use of embroidery stitching only increases the density / thickness of stitching 304 in localized areas where it is desired to increase interlaminar fracture toughness, such as along flexure areas of a finished product (e.g., shoe plate 200).

[0128] In some embodiments, the third density is ten percent (10%) greater than the second density. In some examples, the third density may be ten percent (10%) to fifty percent (50%) greater than the second density. The third density may be twenty percent (20%) to forty percent (40%) greater than the second density. Although these examples show that the third density of stitching 304 in forefoot region 12 is greater than the second density of stitching 304 in midfoot region 14, in other examples, the second density of stitching in midfoot region 14 may be greater than the third density of stitching 304 in forefoot region 12.

[0129] The stitching 304 in the midfoot region 14 along the second length segment of the bundle 300 may include a second average distance between adjacent stitches, and the stitching 304 in the forefoot region 12 along the third length segment of the bundle 300 may include a third average distance between adjacent stitches. In some examples, the third average distance between the stitches in the forefoot region 12 may be greater than the second average distance between the stitches in the midfoot region 14. For example, the third average distance between stitches 304 may be at least ten percent (10%) greater than the second average distance. In some configurations, the third average distance is ten percent (10%) to fifty percent (50%) greater than the second average distance. In some configurations, the third average distance may be twenty percent (20%) to forty percent (40%) greater than the second average distance.

[0130] Although Figure 6A-8The example of describes that the density / thickness of the stitching 304 across the length of the bundle 300 increases from the heel area 16 to the forefoot area 12, but other examples may include that the density / thickness of the stitching 304 across the length of the bundle 300 increases from the forefoot area 12 to the heel area 16 without departing from the scope of the present disclosure. In addition, the density / thickness of the stitching 304 across the length (one or more) of one or more bundles 300 in the midfoot area 14 may be higher or lower than the density / thickness of the stitching 304 in the forefoot and heel areas 12 and 16. Therefore, any length / portion / segment of the bundle 300 extending along the base plate 400 can be selected to incorporate any density / thickness of the stitching 304 to achieve the desired strength and toughness properties in the localized area of ​​the finished product (e.g., the plate 200). For example, a higher density / thickness of the stitching 304 can be used in a localized area associated with the flex area of ​​the shoe plate 200 to mitigate crack propagation due to repeated bending / flexing. Additionally, while the attachment location 305 is shown as being spaced apart from the bundle 300 such that the suture 304 spans the bundle 300, other examples may include the suture 304 penetrating the bundle 300 at one or more locations along the length.

[0131] In some embodiments, the stitched article (ie, bundle 300 and substrate 400) includes a density of stitches 304 that varies in localized areas along the length of the fiber bundle. Fig. 9 , the close-up view shows a corresponding length segment / portion of the bundle 300 of fibers 350 attached to the substrate 400 via stitching 304, such that the density / consistency of the stitches 304 varies along the length segment of the bundle 300. For example, the length segment of the bundle 300 may correspond to one of the segments 302 extending in a direction from the outer side 18 of the substrate 400 to the inner side 20 of the substrate 400, and the density / consistency of the stitches 304 increases along the length segment of the bundle 300 from the inner side 20 to the inner side 18.

[0132] Fig. 9The stitches 304 are shown crossing the bundle 300 of fibers 350 and penetrating the substrate 400 at attachment locations 305-1, 305-2, 305-3, 305-4, 305-5, 305-6, 305-7, 305-8, 305-9, 305-10, 305-11, 305-12, 305-13, 305-14, with each successive attachment location being arranged in an alternating, repeating manner on opposite sides of the bundle 300. In some embodiments, the density / thickness of the stitches 304 is proportional to the length segments L1, L2, L3 separating adjacent attachment locations arranged on the same side of the substrate 400. In the example shown, the length segments separating adjacent attachment locations 305 arranged on the same side of the substrate 400 decrease along the length of the bundle 300 from the inner side 20 to the outer side 18. For example, a first length segment L1 separating adjacent attachment locations 305-2 and 305-4 is associated with a first density / thickness of stitching 304 near the inner side 20 of the base plate 400, a second length segment L2 separating adjacent attachment locations 305-6 and 305-8 is associated with a second density / thickness of stitching 304 within the inner region of the base plate 400, and a third length segment L3 separating adjacent attachment locations 305-10 and 305-12 is associated with a third density / thickness of stitching 304 near the outer side 18. Here, the second density / thickness of stitching 304 associated with the second length segment L2 is greater than the first density / thickness of stitching 304 associated with the longer first length segment L1, but less than the third density / thickness of stitching 304 associated with the shorter third length segment L3. Although this example shows the varying density / thickness of the stitching 304 increasing in a direction from the inner side 20 of the base plate 400 to the outer side 18 of the base plate 400, the density / thickness of the stitching 304 may increase in the opposite direction from the outer side 20 of the base plate 400 to the inner side 20 of the base plate 400 without departing from the scope of the present disclosure. Moreover, the density / thickness of the stitching 304 may also fluctuate between increasing and decreasing multiple times along any given length segment of the bundle 300 of fibers 350, with a maximum density / thickness at the middle portion of the side panel 400 between the outer side 18 and the inner side 20.

[0133] Fig.10A top view of a bundle 300a of fibers 350 that may form a layer 1000 of a shoe plate 200 is provided. The pattern of the bundle 300 of fibers 350 is shown relative to the peripheral edge P of the finished shoe plate 200. In some examples, the bundle 300a of fibers 350 is fixed / attached to a base layer including a corresponding substrate 400 to form a first layer 1000 on the substrate 400. In other examples, the bundle 300a is fixed / attached on top of a base layer that includes an underlying sheet (e.g., a unidirectional tape) or a layer of fiber bundles / bundles, all of which are fixed / attached to a single substrate 400 in a layered configuration. In some configurations, the bundle 300a is formed by a corresponding continuous bundle of fibers 350. However, in other configurations, the bundle 300a is formed by two or more bundles of fibers 350. The size of the bundle 502 can range from about 1,000 fibers per bundle to about 48,000 fibers per bundle. In some examples, bundle 300a includes 12,000 fibers per bundle. Bundle 300a may be made of Figure 1-9 The bundle 300a may be formed of the same or different fiber types. For example, the bundle 300a may include at least one of carbon fibers, glass fibers, boron fibers, and synthetic polymer fibers. The synthetic polymer fibers may include high-tenacity synthetic polymer fibers, such as aramid fibers. The fibers 350 may be mixed with thermosetting polymer materials and / or thermoplastic polymer materials to help secure the bundle 300a to the substrate 400 and / or any other fiber layers / sheets located below or above the bundle 300a to form the board 200 (or other article).

[0134] The base plate 400 defines a length extending from the first end 201 to the second end 202 along the longitudinal axis L and a width extending between the first side 18 (e.g., lateral side) and the second side 20 (e.g., medial side). When the stitched article is associated with the shoe plate 200, the first end 201 corresponds to the toe end of the plate 200 and the second end 202 corresponds to the heel end of the plate 200. In the illustrated example, a series of stitches 304 formed by thread attach a strand portion formed by a bundle 300a of fibers 300 to the base plate 400. The stitches 304 may span the toe portion 300a and penetrate the base plate 400 at an attachment location spaced apart from the strand / toe portion 300a, as described above with reference to Figure 6A-9Said. The stitch 304 may also penetrate the toe portion 300a of the fiber 350 at one or more locations. In some examples, the substrate 400 is a fabric including a first polymer composition, the first polymer composition including one or more first polymers, and the thread associated with the stitch 304 includes a second polymer composition, the second polymer composition including one or more second polymers. In this example, at least one of the one or more first polymers is the same as at least one of the one or more second polymers. Optionally, the material of the thread forming the stitch 304 (e.g., the second polymer material) may have a higher melting point than the material forming the substrate 400 (e.g., the first polymer material), so that when the substrate 400 begins to melt during thermoforming, the stitch 304 keeps the toe portion 300a in place. In some examples, the stitch 304 or at least a portion thereof is formed by a resin. In some examples, the melting temperature of the second polymer composition of the thread may be at least 15 degrees Celsius (°C) higher than the melting temperature of the first polymer composition of the substrate.

[0135] Fig.10 A strand portion formed by the toe portion 300a of the fiber 350 is shown, which includes a loop portion 315 for connecting adjacent sections / routes of the strand 300a. Some of the loop portion 315 extending beyond the peripheral edge P can be removed by cutting along the peripheral edge P to eliminate pinch points that can occur when pressure is applied to consolidate the fibers 350 to form the shoe plate 200. The loop portion 315 further defines a distal end for the adjacent section / route of the strand 300a, which terminates at a corresponding location on the base plate 400 that is spaced from the peripheral edge P at the first end 201 to define a flex zone 450 of the base plate at the distal end 400. The flex zone 450 includes greater flexibility than other areas of the base plate 400 and is therefore configured to provide greater flexibility to the finished shoe plate 200 at areas where the wearer's foot naturally bends / flexes during walking / running or other movements. The flex zone 450 may include a flexibility that is at least five percent (5%) greater than the flexibility of other areas. In other examples, the flexibility of the flex zone 450 is at least ten percent (10%) greater than the flexibility of the other areas. Here, the density of the fibers 350 is reduced by removing the presence of the fibers 350 at the flex zone 450 to accommodate the anatomical features and enhance the performance of the shoe 10 for its intended use. In the illustrated example, the distal ends in the flex zone 450 cooperate to define a transition line 1010 extending from the medial side 20 to the lateral side 18 of the base plate 400. Although Fig.10 The transition line 1010 is arcuate, and the distal end of the bundle 300a may be modified to form a straight transition line. The substrate 400 is exposed between the transition line 1010 and the peripheral edge P at the first end 201 of the substrate 400.

[0136] In some embodiments, the toe 300a includes a first length segment 310 and a second length segment 312, each of which extends in a direction between the first side 18 and the second side 20 (i.e., the toe portion 300a is arranged at a non-zero angle (excluding 180 degrees) relative to the longitudinal axis of the base plate 400, so that the directions of the length segments 310, 312 converge with the longitudinal axis L). In other configurations, the directions can extend parallel to the longitudinal axis L without departing from the scope of the present disclosure.

[0137] In the example shown, the first length segment 310 and the second length segment 320 are associated with the same length of the toe portion 300a, and the bundle includes multiple length segments / segments, each of which extends parallel to each other between the heel region 16 and the forefoot region 12. The density of the stitching 304 can be different along at least one of the multiple length segments / segments than another of the multiple length segments / segments. Along at least one of the multiple length segments / segments, the first length segment 310 is arranged closer to the first end 201 of the base plate 400 than the second end 202 of the base plate 400. For example, the first length segment 310 can be arranged within the flexure zone 450 of the base plate 400, and the second length segment 310 can be arranged outside the flexure zone 450. The stitching 304 in the flexure zone 450 of the base plate 400 may include a first density of the first length segment 310 along the bundle 300a, and the stitching 304 outside the flexure zone may include a second density along the second length segment 310 of the bundle 300a. Since the flexure region 450 of the substrate 400 is at the first length segment 310, the stitches 304 include a higher density along the first length segment 310 than the second length segment 312 to increase interlaminar fracture toughness at the flexure region 450 after the finished panel 200 (or other article) is formed. The detailed views of the respective portions along the first and second length segments 310, 312 of the bundle 300a each show the stitching 304 following a zigzag pattern across the bundle 300a and penetrating the substrate 400 at the corresponding attachment location 305. Optionally, the stitching 304 or a portion thereof may include a "tack" that is configured to attach a portion of the bundle 300a to the substrate 400, or simply configured as an embroidery to increase interlaminar fracture toughness in selected areas.

[0138] In some embodiments, the first density is ten percent (10%) greater than the second density. In some examples, the first density may be ten percent (10%) to fifty percent (50%) greater than the second density. The first density may be twenty percent (20%) to forty percent (40%) greater than the second density.

[0139] Fig.11A top view of the strands / bundles 300b of fibers 350 that may form the layer 1100 of the shoe plate 200 is provided. The pattern of the bundles 300 of fibers 350 is shown relative to the peripheral edge P of the finished shoe plate 200. In some examples, the bundles 300b of fibers 350 are secured / attached to a base layer including a corresponding substrate 400 to form the first layer 1100 on the substrate 400. In other examples, the bundles 300b are secured / attached on top of a base layer including an underlying sheet (e.g., a unidirectional tape) or a layer of fiber strands / bundles that are all secured / attached to a single substrate 400 in a layered configuration. Fig.10 Like the bundle 300a of fibers 350, the bundle 300 of fibers 350 can be formed by one continuous strand of fibers 350 or by two or more strands of fibers 350, and can range in size from about 1,000 fibers per bundle to about 48,000 fibers per bundle, and can include at least one of carbon fibers, glass fibers, boron fibers, and / or synthetic polymer fibers. The synthetic polymer fibers can include high-tenacity synthetic polymer fibers, such as aramid fibers. In addition, the fibers 350 can be mixed with a thermosetting polymer material and / or a thermoplastic polymer material to help secure the bundle 300b to the substrate 400 and / or any other fiber layers / sheets located below or above the bundle 300b to form the board 200 (or other article).

[0140] Embodiments include a series of stitches 304 formed by a thread to attach a bundle 300b of fibers 300 to a substrate 400 by penetrating the substrate 400 and / or penetrating the strands / bundles 300b across the bundle 300b and at an attachment location spaced apart from the strands / bundles 300b. In some examples, the substrate 400 is a fabric comprising a first polymer composition comprising one or more first polymers, and the thread associated with the stitching 304 comprises a second polymer composition comprising one or more second polymers. In this example, at least one of the one or more first polymers is the same as at least one of the one or more second polymers. Optionally, the material of the thread forming the stitching 304 (e.g., the second polymer material) can have a higher melting point than the material forming the substrate 400 (e.g., the first polymer material), so that when the substrate 400 begins to melt during thermoforming, the stitching 304 holds the bundle 300b in place. In some examples, the stitching 304 or at least a portion thereof is formed by a resin. In some examples, the melting temperature of the second polymer composition of the thread can be at least 15 degrees Celsius (° C.) higher than the melting temperature of the first polymer composition of the substrate.

[0141] Fig.11The bundle strand portion formed by the bundle 300b is shown to include a plurality of length segments (i.e., sections) 320 having a longitudinal axis extending in a direction between the forefoot region 12 (e.g., the first region) and the heel region 16 (e.g., the second region) of the base plate 400. Loop portions 325 may connect adjacent length segments 320. Some loop portions 325 extending beyond the peripheral edge P may be removed by cutting along the peripheral edge P to eliminate pinch points that may occur when pressure is applied to consolidate the fibers 350 to form the shoe plate 200 (or other article). In addition, the base plate 400 includes a flexure region 460 having greater flexibility than other regions of the base plate 400. More specifically, the plurality of length segments 320 of the bundle 300b positioned on the base plate 400 include a first substantially straight portion 321 within the midfoot and heel regions 14, 16 and an arched portion 322 within the forefoot region 12 defining the flexure region 460. Thus, the arcuate portions 322 of adjacent length segments 320 of the bundle 300b are aligned to define a flex zone 460, wherein a straight transition line 1110 extends across the width of the base plate 400 between the lateral side 18 (e.g., first side) of the base plate and the medial side 20 (e.g., second side) of the base plate 400. Here, the arcuate portions 322 provide curvature to the path of the bundle 300b of the fibers 350 to thereby change the direction in the load path of the plate 200 to accommodate anatomical features and enhance the performance of the shoe 10 for its intended use. Each length segment 320 of the bundle 300b may further include a second substantially straight portion 323 within the forefoot region 12, extending between the first end (e.g., toe end) 201 of the base plate 400 and the arcuate portion 322 (flex zone 460).

[0142] Flex zone 460 includes greater flexibility than other areas of base plate 400 and is therefore configured to provide greater flexibility to finished shoe plate 200 at areas where a wearer's foot naturally bends / flexes during walking / running or other motions. Flex zone 460 may include at least five percent (5%) greater flexibility than other areas. In other examples, the flexibility of flex zone 460 is at least ten percent (10%) greater than the flexibility of other areas.

[0143] With attachment Fig.10As with the stitches 304 of the bundle 300a of the embodiment of the present invention, the density of the stitches 304 may be different along at least one of the plurality of length segments 320 of the bundle 300b than another of the plurality of length segments 320 of the bundle 300b. The stitches 304 in the flexure zone 460 of the substrate 400 may include a first density along the arcuate portion 322 of the bundle 300b, and the stitches 304 outside the flexure zone may include a second density along the generally straight portions 321, 323 of the bundle 300b. In the example shown, the stitches along each length segment 320 include a higher density within the flexure zone 460 than in other areas to increase the interlaminar fracture toughness at the flexure zone 460 after the finished panel 200 (or other article) is formed. For example, the thickness / density of the stitching 304 attaching the arcuate portion 322 of the bundle 300b to the substrate 400 is greater than the thickness / density of the stitching 304 attaching the first and second substantially straight portions 321, 323 of the bundle 300b to the substrate 400. Fig.10 Like the stitches 304 of the bundle 300a, the stitching 304 along any length segment 320 and / or portion of the arcuate portion 322 of the bundle 300b may follow a zigzag pattern across the bundle 300b and penetrate the substrate 400 at the corresponding attachment location 305. Optionally, the stitching 304 or a portion thereof may include a "tack" configured to attach a portion of the bundle 300b to the substrate 400, or simply configured as an embroidery to increase interlaminar fracture toughness in selected areas.

[0144] In some embodiments, the first density is ten percent (10%) greater than the second density. In some examples, the first density may be ten percent (10%) to fifty percent (50%) greater than the second density. The first density may be twenty percent (20%) to forty percent (40%) greater than the second density.

[0145] Fig.12 A top view of a bundle 300c of fibers 350 that may form layer 1200 of shoe plate 200 is provided. Fig.11 Considering that the structure and function of the components associated with the strands / bundles 300c of layer 1200 are substantially similar relative to the strands / bundles 300b of layer 1100, the same reference numerals are used hereinafter and in the drawings to identify the same components, while like reference numerals including a letter extension are used to identify those components that have been modified.

[0146] and formation Fig.11Like the strands / bundles 300b of the fibers 350 of the layer 1100 of the base 400, the strands formed by the bundles 300c of the fibers 350 include a plurality of length segments (i.e., sections) 330 having a longitudinal axis extending in a direction between the forefoot region 12 (e.g., the first region) and the heel region 16 (e.g., the second region) of the base 400. The length segments 330 of the bundles 300c arranged on the base 400 include a first substantially straight portion 331 in the midfoot and heel regions 14, 16 and an arched portion 332 in the forefoot region 12, the arched portion 332 defining a flexure zone 470 greater than the flexure zone 470 defined by the base 400. Fig.11 4. The arcuate portions 322 of the bundles 300b of the base 400 are aligned to define a flex zone 460. Thus, the arcuate portions 332 of the adjacent length segments 330 of the bundles 300c are aligned to define a flex zone 470, wherein the straight transition line 1110 extends across the width of the base 400 between the lateral side 18 (e.g., first side) of the base and the medial side 20 (e.g., second side) of the base 400. Here, the arcuate portions 332 provide curvature to the path of the bundles 300c of the fibers 350 to thereby change the direction in the load path of the plate 200 to accommodate anatomical features and enhance the performance of the shoe 10 for its intended use. Each length segment 330 of the bundles 300c may further include a second substantially straight portion 333 within the forefoot region 12, which extends between the first end (e.g., toe end) 201 of the base 400 and the arcuate portion 332 (flex zone 470).

[0147] With attachment Fig.11 Like the pins 304 of the bundle 300b of the embodiment of the present invention, the density of the pins 304 may be different along at least one of the plurality of length segments 330 of the bundle 300c than another of the plurality of length segments 330 of the bundle 300c. The pins 304 in the flexure zone 470 of the substrate 400 may include a first density along the arcuate portion 332 of the bundle 300c, and the pins 304 outside the flexure zone may include a second density along the generally straight portions 331, 333 of the bundle 300b. In the example shown, the pins along each length segment 330 include a higher density within the flexure zone 470 than in other areas to increase the interlaminar fracture toughness at the flexure zone 470 after the finished panel 200 (or other article) is formed. For example, the thickness / density of the stitching 304 attaching the arcuate portion 332 of the bundle 300c to the substrate 400 is greater than the thickness / density of the stitching 304 attaching the first and second substantially straight portions 331, 333 of the bundle 300c to the substrate 400. Fig.10 The beam 300a and Fig.11Like the stitches 304 of the bundle 300b, the stitching 304 along any length segment 330 and / or portion of the arcuate portion 332 of the bundle 300c may follow a zigzag pattern across the bundle 300c and penetrate the substrate 400 at the corresponding attachment location 305. Optionally, the stitching 304 or a portion thereof may include a "tack" configured to attach a portion of the bundle 300c to the substrate 400, or simply configured as an embroidery to increase interlaminar fracture toughness in selected areas.

[0148] In some embodiments, the first density is ten percent (10%) greater than the second density. In some examples, the first density may be ten percent (10%) to fifty percent (50%) greater than the second density. The first density may be twenty percent (20%) to forty percent (40%) greater than the second density.

[0149] refer to Fig.13 , the layer 1100 formed by the bundles 300b of the corresponding fibers 350 can be incorporated into the series of stacked layers 500a-500b of fibers 502 to increase the flexibility of one or more localized areas and adjust the stiffness characteristics imparted by the finished shoe plate 200. Fig.10 and Fig.12Any one or both of the layers 1000, 1200 can replace or substitute the layer 1100 formed by the bundle 300b of the corresponding fiber 350 and be incorporated into a series of stacked layers 500a-500b of the fiber 502. In the example shown, the stacked layers 500a-500b are formed by individual bundles 502 of fibers, wherein each bundle 502 refers to a plurality of fibers, monofilaments, yarns or polymer prepreg bundles. For example, the bundle 902 may include a plurality of carbon fibers and a plurality of resin fibers, which, when activated, solidify and maintain the carbon fibers relative to each other in a desired shape and position. As used herein, the term "bundle" refers to a bundle (i.e., multiple) of filaments (e.g., fibers 350) that may be twisted or not, and each bundle may be specified as a size associated with the number of fibers contained in the corresponding bundle. For example, the size range of a single bundle 502 may be from about 1,000 fibers per bundle to about 48,000 fibers per bundle. Each bundle 502 can be fixed to a corresponding substrate 400, or all bundles 502 can be fixed to the same substrate 400 representing the base layer of the shoe plate 200. In other examples, the layers 500a-500b are formed by prepreg fiber sheets, which can be multiaxial fabrics or unidirectional tapes with fibers 502 impregnated with resin. Alternatively, some layers 500a-500b can be unidirectional tapes, while other layers 500a-500b can be multiaxial fabrics. Regardless of whether the layers 500a-500b correspond to layers formed by corresponding bundles 502 or to sheets of multiaxial fabrics or unidirectional tapes with fibers 502, the fibers 502 include at least one of carbon fibers, glass fibers, boron fibers, and / or synthetic polymer fibers. The synthetic polymer fibers may include high-tenacity synthetic polymer fibers, such as aramid fibers. Fibers such as carbon fibers, aromatic fibers, and boron fibers can provide a high Young's modulus, while glass fibers (e.g., glass fibers) and medium-tenacity polymer fibers (e.g., nylon or polyester fibers) can provide a medium modulus. The fiberglass fibers may include E6 318 fibers manufactured by Jushi™. The carbon fibers may include Teryfyl TC35 fibers, Hyosun H2550 fibers, or Tenax-E HTS 40 fibers.

[0150] In some embodiments, the layers 500a-500b include fibers 502 formed at different angles relative to each other, such that the longitudinal axes of the fibers 502 (unidirectional tapes, multiaxial fabrics, strands) are positioned at an angle (Φ) relative to the longitudinal axis (L) of each layer 500a-500b. In one configuration, the fibers 502 of layer 500a are positioned at an angle (Φ) equal to sixty degrees (60°) relative to the longitudinal axis (L), and the fibers 502 of layer 500b are positioned at an angle (Φ) equal to zero degrees (0°) relative to the longitudinal axis (L). Thus, when the layers 500a-500b are stacked on top of each other, the longitudinal axes of the fibers 502 associated with layer 500a are positioned at different angles relative to the longitudinal axis (L) of the board 200, while the longitudinal axes of the fibers 502 associated with layer 500b are positioned parallel to the longitudinal axis (L) of the board 200. In other configurations, layer 500a and / or layer 500b may be positioned at different angles relative to the longitudinal axis (L).

[0151] Fig.13 A stacked configuration comprising five (5) layers is shown, having a bottom layer 500a comprising fibers 502 oriented at 60° relative to the longitudinal axis (L), a next layer 500b comprising fibers 502 oriented at 0° relative to the longitudinal axis (L), a single layer 1100 of bundles 300b of fibers 350, a next layer 500b comprising fibers 502 oriented at 0° relative to the longitudinal axis (L), and a top, final layer 500a comprising fibers 502 oriented at 60° relative to the longitudinal axis (L). In the example shown, the bottom layer 500a is attached to the substrate 400, and the remaining layers 500a, 500b, 1100 are also attached to the substrate 400 on top of the bottom layer 500a. In other examples, at least two of the layers 500a-500b, 1100 are attached to respective substrates 400. Stitching 304 is used to attach the layers 500a-500b, 1100 to the substrate 400. The middle layer 1100 of the bundles 300b of fibers 350 provides a localized area of ​​increased flexibility in the forefoot region 12 due to the flex zone 460 formed by the arched portion 322 of the bundles 300b, and the stitching 304 attaching the bundles 300b of fibers 350 to the base plate 400 includes a density / thickness that is higher in the flexible zone 460 than in other areas to increase the interlaminar fracture toughness of the plate 200 in the localized area of ​​increased flexibility.

[0152] refer to Fig.14 In some embodiments, one or more of the layers 1100 formed from bundles 300b of corresponding fibers 350 may be incorporated into a series of stacked layers 600a-600b of fibers 602 to increase flexibility in one or more localized areas and adjust the stiffness properties imparted by the finished shoe plate 200. Fig.10 and Fig.12Either or both of the layers 1000, 1200 may be incorporated into the series of stacked layers 600a-600b of fibers 602 in place of or in lieu of the layer 1100 formed by the corresponding bundle 300b of fibers 350. Fig.13 Like the stacked layers 500a-500b of the present invention, the stacked layers 600a-600b are formed by individual strands 602 of fibers, wherein each strand 602 refers to a plurality of fibers, monofilaments, yarns, or polymer prepreg bundles. For example, the strands 602 may include a plurality of carbon fibers and a plurality of resin fibers that, when activated, solidify and hold the carbon fibers in a desired shape and position relative to each other. As used herein, the term "bundle" refers to a bundle (i.e., a plurality of) filaments (e.g., fibers 350) that may be twisted or untwisted, and each bundle may be specified as a size associated with the number of fibers contained in the corresponding bundle. For example, the size of a single strand 602 may range from approximately 1,000 fibers per bundle to approximately 48,000 fibers per bundle. Each strand 602 may be fixed to a corresponding substrate 400, or all strands 602 may be fixed to the same substrate 400 representing the base layer of the shoe plate 200. In other examples, the layers 600a-600b are formed by prepreg fiber sheets, which may be multiaxial fabrics or unidirectional tapes with fibers 602 impregnated with resin. Alternatively, some layers 600a-600b may be unidirectional tapes, while other layers 600a-600b may be multiaxial fabrics. Regardless of whether the layers 600a-600b correspond to layers formed by corresponding strands 602 or to sheets of multiaxial fabrics or unidirectional tapes with fibers 602, the fibers 602 include at least one of carbon fibers, glass fibers, boron fibers, and / or synthetic polymer fibers. Synthetic polymer fibers may include high-tenacity synthetic polymer fibers, such as aramid fibers. Fibers such as carbon fibers, aromatic fibers, and boron fibers may provide high Young's modulus, while glass fibers (e.g., glass fibers) and medium-tenacity polymer fibers (e.g., polyester or nylon fibers) may provide medium modulus. Fiberglass fibers may include E6 318 fibers manufactured by Jushi™. The carbon fibers may include Teryfyl TC35 fibers, Hyosun H2550 fibers, or Tenax-E HTS 40 fibers.

[0153] In some embodiments, the layers 600a-600b include fibers 602 formed at different angles relative to each other, such that the longitudinal axes of the fibers 602 (unidirectional tapes, multiaxial fabrics, strands) are positioned at an angle (Φ) relative to the longitudinal axis (L) of each layer 600a-600b. In one configuration, the fibers 602 of layer 600a are positioned at an angle (Φ) equal to sixty degrees (60°) relative to the longitudinal axis (L), and the fibers 602 of layer 600b are positioned at an angle (Φ) equal to zero degrees (0°) relative to the longitudinal axis (L). Thus, when the layers 600a-600b are stacked on top of each other, the longitudinal axes of the fibers 602 associated with layer 600a are positioned at different angles relative to the longitudinal axis (L) of the board 200, while the longitudinal axes of the fibers 602 associated with layer 600b are positioned parallel to the longitudinal axis (L) of the board 200. In other configurations, layer 600a and / or layer 600b may be positioned at different angles relative to the longitudinal axis (L).

[0154] Although Fig.13 The stacked configuration includes a total of five (5) layers, Fig.14 The layers show a stacked configuration including four (4) layers, with a bottom layer 600a including fibers 602 positioned at 60° relative to the longitudinal axis (L), a next layer 600b including fibers 602 positioned at 0° relative to the longitudinal axis (L), a single layer 1100 of bundles 300b of fibers 350, and a top, final layer 600a including fibers 602 positioned at 60° relative to the longitudinal axis (L). In the example shown, the bottom layer 600a is attached to the substrate 400, and the remaining layers 600a, 600b, 1100 are also attached to the substrate 400 on top of the bottom layer 600a. In other examples, at least two of the layers 600a-600b, 1100 are attached to respective substrates 400. Stitching 304 is used to attach the layers 600a-600b, 1100 to the substrate 400. The middle layer 1100 of the bundles 300b of fibers 350 provides a localized area of ​​increased flexibility in the forefoot region 12 due to the flex zone 460 formed by the arched portion 322 of the bundles 300b, and the stitching 304 attaching the bundles 300b of fibers 350 to the base plate 400 includes a density / thickness that is higher in the flexible zone 460 than in other areas to increase the interlaminar fracture toughness of the plate 200 in the localized area of ​​increased flexibility.

[0155] refer to Fig.15 In some embodiments, one or more of the layers 1100 formed from bundles 300b of corresponding fibers 350 may be incorporated into the series of stacked layers 700a of fibers 702 to increase flexibility in one or more localized areas and adjust the stiffness properties imparted by the finished shoe plate 200. Fig.10 and Fig.12Either or both of the layers 1000, 1200 may be incorporated into the series of stacked layers 700a of fibers 702 in place of or in lieu of the layer 1100 formed by the corresponding bundle 300b of fibers 350. Fig.13 and Fig.14 Like the stacked layers 500a-500b, 600a-600b of the present invention, the stacked layer 700a is formed by individual strands 702 of fibers, wherein each strand 702 refers to a plurality of fibers, monofilaments, yarns or polymer prepreg bundles. For example, the strands 702 may include a plurality of carbon fibers and a plurality of resin fibers, which, when activated, solidify and hold the carbon fibers relative to each other in a desired shape and position. As used herein, the term "bundle" refers to a bundle (i.e., a plurality of) filaments (e.g., fibers 350) that may be twisted or untwisted, and each bundle may be specified as a size associated with the number of fibers contained in the corresponding bundle. For example, the size of a single strand 702 may range from about 1,000 fibers per bundle to about 48,000 fibers per bundle. Each strand 702 may be fixed to a corresponding substrate 400, or all strands 702 may be fixed to the same substrate 400 representing the base layer of the shoe plate 200. In other examples, layer 700a is formed by a prepreg fiber sheet, which can be a multiaxial fabric or unidirectional tape with fibers 702 impregnated with resin. Alternatively, some layers 700a can be unidirectional tapes, while other layers 700a can be multiaxial fabrics. Regardless of whether layer 700a corresponds to a layer formed by corresponding strands 702 or a sheet of a multiaxial fabric or unidirectional tape with fibers 702, fibers 702 include at least one of carbon fibers, glass fibers, boron fibers, and / or synthetic polymer fibers. Synthetic polymer fibers may include high-tenacity synthetic polymer fibers, such as aramid fibers. Fibers such as carbon fibers, aromatic fibers, and boron fibers can provide a high Young's modulus, while glass fibers (e.g., glass fibers) and medium-tenacity polymer fibers (e.g., polyester or nylon fibers) can provide a medium modulus. Fiberglass fibers may include E6318 fibers manufactured by JushiTM. Carbon fibers may include Teryfyl TC35 fibers, Hyosun H2550 fibers, or Tenax-EHTS 40 fibers.

[0156] In some embodiments, the layers 700a include fibers 702 formed at different angles relative to each other, such that the longitudinal axes of the fibers 702 (unidirectional tapes, multiaxial fabrics, strands) are positioned at an angle (Φ) relative to the longitudinal axis (L) of each layer 700a. In one configuration, the fibers 702 of the layer 700a are positioned at an angle (Φ) equal to sixty degrees (60°) relative to the longitudinal axis (L). Thus, when the layers 700a are stacked on top of each other, the longitudinal axes of the fibers 702 associated with the layers 700a are positioned at different angles relative to the longitudinal axis (L) of the board 200. In other configurations, the layers 600a may be positioned at different angles relative to the longitudinal axis (L).

[0157] Fig.14 The layers show a stacked configuration including four (4) layers, having a bottom layer 700a including fibers 702 positioned at 60° relative to the longitudinal axis (L), two (2) layers 1100 of bundles 300b of fibers 350, and a top, final layer 700a including fibers 702 positioned at 60° relative to the longitudinal axis (L). In the example shown, the bottom layer 700a is attached to the substrate 400, and the remaining layers 700a, 1100 are also attached to the substrate 400 on top of the bottom layer 700a. In other examples, at least two of the layers 700a, 1100 are attached to respective substrates 400. Stitching 304 is used to attach the layers 700a, 1100 to the substrate 400. The two intermediate layers 1100 of the bundles 300b of fibers 350 provide local areas of increased flexibility in the forefoot region 12 due to the flex zones 460 formed by the arched portions 322 of the bundles 300b, and the stitching 304 attaching each bundle 300b of fibers 350 to the base plate 400 includes a density / thickness that is higher in the flexible zones 460 than in other areas to increase the interlaminar fracture toughness of the plate 200 in the local areas of increased flexibility.

[0158] Although Figure 13-15 Examples of the invention relate to stacking layers of fibers 702 on one or more substrates 400 to form a shoe plate, other examples may include stacking fiber layers on one or more differently shaped substrates 400 to form other stitched articles that include increased flexibility in one or more localized regions. For example, such other articles formed to have increased flexibility in one or more localized regions may include a higher density / thickness of stitching 304 in the localized region(s) to increase the interlaminar fracture toughness of the finished product in the localized region(s) of increased flexibility.

[0159] Figure 13-15Depicted is a first strand portion formed of a first fiber bundle being attachable to a base plate in at least first and second regions (e.g., a heel and forefoot) via a series of stitches formed with a second thread, and at least a second strand portion formed of a second fiber bundle being attachable to a base plate in at least first and second regions via a series of stitches formed with a second thread. The first fiber bundle may include carbon fiber and the second fiber bundle may include glass fiber. In some examples, a density of the first fiber bundle in the first region is at least five percent (5%) greater than a density of the first fiber bundle in the second region. Additionally or alternatively, a density of the second fiber bundle in the second region is at least five percent (5%) greater than a density of the second fiber bundle in the first region.

[0160] Special reference Fig.16 and 17 , the formation of the shoe plate 200 is described in conjunction with a mold 800. The mold 800 includes a first mold half 802 and a second mold half 804. The mold halves 802, 804 include a mold cavity 806 having the shape of the shoe plate 200 to allow the mold 800 to impart the desired shape of a particular plate 200. Fig.13 The stacked layers 500a-500b, Fig.14 The stacked layers 600a-600b or Fig.15 The stacked layer 700a, wherein the Fig.13 The stacked layers 500a-500b are incorporated into the first bundles 300a, 300b, 300c of the fibers 350. Figure 10-12 One or more of the layers 1000, 1100, 1200, the Fig.14 The stacked layers 600a-600b are incorporated into the first bundles 300a, 300b, 300c of the fibers 350. Figure 10-12 One or more of the layers 1000, 1100, 1200, the Fig.15 The stacked layer 700a is incorporated into the corresponding first bundles 300a, 300b, 300c of fibers 350. Figure 10-12 One or more of layers 1000, 1100, 1200.

[0161] In some examples, the bundles 300a, 300b, 300c attached to the corresponding substrate 400 via the stitching 304 are solidified via resin, such as a liquid resin material applied to the bundles 300a, 300b, 300c, the substrate 400 and the stitching 304. The liquid resin may include a liquid epoxy resin. The liquid resin may be formed by combining the first and second reactive compositions to form a liquid resin. The application of the resin material may flow through the bundles 300a, 300b, 300c, the substrate 400 and the stitching 304, and then solidify when subjected to the heat and pressure of the mold 800. As discussed above, the stitching 304 may be formed by a line that may span the bundles 300a, 300b, 300c and / or penetrate the bundles 300a, 300b, 300c or other fiber layers below to fix the bundles 300a, 300b, 300c to the substrate. For example, the thread can be formed of a material having a higher melting point than the substrate 400, so that when the substrate 400 begins to melt during the thermoforming process, the stitching 304 can keep the bundles 300a, 300b, 300c in place. The thread can be formed of a resin and / or formed of the same or different material as the substrate. The substrate 400 can be formed of a fabric comprising a first polymer composition having one or more first polymers, and the thread can be formed of a second polymer composition having one or more second polymers, whereby at least one of the one or more first polymers is the same as at least one of the one or more second polymers. The fabric forming the substrate 400 can be a non-woven fabric. In some examples, the melting temperature of the second polymer composition of the thread can be at least 15 degrees Celsius (°C) higher than the melting temperature of the first polymer composition of the substrate.

[0162] After forming the stacked sheets / layers 500a-500b, 600a-600b, 700a, the sheets / layers 500a-500b, 600a-600b, 700a are inserted between the mold halves 802, 804 within the mold cavity 806. At this point, the mold 800 is closed by moving the mold halves 802, 804 toward each other or by moving one of the mold halves 802, 804 toward the other mold half 802, 804. Once closed, the mold 800 applies heat and pressure to the stacked sheets / layers 500a-500b, 600a-600b, 700a disposed within the mold cavity 806 to activate the resin associated with the stacked sheets / layers 500a-500b, 600a-600b, 700a. The heat and pressure applied to the stacked sheets / layers 500a-500b, 600a-600b, 700a causes the specific shape of the mold cavity 806 to be applied to the stacked sheets / layers 500a-500b, 600a-600b, 700a, and once cured, the resin associated with the stacked sheets / layers 500a-500b, 600a-600b, 700a hardens and maintains the desired shape of the stacked sheets / layers 500a-500b, 600a-600b, 700a. In some examples, when the resin composition includes a liquid epoxy resin composition, the liquid epoxy resin composition is cured before removing the composite article from the mold. In addition, the incorporated layer(s) 1000, 1100, 1200 formed by the respective bundles 300a, 300b, 300c of fibers 350 may include thermoplastic yarns and / or stitching 304 formed from a thermoplastic or thermoset material to assist in attachment to the stacked layers 500a-500b, 600a-600b, 700a to maintain a desired shape.

[0163] In some embodiments, the resin composition is a thermoplastic resin composition contained within at least one of the base plate, the strand portions 300, 300b, 300c, and the threads of the stitching 304. The thermoplastic resin may consolidate the base plate, the strand portions, and the threads of the stitching 304 by flowing and penetrating the fibers 350 of the strand portions. The thermoplastic resin composition may be allowed to re-solidify before the composite article is removed from the mold.

[0164] It should be noted that although the sheets / layers 500a - 500b , 600a - 600b , 700a are described as comprising a resin material, the sheets / layers 500a - 500b , 600a - 600b , 700a may alternatively be provided with a resin injected into the mold 800 .

[0165] The injected resin may be in addition to the impregnating resin of the sheets / layers 500a-500b, 600a-600b, 700a, or alternatively, may be used in place of the impregnating resin. The injected resin may include a liquid epoxy, thermoplastic or thermosetting material.

[0166] The foregoing process can be used to form a shoe plate and cushioning elements that can be used to manufacture custom footwear. For example, various measurements of the foot can be recorded to determine the appropriate size of the shoe plate and cushioning member(s) to be incorporated into the article of footwear. In addition, data associated with the foot gate can be obtained to determine whether the foot represents a toe strike or a heel strike. The foot measurements and the data obtained can be used to determine the optimal angle and radius of curvature of the shoe plate, as well as the thickness of the one or more cushioning members located above, below, or encapsulating the insole of the shoe plate.

[0167] Furthermore, the length and width of the shoe plate can be determined based on the collected data and the measurements of the foot. In some examples, the measurements of the foot and the collected data are used to select the shoe plate and / or cushioning member(s) from a plurality of prefabricated shoe plates and / or cushioning members having various sizes and dimensions that closely match the wearer's foot.

[0168] Customized shoe plates may further allow the stiffness of the plate to be customized for a particular wearer of the footwear. For example, an athlete's tendon stiffness and calf muscle strength may be measured to determine the appropriate stiffness of the plate to be used by the athlete. Here, the stiffness of the shoe plate may vary with the athlete's strength or the athlete's tendon size / condition.

[0169] Additionally or alternatively, the stiffness of the plate can be customized based on the biomechanics and running mechanics of a particular athlete, such as how the athlete's joint angles change during the running motion. In some examples, the athlete's force and motion measurements are obtained before a custom plate is manufactured for the athlete. In other examples, plates are manufactured in specific stiffness ranges or increments to provide a semi-custom shoe so that individual athletes can select the appropriate stiffness.

[0170] The following clauses provide exemplary configurations of methods for forming the panels of the above-described articles of footwear.

[0171] Item 1: A sewn article comprising: a substrate having a first region and a second region; and a first strand portion formed by a first fiber bundle, wherein the first fiber bundle is attached to the substrate in the first region and the second region via a series of stitches formed with a first thread, and the first fiber bundle forms a first layer on the substrate, and the article has a first stitch density in the first region along a first length segment of the first strand portion, and has a second stitch density different from the first density in the second region along a second length segment of the first strand portion.

[0172] Clause 2: The sewn article of Clause 1, wherein the stitch crosses over the first strand portion and penetrates the base plate at a first attachment location spaced from the first strand portion, and crosses over the second strand portion and penetrates the base plate at a second attachment location spaced from the second strand portion.

[0173] Clause 3: The sewn article of Clause 1, wherein the stitch penetrates the first bundle of strands, the second bundle of strands, or both.

[0174] Clause 4: The sewn article of any preceding clause, wherein the first length segment extends in a direction between an inner side of the base plate and an outer side of the base plate.

[0175] Clause 5: The sewn article of Clause 4, wherein the second length segment extends in a direction between an inner side of the base plate and an outer side of the base plate.

[0176] Clause 6: The sewn article of any preceding clause, wherein the first density is greater than the second density.

[0177] Clause 7: The sewn article of Clause 6, wherein the first density is at least ten percent greater than the second density.

[0178] Clause 8: The sewn article of Clause 7, wherein the first density is ten to fifty percent greater than the second density.

[0179] Clause 9: The sewn article of Clause 8, wherein the first density is twenty to forty percent greater than the second density.

[0180] Clause 10: The sewn article of any preceding clause, wherein a first average distance between stitches in the first region is greater than a second average distance between stitches in the second region.

[0181] Clause 11: The sewn article of Clause 10, wherein the first average distance between stitches is ten percent greater than the second average distance between stitches.

[0182] Clause 12: The sewn article of Clause 11, wherein the first average distance between stitches is ten to fifty percent greater than the second average distance between stitches.

[0183] Clause 13: The sewn article of Clause 12, wherein the first average distance between stitches is twenty to forty percent greater than the second average distance between stitches.

[0184] Clause 14: The sewn article of any of Clauses 1-5 or 10-13, wherein the second density is greater than the first density.

[0185] Clause 15: The sewn article of Clause 14, wherein the second density is at least ten percent greater than the first density.

[0186] Clause 16: The sewn article of Clause 15, wherein the second density is ten to fifty percent greater than the first density.

[0187] Clause 17: The sewn article of Clause 16, wherein the second density is 20 to 40 percent greater than the first density.

[0188] Clause 18: The sewn article of any of Clauses 1-9 or 14-17, wherein the second average distance between stitches in the first region is greater than the first average distance between stitches in the second region.

[0189] Clause 19: The sewn article of Clause 18, wherein the second average distance between stitches is ten percent greater than the first average distance between stitches.

[0190] Clause 20: The sewn article of Clause 19, wherein the second average distance between stitches is ten to fifty percent greater than the first average distance between stitches.

[0191] Clause 21: The sewn article of Clause 20, wherein the second average distance between stitches is twenty to forty percent greater than the first average distance between stitches.

[0192] Clause 22: The sewn article of any preceding clause, wherein the substrate is a fabric comprising a first polymer composition comprising one or more first polymers.

[0193] Clause 23: The sewn article of any preceding clause, wherein the thread comprises a second polymer composition comprising one or more second polymers.

[0194] Item 24: The sewn article of Item 23, wherein both the first polymer composition of the fabric and the second polymer composition of the thread are thermoplastic compositions.

[0195] Clause 25: The sewn article of Clause 23 or 24, wherein both the one or more first polymers of the first polymer composition of the fabric and the one or more second polymers of the second polymer composition of the thread comprise polyurethane, polyester, polyether, polyamide, or polyolefin.

[0196] Clause 26: The sewn article of Clause 22, wherein the fabric is a nonwoven fabric.

[0197] Clause 27: The sewn article of any of the preceding clauses, wherein the fiber bundle comprises at least one of carbon fibers, boron fibers, glass fibers, and synthetic polymer fibers.

[0198] Clause 28: The sewn article of Clause 27, wherein the synthetic polymer fibers include aramid fibers.

[0199] Clause 29: A sewn article as claimed in any preceding clause, wherein the sewn article comprises a second strand portion formed from a second fiber bundle and the second strand portion is attached to the base plate in the first and second regions via a series of stitches formed with a second thread.

[0200] Clause 30: The sewn article of any preceding clause, wherein the first fiber bundle comprises carbon fibers.

[0201] Clause 31: The sewn article of Clause 29 or 30, wherein the second fiber bundle comprises glass fibers.

[0202] Clause 32: The sewn article of any of Clauses 29 to 31, wherein a density of the first fiber bundles in the first region is at least five weight percent greater than a density of the first fiber bundles in the second region.

[0203] Clause 33: The sewn article of any of Clauses 29 to 32, wherein a density of the second fiber bundles in the second region is at least five weight percent greater than a density of the second fiber bundles in the first region.

[0204] Clause 34: The sewn article of any of Clauses 23-33, wherein the melting temperature of the second polymer composition of the thread is at least 20 degrees Celsius higher than the melting temperature of the first polymer composition of the substrate.

[0205] Clause 35: The sewn article of any preceding clause, wherein the series of stitches spans across the first strand portion.

[0206] Clause 36: The sewn article of any preceding clause, wherein the second region defines a flex zone having a greater flexibility than the first region.

[0207] Clause 37: The sewn article of Clause 36, wherein the flexibility of the second region is at least five percent greater than the flexibility of the first region.

[0208] Clause 38: The sewn article of Clause 37, wherein the flexibility of the second region is at least ten percent greater than the flexibility of the first region.

[0209] Clause 39: The sewn article of clauses 22-31 or 33-38, wherein the second density is greater than the first density.

[0210] Clause 40: The sewn article of any preceding clause, wherein the sewn article is a component of an article of footwear, an article of apparel, or an article of sporting equipment.

[0211] Clause 41: The sewn article of Clause 40, wherein the sewn article is a component of an article of footwear.

[0212] Clause 42: The sewn article of Clause 41, wherein the component of the article of footwear is a component of a plate of the article of footwear.

[0213] Item 43: A sewn article comprising: a base having a first side and a second side, and a strand portion formed by a fiber bundle; wherein the strand portion is attached to the base via a series of stitches formed with thread, the strand portion forming a first layer on the base, the strand portion comprising a first length segment extending in a direction between the first side and the second side and a second length segment extending in a direction between the first side and the second side, the stitches having a different density along the first length segment than along the second length segment.

[0214] Clause 44: The sewn article of Clause 43, wherein the stitch spans the strand portion and penetrates the base plate at a first attachment location spaced apart from the strand portion.

[0215] Clause 45: The sewn article of Clause 43, wherein the stitches penetrate the strand portion.

[0216] Clause 46: The sewn article of any preceding clause, wherein the base plate includes a first end and a second end, the first length segment is closer to the first end than the second length segment, and the first length segment has a greater stitch density than the second length segment.

[0217] Clause 47: The sewn article of Clause 46, wherein the base plate includes a flex region at the first length segment, the flex region having greater flexibility than other regions of the base plate.

[0218] Item 48: A sewn article as described in any of the preceding items, wherein the substrate is a fabric comprising a first polymer composition having one or more first polymers, and the thread comprises a second polymer composition having one or more second polymers, wherein at least one of the one or more first polymers is the same as at least one of the one or more second polymers.

[0219] Clause 49: The sewn article of any preceding clause, wherein the fiber bundle comprises at least one of carbon fibers, boron fibers, glass fibers, and synthetic polymer fibers.

[0220] Item 50: The sewn article of Item 48 or 49, wherein both the first polymer composition of the fabric and the second polymer composition of the thread are thermoplastic compositions.

[0221] Clause 51: The sewn article of Clause 48 or 50, wherein both the one or more first polymers of the first polymer composition of the fabric and the one or more second polymers of the second polymer composition of the thread comprise polyurethane, polyester, polyether, polyamide, or polyolefin.

[0222] Clause 52: The sewn article of any of Clauses 48-51, wherein the melting temperature of the second polymer composition of the thread may be at least 20 degrees Celsius higher than the melting temperature of the first polymer composition of the substrate.

[0223] Clause 53: The sewn article of any preceding clause, wherein the series of stitches spans across a strand portion.

[0224] Item 54: The sewn article includes a base plate having a first side and a second side and a strand portion formed by a fiber bundle, the strand portion being attached to the base plate via a series of stitches formed with thread, forming a first layer on the base plate, and including a first length segment extending in a direction between the first side and the second side and a second length segment extending in a direction between the first side and the second side, the density of the stitches varying between the first side and the second side along at least one of the first length segment and the second length segment.

[0225] Clause 55: The sewn article of Clause 54, wherein the stitch spans the strand portion and penetrates the base plate at a first attachment location spaced apart from the strand portion.

[0226] Clause 56: The sewn article of Clause 54, wherein the stitches penetrate the strand portion.

[0227] Clause 57: The sewn article of any preceding clause, wherein the base plate includes a first end and a second end, the first length segment being closer to the first end than the second length segment and having a greater stitch density than the second length segment.

[0228] Clause 58: The sewn article of Clause 57, wherein the base plate includes a flexure region at the first length segment, the flexure region having greater flexibility than other regions of the base plate.

[0229] Item 59: A sewn article as described in any of the preceding items, wherein the substrate is a fabric comprising a first polymer composition having one or more first polymers, and the thread comprises a second polymer composition having one or more second polymers, wherein at least one of the one or more first polymers is the same as at least one of the one or more second polymers.

[0230] Clause 60: The sewn article of any of the preceding clauses, wherein the fiber bundle comprises at least one of carbon fibers, aramid fibers, boron fibers, glass fibers, and polymer fibers.

[0231] Clause 61: The sewn article of any preceding clause, wherein the thread is formed of a resin.

[0232] Clause 62: The sewn article of any preceding clause, wherein the thread is formed from the same material as the substrate.

[0233] Clause 63: The sewn article of any preceding clause, wherein the material forming the thread has a higher melting point than the substrate.

[0234] Clause 64: The sewn article of any preceding clause, wherein the series of stitches spans across a strand portion.

[0235] Item 65: A sewn article comprising a substrate having a first region and a second region, and a strand portion formed by a fiber bundle, the strand portion being attached to the substrate via a series of stitches formed with thread, forming a first layer on the substrate, and comprising a plurality of length segments having a longitudinal axis extending in a direction between the first region and the second region and distal ends terminating at corresponding positions on the substrate, the corresponding positions being spaced from an edge of the substrate to define a flexure region of the substrate at the distal end, the flexure region having greater flexibility than other regions of the substrate.

[0236] Clause 66: The sewn article of Clause 65, wherein the distal ends cooperate to form a transition line extending across a width of the base plate between the first side of the base plate and the second side of the base plate.

[0237] Clause 67: The sewn article of Clause 66, wherein the transition line is arcuate.

[0238] Clause 68: The sewn article of Clause 66, wherein the transition line is straight.

[0239] Clause 69: The sewn article of any of Clauses 66-68, wherein the transition line extends from the first side to the second side.

[0240] Clause 70: The sewn article of any of Clauses 66-69, wherein the substrate is exposed between the transition line and the edge.

[0241] Clause 71: The sewn article of Clause 65, wherein the base plate is exposed between the distal end and the edge.

[0242] Clause 72: The sewn article of Clause 65, wherein the stitch spans the strand portion and penetrates the base plate at a first attachment location spaced apart from the strand portion.

[0243] Clause 73: The sewn article of Clause 65, wherein the stitches penetrate the strand portion.

[0244] Clause 74: The sewn article of any preceding clause, wherein a stitch density along at least one of the plurality of length segments is different than a stitch density along another of the plurality of length segments.

[0245] Clause 75: The sewn article of Clause 74, wherein a density of stitches varies along at least one of the plurality of length segments.

[0246] Clause 76: The sewn article of Clause 65, wherein a density of stitches varies along at least one of the plurality of length segments.

[0247] Item 77: A sewn article as described in any of the preceding items, wherein the substrate is a fabric comprising a first polymer composition having one or more first polymers, and the thread comprises a second polymer composition having one or more second polymers, wherein at least one of the one or more first polymers is the same as at least one of the one or more second polymers.

[0248] Clause 78: The sewn article of any of the preceding clauses, wherein the fiber bundle comprises at least one of carbon fibers, aramid fibers, boron fibers, glass fibers, and polymer fibers.

[0249] Clause 79: The sewn article of any preceding clause, wherein the thread is formed of a resin.

[0250] Clause 80: The sewn article of any preceding clause, wherein the thread is formed from the same material as the substrate.

[0251] Clause 81: The sewn article of any preceding clause, wherein the material forming the thread has a higher melting point than the substrate.

[0252] Clause 82: The sewn article of any preceding clause, wherein the series of stitches spans across a strand portion.

[0253] Item 83: A sewn article comprising a substrate having a first region and a second region and a strand portion formed of a fiber bundle, the strand portion being attached to the substrate via a series of stitches formed with thread, forming a first layer on the substrate, and comprising a flexure region having greater flexibility than other regions of the substrate, the stitches having a greater density over the length of the strand portion within the flexure region than in other regions of the substrate.

[0254] Clause 84: The sewn article of Clause 83, wherein the flex zone defines a transition line extending across a width of the substrate between the first side of the substrate and the second side of the substrate.

[0255] Clause 85: The sewn article of clause 84, wherein the transition line is arcuate.

[0256] Clause 86: The sewn article of clause 84, wherein the transition line is straight.

[0257] Clause 87: The sewn article of any of Clauses 84-86, wherein the transition line extends from the first side to the second side.

[0258] Clause 88: The sewn article of any of Clauses 84-87, wherein the base panel is exposed between the transition line and an edge of the base panel.

[0259] Clause 89: The sewn article of Clause 83, wherein the stitch spans the strand portion and penetrates the base plate at a first attachment location spaced apart from the strand portion.

[0260] Clause 90: The sewn article of clause 83, wherein the stitches penetrate the strand portion.

[0261] Item 91: A sewn article as described in any of the preceding items, wherein the substrate is a fabric comprising a first polymer composition having one or more first polymers, and the thread comprises a second polymer composition having one or more second polymers, wherein at least one of the one or more first polymers is the same as at least one of the one or more second polymers.

[0262] Clause 92: The sewn article of any preceding clause, wherein the fiber bundle comprises at least one of carbon fibers, boron fibers, glass fibers, and synthetic polymer fibers.

[0263] Clause 93: The sewn article of any preceding clause, wherein the thread is formed of a resin.

[0264] Clause 94: The sewn article of any preceding clause, wherein the thread is formed from the same material as the substrate.

[0265] Clause 95: The sewn article of any preceding clause, wherein the material forming the thread has a higher melting point than the substrate.

[0266] Clause 96: The sewn article of any preceding clause, wherein the series of stitches spans across a strand portion.

[0267] Item 97: A method of forming a sewn article, the method comprising positioning a base plate, arranging a strand portion formed by a fiber bundle on the base plate, and attaching the strand portion to the base plate via a series of stitches formed with thread, so that a first area of ​​the sewn article has a first stitch density and a second area of ​​the sewn article has a second stitch density, wherein the first stitch density is at least ten percent greater than the second stitch density.

[0268] Clause 98: The method of clause 97, wherein the sewn article is a sewn article as described in any one of clauses 1 to 96.

[0269] Item 99: A method of forming a composite article, the method comprising positioning a sewn article in a mold, the sewn article comprising a strand portion of a fiber bundle sewn to a base plate with thread; while the sewn article is positioned in the mold, consolidating the base plate, the strand portion, and the stitches via a resin composition to form the composite article; and removing the composite article from the mold, wherein the composite article comprises a first region and a second region, the second region comprising a flex region having greater flexibility than the first region.

[0270] Clause 100: The method of Clause 99, further comprising forming the sewn article prior to positioning the sewn article in the mold.

[0271] Item 101: A method as described in Item 100, wherein forming a sewn article includes placing a strand portion formed by a fiber bundle on a substrate and attaching the strand portion to the substrate via a series of stitches formed with thread in a first area and a second area, the first area having a first stitch density and the second area having a second stitch area greater than the first stitch density.

[0272] Clause 102: The method of clause 101, wherein the sewn article is a sewn article as described in any one of clauses 1 to 96.

[0273] Clause 103: The method of any preceding clause, wherein consolidating the base plate, strand portions, and seams comprises applying a resin composition to the base plate, strand portions, and seams while the sewn article is in the mold.

[0274] Clause 104: The method of Clause 99, wherein applying the resin composition comprises combining the first and second reactive compositions to form a liquid resin composition, and applying the liquid composition to the sewn article.

[0275] Item 105: The method of Item 104, wherein the liquid resin composition is a liquid epoxy resin composition.

[0276] Clause 106: The method of any one of Clauses 103 to 105, further comprising curing the resin composition before removing the composite article from the mold.

[0277] Item 107: A method as described in any of items 103 to 106, wherein the resin composition is a thermoplastic resin composition contained within at least one of a base, a strand portion, and a thread of the sewn article, and consolidating the base, the strand portion, and the thread includes allowing the resin composition to flow and penetrate into the fibers of the strand portion, and then allowing the resin composition to re-solidify before removing the composite article from the mold.

[0278] Clause 108: The method of any preceding clause, wherein the method further comprises trimming the perimeter of the composite article.

[0279] Clause 109: The method of Clause 108, further comprising forming the base plate, the strand portions, and the stitching into a plate for an article of footwear.

[0280] Clause 110: The method of Clause 109, further comprising incorporating the plate into an article of footwear.

[0281] Item 111: A method as described in Item 99, wherein arranging the bundle portion on the substrate includes positioning the bundle portion in a plurality of length segments, the plurality of length segments having a longitudinal axis extending in a direction between a first region and a second region, the plurality of length segments having distal ends terminating at corresponding positions on the substrate, the corresponding positions being spaced apart from an edge of the substrate to define a flexure region.

[0282] Clause 112: The method of clause 99, wherein arranging the strand portions on the substrate comprises positioning the strand portions in a plurality of length segments having a first substantially straight portion within a first region and an arcuate portion defining a flexure zone within a second region.

[0283] Clause 113: The method of clause 99, further comprising aligning the arcuate portions of adjacent lengths to define a flexure zone.

[0284] Clause 114: The method of any preceding clause, wherein attaching the strand portion via a series of stitches formed with the thread comprises stitching across the strand portion and through the substrate at a first attachment location spaced from the strand portion.

[0285] Clause 115: The method of clauses 99-108, wherein attaching the strand portion via a series of stitches formed with the thread comprises penetrating the stitches through the strand portion.

[0286] Item 116: A method of manufacturing an article of footwear, apparel, or sporting equipment, the method comprising positioning a composite article, the composite article comprising a sewn article having a strand portion of a fiber bundle sewn to a substrate with thread, wherein the fibers are consolidated by a resin composition, wherein the composite article is a component of the article of footwear, apparel, or sporting equipment, and securing the composite article and a second component to each other, wherein the second component is a second component of the article of footwear, apparel, or sporting equipment.

[0287] Clause 117: The method of clause 116, wherein the composite article is a component of an article of footwear and the second component is a second component of the article of footwear.

[0288] Clause 118: The method of clause 117, wherein the composite article is a component of an article of footwear.

[0289] Item 119: A composite article comprising: the sewn article of any one of Items 1 to 96 and a resin composition, wherein the resin composition consolidates fibers of at least a first fiber bundle of the strand portion.

[0290] Item 120: The sewn article of Item 119, wherein the resin composition solidifies fibers of at least the first fiber bundle of the strand portion, fibers and / or yarns of the substrate, and threads of the sewn article.

[0291] Item 121: The composite article of Item 119 or 120, wherein the resin composition is a thermosetting resin composition, which optionally includes an epoxy resin.

[0292] Clause 122: The composite article of any one of clauses 119-121, wherein the resin composition is a thermoplastic resin composition, and the thermoplastic resin composition optionally comprises thermoplastic polyurethane, thermoplastic polyester, thermoplastic polyether, thermoplastic polyamide, thermoplastic polyolefin, or any combination thereof.

[0293] Clause 123: A composite article according to any one of Clauses 119 to 121, wherein the composite article is a component of an article of footwear.

[0294] Clause 124: A plate for an article of footwear as described in clause 123, wherein the plate includes a plurality of traction elements; and one or more of the plurality of traction elements optionally include a tip configured to contact the ground, and optionally, wherein the tip is formed from a polymer material different from the resin composition of the plate.

[0295] Item 125: A method of forming a plate for an article of footwear, the method comprising positioning a base plate, arranging a strand portion formed from fiber bundles on the base plate, and attaching the strand portion to the base plate via a series of stitches formed with thread, such that a first area of ​​the sewn article has a first stitch density and a second area of ​​the sewn article has a second stitch density, wherein the first stitch density is at least ten percent greater than the second stitch density.

[0296] Item 126: A method as described in Item 125, wherein the method further includes positioning the stitched article in a mold, disposing a liquid resin composition between and around a plurality of fibers of a fiber bundle stitched to a substrate, curing the liquid resin composition, consolidating the plurality of fibers with the solid resin composition, and forming a composite plate for the footwear article, and removing the composite plate from the mold.

[0297] Clause 127: The method of Clause 126, further comprising placing at least one traction element in the mold prior to placing the liquid resin composition, and attaching the traction element to the composite panel prior to removing the composite panel from the mold.

[0298] Clause 128: The method of clauses 125-127, further comprising incorporating the plate into a sole structure of an article of footwear.

[0299] Clause 129: The method of clauses 125-127, further comprising incorporating the plate into an article of footwear.

[0300] Clause 130: A panel formed by the method of any of Clauses 125-127.

[0301] Clause 131: A sole structure formed by the method of any of Clauses 125-127.

[0302] Clause 132: An article of footwear formed by the method of any of Clauses 125-127.

[0303] Item 133: A method of forming a composite plate for an article of footwear, comprising positioning a sewn article in a mold, the sewn article comprising a strand portion of a fiber bundle sewn to a base plate with thread, wherein a first area of ​​the sewn article has a first stitch density and a second area of ​​the sewn article has a second stitch density, wherein the first stitch density is at least ten percent greater than the second stitch density, and when the sewn article is positioned in the mold, arranging a resin composition between and around a plurality of fibers of the fiber bundle sewn to the base plate, causing the plurality of fibers to consolidate with the resin composition and form a composite plate for an article of footwear, the composite plate comprising a first area and a second area, the second area comprising a flexure area having greater flexibility than the first area; and removing the composite plate from the mold.

[0304] Clause 134: The method of clause 133, wherein the method further comprises forming the sewn article prior to positioning the sewn article in the mold.

[0305] Clause 135: The method of clauses 133-134, further comprising incorporating the plate into a sole structure of an article of footwear.

[0306] Clause 136: The method of clauses 133-134, further comprising incorporating the plate into an article of footwear.

[0307] Clause 137: A panel formed by the method of any of Clauses 133-134.

[0308] Clause 138: A sole structure formed by the method of any of clauses 133-134.

[0309] Clause 139: An article of footwear formed by the method of any of Clauses 133-134.

[0310] The foregoing description has been provided for purposes of illustration and description. It is not intended to exaggerate or limit this specification. Individual elements or features of a particular configuration are generally not limited to that particular configuration, but are interchangeable where appropriate and can be used in a selected configuration, even if not specifically shown or described. Individual elements or features of a particular embodiment may also be varied in a variety of ways. Such variations should not be considered to depart from this specification, and all such variations are intended to be included within the scope of this specification.

Claims

1. A method of forming a plate for an article of footwear, the method comprising: Forming sewn items, including: providing a substrate having a first region and a second region; positioning the substrate; disposing a first strand portion formed of a first fiber bundle on the substrate; and The first strand portion formed by the first fiber bundle is attached to the substrate in the first area and the second area via a series of stitches formed with a first thread to form a first layer on the substrate, the sewn article having a first stitch density in the first area along a first length segment of the first strand portion, and having a second stitch density different from the first stitch density in the second area along a second length segment of the first strand portion, wherein the method also includes the stitches crossing the first strand portion and penetrating the substrate at a first attachment position spaced apart from the first strand portion.

2. The method according to claim 1 further includes, when the sewn article is in a mold, consolidating (i) fibers of at least the first fiber bundle of the first strand portion with a resin composition, or consolidating (ii) fibers and / or yarns of the substrate and (iii) at least one of the first threads of the sewn article and (i) fibers of at least the first fiber bundle of the first strand portion with a resin composition. 3 . The method of claim 1 , further comprising extending the first length of the first strand portion in a direction between an inner side of the substrate and an outer side of the substrate. 4 . The method of claim 3 , further comprising extending the second length of the first strand portion in a direction between the inner side of the substrate and the outer side of the substrate.

5. The method according to claim 1, wherein: The first stitch density is greater than the second stitch density. 6 . The method of claim 1 , further comprising providing a first average distance between stitches in the first region, the first average distance being greater than a second average distance between stitches in the second region.

7. The method according to claim 1, wherein: The first fiber bundle includes at least one of carbon fibers, boron fibers, glass fibers, and synthetic polymer fibers.

8. The method according to claim 1, wherein: Forming the sewn article includes arranging a second strand portion formed of a second fiber bundle on the base plate and attaching the second strand portion formed of the second fiber bundle to the base plate in the first region and the second region via a series of stitches formed with a second thread.

9. The method according to claim 8, wherein: The first fiber bundle includes carbon fibers, and the second fiber bundle includes glass fibers.

10. The method of claim 1, wherein the substrate is a fabric comprising fibers and / or yarns formed from a first polymer composition comprising one or more first polymers, and the first yarn comprises a second polymer composition comprising one or more second polymers.

11. The method of claim 10, wherein both the first polymer composition of the fabric and the second polymer composition of the first thread are thermoplastic compositions.

12. The method according to claim 10, wherein the one or more first polymers of the first polymer composition of the fabric and the one or more second polymers of the second polymer composition of the first thread both comprise polyurethane, or comprise polyester, or comprise polyether, or comprise polyamide, or comprise polyolefin.

13. The method of claim 10, wherein the second polymer composition of the first line has a melting temperature that is at least 20 degrees Celsius higher than a melting temperature of the first polymer composition of the substrate.

14. The method of claim 2, further comprising, when the resin composition is a liquid resin composition, placing at least one traction element in the mold prior to placing the liquid resin composition; and attaching the traction element to the panel prior to removing the panel from the mold.

15. A method of forming a plate for an article of footwear, the method comprising: Positioning substrate; Arranging a strand portion formed of a fiber bundle on the substrate; as well as The strand portion is attached to the base plate via a series of stitches formed with thread to form a sewn article, a first area of ​​the sewn article having a first stitch density and a second area of ​​the sewn article having a second stitch density, wherein the first stitch density is at least ten percent greater than the second stitch density.

16. The method according to claim 15, wherein: The method further includes positioning the sewn article in a mold; disposing a liquid resin composition between and around a plurality of fibers of the fiber bundle sewn to the substrate; solidifying the liquid resin composition to consolidate the plurality of fibers and the solid resin composition to form a composite plate for footwear; as well as The composite panel is removed from the mold.

17. The method of claim 16, further comprising placing at least one traction element in the mold prior to placing the liquid resin composition; and The traction elements are attached to the composite panel prior to removing the composite panel from the mold.

18. A method of forming a composite panel for an article of footwear, the method comprising: Positioning a sewn article in a mold, the sewn article comprising a strand portion of a fiber bundle sewn to a base plate with thread, wherein a first area of ​​the sewn article has a first stitch density and a second area of ​​the sewn article has a second stitch density, wherein the first stitch density is at least ten percent greater than the second stitch density; disposing a resin composition between and around a plurality of fibers of the fiber bundle sewn to the base plate while the sewn article is positioned in the mold, consolidating the plurality of fibers with the resin composition and forming a composite plate for an article of footwear, the composite plate comprising a first region and a second region, the second region comprising a flex region having greater flexibility than the first region; and The composite panel is removed from the mold.

19. The method according to claim 18, wherein: The method also includes forming the sewn article prior to positioning the sewn article in the mold.

20. A plate for an article of footwear, comprising: Sewn articles, including: a substrate having a first region and a second region; and a first strand portion formed by a first fiber bundle and comprising a plurality of adjacent segments extending continuously between two different locations along a peripheral edge of the substrate, wherein (i) the first fiber bundle is attached to the substrate in the first region and the second region via a series of stitches formed with a first thread, the series of stitches formed with the first thread spanning the first strand portion and penetrating the substrate at a first attachment location spaced apart from the first strand portion, (ii) the first fiber bundle forms a first layer on the substrate, and (iii) the plurality of adjacent segments have a longitudinal axis extending in a direction between the first region and the second region of the substrate, the plurality of adjacent segments of the first fiber bundle positioned on the substrate comprising a first substantially straight portion within the first region and an arcuate portion defining a flexure region within the second region, the arcuate portions of the adjacent segments being aligned to define the flexure region; and A resin composition, wherein the resin composition consolidates fibers of at least a first fiber bundle of the first strand portion.

21. The panel of claim 20, wherein the resin composition consolidates fibers of at least the first fiber bundle of the first strand portion, fibers and / or yarns of the substrate, and the first thread of the sewn article.

22. The panel of claim 20, wherein the first fiber bundle comprises at least one of carbon fibers, boron fibers, glass fibers, and synthetic polymer fibers.

23. The panel of claim 20, wherein the substrate is a fabric comprising a first polymer composition comprising one or more first polymers, and the first threads comprise a second polymer composition comprising one or more second polymers.

24. The panel of claim 23, wherein both the first polymer composition of the fabric and the second polymer composition of the first threads are thermoplastic compositions.

25. The panel of claim 23, wherein the one or more first polymers of the first polymer composition of the fabric and the one or more second polymers of the second polymer composition of the first thread both comprise polyurethane, or comprise polyester, or comprise polyether, or comprise polyamide, or comprise polyolefin.

26. The panel of claim 23, wherein the melting temperature of the second polymer composition of the first thread is at least 20 degrees Celsius higher than the melting temperature of the first polymer composition of the substrate.

27. The plate of claim 20, wherein the plurality of adjacent segments of the first fiber bundles positioned on the base plate include an arched portion in a forefoot region defining the flex zone and first substantially straight portions in a midfoot region and a heel region.

28. The board of claim 27, wherein the plurality of adjacent segments of the first fiber bundles positioned on the base plate further include a second substantially straight portion within the forefoot region extending between a toe end of the base plate and the arch portion.

29. The plate of claim 28, wherein the series of stitches has a higher density of stitches along the arcuate portion than along the first substantially straight portion and along the second substantially straight portion.

30. The panel of claim 20, wherein the series of stitches have a higher density of stitches along the arcuate portion than along other portions of the first fiber bundle.

31. A sole structure comprising the plate according to claim 20.

32. An article of footwear comprising the plate of claim 20.

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