shoe plate

Abstract

This application relates to shoe plates. A method for forming a plate for footwear is disclosed. The method includes applying a first thread portion to a base layer, wherein applying the first thread portion to the base layer includes positioning adjacent segments of the first thread portion to form a first layer on the base layer. The adjacent segments of the first thread portion have a greater density in the width of the plate between the inner and outer portions at the midfoot region of the plate than at the forefoot region and the heel region of the plate. The method further includes applying at least one of heat and pressure to the first thread portion and the base layer to conform the first thread portion and the base layer to a predetermined shape.

Description

[0001] This application is a divisional application of the application filed on July 20, 2017, with application number 202110518050.9 and invention title "Shoe Board".

[0002] The application with the application date of July 20, 2017, application number 202110518050.9, and invention title "Shoe Board" is a divisional application of the application with the application date of July 20, 2017, application number 201780044431.X, and invention title "Shoe Board".

[0003] Cross-references to related applications

[0004] This application claims priority to U.S. Provisional Application No. 62 / 364,594, filed July 20, 2016; U.S. Provisional Application No. 62 / 364,585, filed July 20, 2016; and U.S. Provisional Application No. 62 / 474,030, filed March 20, 2017, the entire contents of which are incorporated herein by reference. Technical Field

[0005] This disclosure relates to footwear including sole structures having a shoe plate. Background Technology

[0006] This section provides background information relating to this disclosure, which is not necessarily prior art.

[0007] Footwear typically consists of an upper and a sole structure. The upper can be made of any suitable material to receive, secure, and support the foot on the sole structure. The upper can be fitted with laces, straps, or other fasteners to adjust the fit around the foot. The bottom portion of the upper, closest to the foot, is attached to the sole structure.

[0008] The sole construction typically comprises a layered arrangement extending between the ground and the upper. One layer of the sole construction includes an outsole that provides abrasion resistance and traction with the ground. The outsole may be formed of rubber or other materials that impart durability and abrasion resistance and enhance traction with the ground. Another layer of the sole construction includes a midsole disposed between the outsole and the upper. The midsole provides cushioning for the foot and is typically at least partially formed of a polymer foam material that elastically compresses under applied loads to protect the foot by reducing ground reaction forces. The midsole may define a sole surface opposite the outsole on one side and a footbed on the opposite side, the footbed being profiled to conform to the contours of the foot's sole surface. The sole construction may also include an insole or insole for enhanced comfort, located within a cavity near the bottom portion of the upper.

[0009] It is known that the metatarsophalangeal (MTP) joint of the foot absorbs energy during running by dorsiflexion. Since the foot does not move through plantarflexion before leaving the ground, the MTP joint returns almost no of its absorbed energy to the running motion; therefore, this is considered a source of energy loss during running. It is known to increase the overall stiffness of the sole structure by embedding a flat, rigid plate with longitudinal stiffness within the sole structure. While the use of a flat plate strengthens the sole structure to reduce energy loss at the MTP joint by preventing energy absorption through dorsiflexion, it also unfavorably increases the mechanical demands on the plantar flexors of the ankle, thus reducing the foot's efficiency during running, especially over longer distances. Attached Figure Description

[0010] The accompanying drawings described herein are for illustrative purposes only and are not intended to limit the scope of this disclosure.

[0011] Figure 1 It is a top perspective view of a footwear product based on the principles of this disclosure;

[0012] Figure 2 yes Figure 1 An exploded view of the footwear shows the shoe plate and cushioning components located within a cavity between the inner surface of the outsole and the bottom surface of the midsole.

[0013] Figure 3 It is along Figure 1 The cross-sectional view taken by line 3-3 shows the shoe plate and cushioning components disposed in the cavity between the inner surface of the outsole and the bottom surface of the midsole;

[0014] Figure 4 It is a top perspective view of a shoe plate used in footwear products based on the principles of this disclosure;

[0015] Figure 5 yes Figure 4 Side view of the shoe plate;

[0016] Figure 6 yes Figure 4 A top view of the shoe sole;

[0017] Figure 7 This is an exploded view of a stack of prepreg fiber sheets used to form a shoe plate, based on the principles of this disclosure;

[0018] Figures 8A to 8E Various prepreg sheets used in forming shoe plates according to the principles of this disclosure are shown;

[0019] Figure 9This is an exploded view of a layer formed of fiber strands for forming a shoe plate, based on the principles of this disclosure;

[0020] Figures 10A to 10E Various layers formed of fiber strands are shown in the process of forming a shoe plate according to the principles of this disclosure;

[0021] Figure 11 This is a top view of the first filament bundle of fibers used to form the corresponding layer of the shoe plate according to the principles of this disclosure;

[0022] Figure 12 yes Figure 11 A top view of the first bundle of fibers cut and aligned around the perimeter of the finished shoe plate;

[0023] Figure 13 This is a top view of the second filament bundle of fibers used to form the corresponding layer of the shoe plate according to the principles of this disclosure;

[0024] Figure 14 yes Figure 13 A top view of the fibers cut into second bundles aligned around the perimeter of the finished shoe plate;

[0025] Figure 15 This is a top view of the third filament bundle of fibers used to form the corresponding layer of the shoe plate, according to the principles of this disclosure;

[0026] Figure 16 yes Figure 15 A top view of the fibers cut into third bundles aligned around the perimeter of the finished shoe plate;

[0027] Figure 17 This is a top view of the fourth filament bundle of fibers used to form the corresponding layer of the shoe plate, according to the principles of this disclosure;

[0028] Figure 18 This is a top view of the fifth filament bundle of fibers used to form the corresponding layer of the shoe plate, according to the principles of this disclosure;

[0029] Figure 19 This is a top view of the sixth filament bundle of fibers used to form the corresponding layer of the shoe plate, according to the principles of this disclosure;

[0030] Figure 20 This is a perspective view of a mold used in forming a shoe plate according to the principles of this disclosure, which is shown in conjunction with the fiber stack before being formed into a shoe plate;

[0031] Figure 21 This is a perspective view of a mold used in forming a shoe plate according to the principles of this disclosure, which is shown in conjunction with the formed shoe plate;

[0032] Figure 22It is a bottom-view perspective view of a footwear product based on the principles of this disclosure;

[0033] Figure 23 yes Figure 22 An exploded view of a footwear product showing a cushioning member encapsulating the shoe plate and disposed within a cavity between the inner surface of the outsole and the bottom surface of the midsole;

[0034] Figure 24 It is the fiber used to form Figure 22 A top view of the first filament bundle of the corresponding layer of the shoe plate;

[0035] Figure 25 yes Figure 24 A top view of the first bundle of fibers cut and aligned around the perimeter of the finished shoe plate;

[0036] Figure 26 It shows the formation of Figure 22 The fiber strands of the shoe plate and Figure 25 The various layers formed by the first bundle of fibers;

[0037] Figure 27 It is the fiber used to form Figure 22 A top view of the second filament bundle of the corresponding layer of the shoe plate;

[0038] Figure 28 yes Figure 27 A top view of the first bundle of fibers cut and aligned around the perimeter of the finished shoe plate;

[0039] Figure 29 It shows the formation of Figure 22 The fiber strands of the shoe plate and Figure 28 Various layers formed by the second bundle of fibers;

[0040] Figure 30 It is formed based on the principles of this disclosure. Figure 22 A perspective view of the mold used in the shoe plate making process is shown, illustrating the combination of the mold with the fiber stacks before they are formed into the shoe plate; and

[0041] Figure 31 It is formed based on the principles of this disclosure. Figure 22 A three-dimensional diagram of the mold used in making the shoe plate, which is shown in conjunction with the formed shoe plate.

[0042] Throughout the accompanying drawings, corresponding reference numerals indicate corresponding parts. Detailed Implementation

[0043] Example configurations will now be described more fully with reference to the accompanying drawings. Example configurations are provided so that this disclosure will be exhaustive and fully convey the scope of this disclosure to those skilled in the art. Specific details, such as examples of specific components, apparatus, and methods, are set forth to provide a detailed understanding of the configurations of this disclosure. It will be apparent to those skilled in the art that specific details are not necessary, and that the example configurations may be implemented in many different forms, and that these specific details and exemplary configurations should not be construed as limiting the scope of this disclosure.

[0044] The terminology used herein is for the purpose of describing particular exemplary configurations only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprising,” “including,” “including,” and “having” are inclusive and thus describe the presence of features, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, steps, operations, elements, components, and / or groups thereof. The method steps, processes, and operations described herein should not be construed as requiring them to be performed in a particular order as discussed or illustrated, unless specifically stated otherwise. Additional or alternative steps may be employed.

[0045] When an element or layer is referred to as “on another element or layer,” “joined to another element or layer,” “connected to another element or layer,” “attached to another element or layer,” or “linked to another element or layer,” the element or layer may be directly joined, connected, attached to, or linked to the other element or layer, or there may be intermediate elements or layers present. In contrast, when an element is referred to as “directly on another element or layer,” “directly joined to another element or layer,” “directly connected to another element or layer,” “directly attached to another element or layer,” or “directly linked to another element or layer,” there may be no intermediate elements or layers present. Other terms used to describe relationships between elements (e.g., “between” and “directly between,” “adjacent” and “directly adjacent,” etc.) should be understood in a similar manner. As used herein, the term “and / or” includes any and all combinations of one or more of the associated enumerations.

[0046] The terms "first," "second," "third," etc., may be used in this document to describe various elements, components, regions, layers, and / or segments, but these elements, components, regions, layers, and / or segments should not be limited by these terms. These terms may be used only to distinguish one element, component, region, layer, or segment from another. For example, the terms "first," "second," and other numerical terms do not imply order or sequence unless the context clearly indicates otherwise. Therefore, the first element, component, region, layer, or segment discussed below may be referred to as a second element, component, region, layer, or segment without departing from the teachings of the example configuration.

[0047] One aspect of this disclosure provides a method for forming a plate for footwear. The method includes applying a first strand portion to a base layer, wherein applying the first strand portion to the base layer includes positioning first segments of the first strand portion adjacent to each other on the base layer to form a first layer on the base layer. The method further includes removing portions of the first segments to define an outer edge of the plate and applying at least one of heat and pressure to the first strand portion and the base layer to conform the first strand portion and the base layer to a predetermined shape.

[0048] Implementations of this disclosure may include one or more of the following optional features. In some implementations, removing a portion of the first segment includes cutting off a portion of the first strand at a first end of each first segment and cutting off the portion of the first strand at a second end of each first segment located at the end opposite to the first end of the corresponding portion of the first strand. Removing a portion of the first segment may include removing an annular portion connecting adjacent first segments from the first strand portion.

[0049] In some examples, applying the first strand portion to the base layer may include applying the first strand portion to a second layer having multiple fibers and / or to a second layer formed of unidirectional tape. Applying the first strand portion to the base layer may also include applying the first strand portion to a substrate. Applying the first strand portion to the base layer may also include attaching the first strand portion to the base layer via a suture. Applying the first strand portion to the base layer may also include applying a continuous strand.

[0050] In some implementations, the continuous strands of the first strand portion include annular portions forming the first strand portion. Removing the first segment may include removing the annular portions between adjacent first segments of the first strand portion. The method may also include forming the first strand portion from a first bundle of fibers. Forming the first strand portion from a first bundle of fibers may include forming the first strand portion from at least one of carbon fibers, boron fibers, glass fibers, and polymer fibers.

[0051] Applying the first thread portion to the base layer may include positioning adjacent first segments on the width between the inner and outer sides of the plate so that they are closer to each other in the midfoot region of the plate than in the forefoot region. In some examples, applying the first thread portion to the base layer includes positioning adjacent first segments on the width between the inner and outer sides of the plate so that they are closer to each other in the midfoot region of the plate than in the heel region. The method also includes incorporating the plate into a footwear product.

[0052] Another aspect of this disclosure provides a method for forming a plate for footwear, the method comprising applying a first thread portion to a base layer, the application of the first thread portion to the base layer comprising positioning adjacent first segments of the first thread portion on the width of the plate between an inner and outer portion such that they are closer to each other at a midfoot region of the plate than at a heel region of the plate, to form a first layer on the base layer. The method further comprises applying at least one of heat and pressure to the first thread portion and the base layer to conform the first thread portion and the base layer to a predetermined shape.

[0053] Implementations of this disclosure may include one or more of the following optional features. In some implementations, the method includes removing a portion of the first segment to define the outer edge of the plate. Removing a portion of the first segment may include cutting off a first strand portion at a first end of each first segment and cutting off the first strand portion at a second end of each first segment located at the end opposite to the first end of the respective first strand portion. Removing a portion of the first segment may also include removing an annular portion connecting adjacent first segments from the first strand portion.

[0054] In some examples, applying the first strand portion to the base layer includes applying the first strand portion to a second layer having multiple fibers and / or to a second layer formed of unidirectional tape. Applying the first strand portion to the base layer may also include applying the first strand portion to a substrate. Applying the first strand portion to the base layer may also include attaching the first strand portion to the base layer via a suture. In some examples, applying the first strand portion to the base layer includes applying a continuous strand. The continuous strand for applying the first strand portion may include an annular portion forming the first strand portion.

[0055] In some implementations, the method includes removing the annular portion between adjacent first segments of the first strand portion to define the outer edge of the plate. The method may also include forming the first strand portion from a first bundle of fibers. Forming the first strand portion from a first bundle of fibers may include forming the first strand portion from at least one of carbon fiber, boron fiber, glass fiber, and polymer fiber. Applying the first strand portion to the base layer may include positioning adjacent first segments across the width of the plate between the inner and outer portions such that they are closer to each other in the midfoot region of the plate than in the forefoot region. The method also includes bonding the plate to a footwear product.

[0056] Another aspect of this disclosure provides a method for forming a plate for footwear. The method includes applying a first thread portion to a base layer, wherein applying the first thread portion to the base layer includes positioning adjacent first segments of the first thread portion on the width of the plate between an inner and outer portion such that they are closer to each other at a midfoot region of the plate than at a forefoot region of the plate, to form a first layer on the base layer. The method further includes applying at least one of heat and pressure to the first thread portion and the base layer to conform the first thread portion and the base layer to a predetermined shape.

[0057] Implementations of this disclosure may include one or more of the following optional features. In some implementations, the method includes removing a portion of the first segment to define the outer edge of the plate. Removing a portion of the first segment may include cutting off a first strand portion at a first end of each first segment and cutting off the first strand portion at a second end of each first segment located at the end opposite to the first end of the respective first strand portion. Removing a portion of the first segment may also include removing an annular portion connecting adjacent first segments from the first strand portion.

[0058] In some examples, applying the first strand portion to the base layer includes applying the first strand portion to a second layer having multiple fibers and / or to a second layer formed of unidirectional tape. Applying the first strand portion to the base layer may include applying the first strand portion to a substrate. Applying the first strand portion to the base layer may also include attaching the first strand portion to the base layer via a suture. Applying the first strand portion to the base layer may also include applying a continuous strand. The continuous strand for applying the first strand portion may include an annular portion forming the first strand portion.

[0059] In some implementations, the method includes removing annular portions between adjacent first segments of the first strand portion to define an outer edge of the plate. The method may also include forming the first strand portion from a first bundle of fibers. Forming the first strand portion from a first bundle of fibers may include forming the first strand portion from at least one of carbon fiber, boron fiber, glass fiber, and polymer fiber. Applying the first strand portion to the base layer may include positioning adjacent first segments across the width of the plate between the inner and outer portions such that they are closer to each other in the midfoot region of the plate than in the heel region. The method also includes incorporating the plate into a footwear product.

[0060] Another aspect of this disclosure provides a board for footwear. The board includes a first layer, a second layer, and a third layer, the first layer including a first high-tensile-strength fiber, the second layer including a second high-tensile-strength fiber, and the third layer including a third high-tensile-strength fiber. The board also includes a polymer resin that binds the first, second, and third high-tensile-strength fibers together. The board includes a forefoot region, a heel region, and a midfoot region disposed between the forefoot region and the heel region. The forefoot region has a stiffness of about 80 N / mm to about 90 N / mm.

[0061] Implementations of this disclosure may include one or more of the following optional features. In some implementations, the stiffness of the heel region is from about 20 N / mm to about 30 N / mm. The stiffness of the midfoot region may be from about 75 N / mm to about 120 N / mm. In other implementations, the stiffness of the heel region is from about 50 N / mm to about 60 N / mm. The stiffness of the midfoot region may be from about 20 N / mm to about 55 N / mm.

[0062] In some examples, at least one of the first high-tensile-strength fiber, the second high-tensile-strength fiber, and the third high-tensile-strength fiber comprises at least one of carbon fiber, boron fiber, glass fiber, and polymer fiber. The polymer resin may be a thermosetting resin or a thermoplastic resin.

[0063] In some configurations, at least one of the first, second, and third high-tensile-strength fibers is applied as a unidirectional tape. In other configurations, at least one of the first, second, and third high-tensile-strength fibers is applied as a strand of fiber sewn downwards into the base layer. Additionally or alternatively, at least two of the first, second, and third high-tensile-strength fibers may be applied as a unidirectional tape, and the other of the first, second, and third high-tensile-strength fibers may be applied as a strand of fiber sewn downwards into the base layer.

[0064] In some examples, at least one of the first, second, and third high-tensile-strength fibers is applied as strands of fibers sewn downwards into the base layer. Here, adjacent segments of the fiber strands may be positioned closer to each other in the middle leg region of the plate than in the heel region of the plate, across the width between the inner and outer portions of the plate, to form a first layer. Similarly, adjacent segments of the fiber strands may be positioned closer to each other in the middle leg region of the plate than in the front leg region of the plate, across the width between the inner and outer portions of the plate, to form a first layer.

[0065] Another aspect of this disclosure provides a plate for footwear. The plate includes a first layer, a second layer, and a third layer, the first layer including a first high-tensile-strength fiber, the second layer including a second high-tensile-strength fiber, and the third layer including a third high-tensile-strength fiber. The plate also includes a polymer resin that binds the first, second, and third high-tensile-strength fibers together. The plate includes a forefoot region, a heel region, and a midfoot region disposed between the forefoot region and the heel region. The midfoot region has a stiffness of about 60 N / mm to about 70 N / mm.

[0066] Implementations of this disclosure may include one or more of the following optional features. In some implementations, the stiffness of the heel region is from about 20 N / mm to about 30 N / mm. The stiffness of the forefoot region may be from about 95 N / mm to about 105 N / mm. In other implementations, the stiffness of the heel region is from about 50 N / mm to about 60 N / mm. The stiffness of the forefoot region is from about 75 N / mm to about 120 N / mm.

[0067] In some implementations, at least one of the first high-tensile-strength fiber, the second high-tensile-strength fiber, and the third high-tensile-strength fiber comprises at least one of carbon fiber, boron fiber, glass fiber, and polymer fiber. The polymer resin may be a thermosetting resin or a thermoplastic resin.

[0068] In some examples, at least one of the first, second, and third high-tensile-strength fibers is applied as a unidirectional tape. In other examples, at least one of the first, second, and third high-tensile-strength fibers is applied as a strand of fibers sewn downwards into the base layer. Additionally or alternatively, at least two of the first, second, and third high-tensile-strength fibers are applied as a unidirectional tape, and the other of the first, second, and third high-tensile-strength fibers may be applied as a strand of fibers sewn downwards into the base layer. Alternatively, the first, second, and third high-tensile-strength fibers are applied as strands of fibers sewn downwards into the base layer, each comprising a different pattern.

[0069] In some configurations, at least one of the first, second, and third high-tensile-strength fibers is applied as strands of fibers sewn downwards into the base layer. Here, adjacent segments of the fiber strands are positioned along the width between the inner and outer portions of the plate such that they are closer to each other at the middle foot region of the plate than at the heel region, to form a first layer. Similarly, adjacent segments of the fiber strands are positioned along the width between the inner and outer portions of the plate such that they are closer to each other at the middle foot region of the plate than at the front foot region, to form a first layer.

[0070] Another aspect of this disclosure provides a plate for footwear. The plate includes a first layer, a second layer, a third layer, and a polymer resin. The first layer includes a first high-tensile-strength fiber, the second layer includes a second high-tensile-strength fiber, and the third layer includes a third high-tensile-strength fiber. The polymer resin binds the first, second, and third high-tensile-strength fibers together. The plate also includes a forefoot region, a heel region, and a midfoot region disposed between the forefoot region and the heel region. The heel region has a stiffness of about 35 N / mm to about 45 N / mm.

[0071] Implementations of this disclosure may include one or more of the following optional features. In some implementations, the stiffness of the middle foot region is from about 20 N / mm to about 55 N / mm, and the stiffness of the front foot region is from about 95 N / mm to about 105 N / mm. In other implementations, the stiffness of the middle foot region is from about 75 N / mm to about 120 N / mm, and the stiffness of the front foot region is from about 75 N / mm to about 120 N / mm.

[0072] In some examples, at least one of the first high-tensile-strength fiber, the second high-tensile-strength fiber, and the third high-tensile-strength fiber comprises at least one of carbon fiber, boron fiber, glass fiber, and polymer fiber. The polymer resin may be a thermosetting resin or a thermoplastic resin.

[0073] In some configurations, at least one of the first, second, and third high-tensile-strength fibers is applied as a unidirectional tape. In other configurations, at least one of the first, second, and third high-tensile-strength fibers is applied as a strand of fibers sewn downwards into the base layer. Additionally or alternatively, at least two of the first, second, and third high-tensile-strength fibers may be applied as a unidirectional tape, and the other of the first, second, and third high-tensile-strength fibers may be applied as a strand of fibers sewn downwards into the base layer. Alternatively, the first, second, and third high-tensile-strength fibers may be applied as strands of fibers sewn downwards into the base layer, each comprising a different pattern.

[0074] In some examples, at least one of the first, second, and third high-tensile-strength fibers is applied as strands of fibers sewn downwards into the base layer. Here, adjacent segments of the fiber strands are positioned along the width between the inner and outer portions of the board such that they are closer to each other at the middle foot region than at the heel region of the board, to form a first layer. Similarly, adjacent segments of the fiber strands are positioned along the width between the inner and outer portions of the board such that they are closer to each other at the middle foot region than at the front foot region of the board, to form a first layer.

[0075] Another aspect of this disclosure provides a method for forming a plate for footwear, the method comprising applying a first strand portion to a base layer, the application of the first strand portion to the base layer comprising positioning adjacent segments of the first strand portion to form a first layer on the base layer, the adjacent segments of the first strand portion having a greater density in the midfoot region of the plate than in the forefoot region and the heel region of the plate over a width between an inner and outer portion. The method further comprises applying at least one of heat and pressure to the first strand portion and the base layer to conform the first strand portion and the base layer to a predetermined shape.

[0076] Implementations of this disclosure may include one or more of the following optional features. In some examples, the method includes removing the annular portion connecting adjacent segments of the first strand portion to define the outer edge of the plate. Applying the first strand portion to the base layer may include applying the first strand portion to a substrate and at least one of a second layer having multiple fibers and / or a second layer formed of unidirectional tape.

[0077] In some implementations, the method includes positioning a second strand portion on a first layer to form a second layer on the first layer. In some examples, applying the first strand portion to the base layer includes applying a first seam that crosses the first strand portion at a first attachment location spaced apart from the first strand portion and penetrates the base layer. Positioning the second strand portion on the first layer may include applying a second seam that crosses the second strand portion at a second attachment location, extends through the first strand portion, and penetrates the base layer. Applying the first strand portion to the base layer may also include positioning adjacent segments on the width of the board between the inner and outer portions such that they are closer to each other at the middle foot region of the board than at the front foot region and the heel region of the board.

[0078] In some examples, applying the first strand portion to the base layer includes positioning a first segment of the first strand portion on the base layer. In these examples, each first segment has a corresponding length extending between a corresponding first end and a corresponding second end. The first end is located near one of the inner and outer portions in the front foot region of the plate, and the second end is located near one of the inner and outer portions in the heel region of the plate. The first segments may be arranged adjacent to each other and substantially parallel.

[0079] Applying the first strand portion to the base layer may further include positioning a second segment of the first strand portion on the base layer. Here, each second segment has a corresponding length extending between a corresponding first end and a corresponding second end. The first end is located near the other of the inner and outer portions in the front foot region of the plate, and the second end is located near the other of the inner and outer portions in the heel region of the plate. The second segments may converge with the first segments, and the second segments are arranged adjacent to each other and substantially parallel.

[0080] In some examples, positioning the second segment of the first strand on the base layer also includes making the second segment intersect the first segment in an inner region of the plate located at the center foot region. Additionally, positioning the first segment may also include positioning each adjacent first segment with a substantially consistent interval along its corresponding length. Similarly, positioning the second segment may include positioning each adjacent second segment with a substantially consistent interval along its corresponding length.

[0081] In some implementations, the method includes forming a first strand portion from a first bundle of fibers having at least one of carbon fiber, boron fiber, glass fiber, and polymer fiber. The method may also include consolidating the fibers of the first strand portion with a polymer resin, which is a thermosetting or thermoplastic resin, during the application of heat and / or pressure.

[0082] In some examples, forming a plate includes forming a plate having a front leg region with a stiffness of about 80 N / mm to about 90 N / mm, a middle leg region with a stiffness of about 75 N / mm to about 120 N / mm or about 20 N / mm to about 55 N / mm, and a heel region with a stiffness of about 20 N / mm to about 30 N / mm or about 50 N / mm to about 60 N / mm.

[0083] In other examples, forming a plate includes forming a plate having a front leg region with a stiffness of about 95 N / mm to about 105 N / mm or about 75 N / mm to about 120 N / mm, a middle leg region with a stiffness of about 60 N / mm to about 70 N / mm, and a heel region with a stiffness of about 20 N / mm to about 30 N / mm or about 50 N / mm to about 60 N / mm.

[0084] In another example, forming a plate includes forming a plate having a front leg region with a stiffness of about 95 N / mm to about 105 N / mm or about 75 N / mm to about 120 N / mm, a middle leg region with a stiffness of about 20 N / mm to about 55 N / mm or about 75 N / mm to about 120 N / mm, and a heel region with a stiffness of about 35 N / mm to about 45 N / mm.

[0085] Another aspect of this disclosure provides a method for forming a plate for footwear. The method includes applying a first strand portion to a base layer, the application of the first strand portion to the base layer including positioning adjacent segments of the first strand portion to form a first layer on the base layer, the adjacent segments of the first strand portion having a greater density in the midfoot region of the plate than in the forefoot region and the heel region of the plate over a width between the inner and outer portions. The method further includes applying at least one of heat and pressure to the first strand portion and the base layer to conform the first strand portion and the base layer to a predetermined shape.

[0086] Implementations of this disclosure may include one or more of the following optional features. In some implementations, the method includes removing a portion of a segment to define an outer edge of a plate. Removing a portion of a segment may include cutting off a first strand portion at a first end of each segment and cutting off the first strand portion at a second end of each segment located at the end opposite to the first end of the respective first strand portion. The portion of a segment being removed may also include an annular portion connecting adjacent segments from which the first strand portion is removed.

[0087] In some configurations, applying the first strand portion to the base layer includes applying the first strand portion to a second layer having multiple fibers and / or to a second layer formed of unidirectional tape. Applying the first strand portion to the base layer may also include applying the first strand portion to a substrate. In some examples, applying the first strand portion to the base layer includes applying a suture to attach the first strand portion to the base layer. Applying the suture may include zigzagging the suture across the first strand portion between first attachment locations.

[0088] In some implementations, the method includes positioning a second strand portion on a first layer to form a second layer on the first layer. Applying the first strand portion to the base layer may include applying a first stitch that crosses the first strand portion at a first attachment location spaced apart from the first strand portion and penetrates the base layer. Similarly, positioning the second strand portion on the first layer may include applying a second stitch that crosses the second strand portion at a second attachment location, extends through the first strand portion, and penetrates the base layer.

[0089] In some examples, applying the first strand portion to the base layer includes positioning adjacent segments on the width between the inner and outer portions of the board so that they are closer to each other at the middle foot region of the board than at the front foot region. Applying the first strand portion to the base layer may also include positioning adjacent segments on the width between the inner and outer portions of the board so that they are closer to each other at the middle foot region of the board than at the rear foot region of the board.

[0090] In some implementations, applying the first strand portion to the base layer includes positioning adjacent first segments of the first strand portion on the base layer. In these examples, each first segment has a corresponding length extending between a corresponding first end and a corresponding second end. The first end may be located near one of the inner and outer portions at the front foot region of the plate, and the second end may be located near one of the inner and outer portions at the rear heel region of the plate.

[0091] Applying the first strand portion to the base layer may include positioning adjacent second segments of the first strand portion on the base layer, wherein each second segment has a corresponding length extending between a corresponding first end and a corresponding second end. The first end may be located near the other of the inner and outer portions in the front foot region of the board, and the second end may be located near the other of the inner and outer portions in the heel region of the board. In some examples, positioning adjacent first segments and positioning adjacent second segments includes causing the first and second segments to overlap each other in an inner region of the board located in the middle foot region.

[0092] Positioning adjacent first segments and positioning adjacent second segments may further include: extending the first and second segments substantially parallel to the longitudinal axis of the plate at the middle foot region, and separating the first and second segments from each other as they extend from the middle foot region toward the corresponding first ends at the front foot region.

[0093] In some configurations, positioning adjacent first segments includes positioning adjacent first segments such that they have a substantially uniform interval along their corresponding lengths. Similarly, positioning adjacent second segments may include positioning adjacent second segments such that they have a substantially uniform interval along their corresponding lengths. Additionally, positioning adjacent second segments may include positioning adjacent second segments such that they have a corresponding length that is longer than the corresponding length of the adjacent first segments.

[0094] In some implementations, applying the first strand portion to the base layer includes positioning adjacent third segments of the first strand portion on the base layer between the first and second segments. In these examples, each third segment has a corresponding length extending between a corresponding first end located in the front foot region of the plate and a corresponding second end located in the rear heel region of the plate. Positioning adjacent third segments of the first strand portion may also include positioning the adjacent third segments to have corresponding lengths different from the corresponding lengths of the first and third segments.

[0095] In some examples, applying a first strand portion to the base layer includes applying a continuous strand. The continuous strand for applying the first strand portion may include an annular portion forming the first strand portion. Applying the continuous strand for the first strand portion may also include removing the annular portion between adjacent segments of the first strand portion to define the outer edge of the plate.

[0096] In some implementations, the method includes forming a first strand portion from a first bundle of fibers. Forming the first strand portion from the first bundle of fibers may include forming the first strand portion from at least one of carbon fibers, boron fibers, glass fibers, and polymer fibers. The method may also include bonding a plate to a footwear product. In some examples, the method includes consolidating the fibers of the first strand portion with a polymer resin. Here, consolidating the fibers with a polymer resin is performed during the application of heat and / or pressure.

[0097] Details of one or more implementations of this disclosure are set forth in the accompanying drawings and the following description. Other aspects, features, and advantages will become apparent from the specification, the drawings, and the claims.

[0098] During running, the point of application of the shoe's push-off force is located in the forefoot portion of the shoe. This point of application is opposite the metatarsophalangeal (MTP) joint of the foot. The distance between the athlete's ankle joint and the line of action of the point of application providing the push-off force defines the lever arm length with respect to the ankle. The mechanical demands on ankle plantar flexion (e.g., the calf tendon unit) can be based on the push-off torque at the ankle, determined by multiplying the length of the lever arm by the magnitude of the push-off force controlled by the athlete. Rigid and flat shoe plates generally increase the mechanical demands at the ankle because a rigid, flat plate causes the point of application to the ground to shift forward. As a result, the lever arm distance and push-off torque increase at the ankle joint. The implementation described in this paper involves shortening the lever arm distance from the ankle joint to reduce the push-off torque at the ankle.

[0099] Reference Figures 1 to 3 A footwear article 10 is provided, comprising an upper 100 and a sole structure 200 attached to the upper 100. The footwear article 10 may be divided into one or more portions. These portions may include a forefoot portion 12, a midfoot portion 14, and a heel portion 16. During use of the footwear 10, the forefoot portion 12 may correspond to the toes and the joints connecting the metatarsals and phalanges of the foot. The forefoot portion 12 may correspond to the metatarsophalangeal (MTP) joint of the foot. During use of the footwear article 10, the midfoot portion 14 may correspond to the arch region of the foot, and the heel portion 16 may correspond to the posterior portion of the foot, including the calcaneus. The footwear 10 may include a lateral portion 18 and a medial portion 20, which correspond to opposite sides of the footwear 10 and extend through portions 12, 14, and 16, respectively.

[0100] The upper 100 includes an inner surface defining an interior space 102 that receives and secures the foot during use of the footwear 10 to support the foot on the sole structure 200. An ankle opening 104 in the heel portion 16 provides access to the interior space 102. For example, the ankle opening 104 may receive the foot to secure it within the space 102 and facilitate entry and exit from the interior space 102. In some examples, one or more fasteners 106 extend along the upper 100 to adjust the fit of the interior space 102 around the foot and simultaneously accommodate entry and exit from the interior space 102. The upper 100 may include openings such as eyelets and / or other engagement features such as fabric loops or mesh loops for receiving the fasteners 106. The fasteners 106 may include laces, straps, cords, hooks and loops, or any other suitable type of fastener.

[0101] The upper 100 may include a tongue portion 110 extending between the interior space 102 and the fastener 106. The upper 100 may be formed of one or more materials stitched or bonded together to form the interior space 102. The materials of the upper may include, but are not limited to, textiles, foam, leather, and synthetic leather. The materials may be selected and positioned to impart properties such as durability, breathability, abrasion resistance, flexibility, and comfort.

[0102] In some implementations, the sole structure 200 includes an outsole 210, a cushioning member 250, and a midsole 220 arranged in a layered configuration. The midsole 220 is optional and corresponds to a conventional padding. The sole structure 200 (e.g., outsole 210, cushioning member 250, and midsole 220) defines a longitudinal axis L. For example, the outsole 210 engages with the ground during use of the footwear 10. The midsole 220 is attached to the upper 100, and the cushioning member 250 is disposed between the midsole 220 and the outsole 210 to separate the midsole 220 from the outsole 210. For example, the cushioning member 250 defines a bottom surface 252 opposite to the outsole 210 and a top surface 254 disposed on the side of the cushioning member 250 opposite to the bottom surface 252 and opposite to the midsole 220. The top surface 254 may be profiled to conform to the profile of the bottom surface (e.g., the sole) of the foot within the internal space 102. In some examples, the sole structure 200 may also include additional layers, such as the insole 260. Figure 2 and Figure 3 The insole 260 or insole may be located within the internal space 102 of the upper 100 to receive the sole surface of the foot, thereby enhancing the comfort of the shoe 10. In some examples, sidewalls surround at least a portion of the periphery of the cushioning member 250 and separate the cushioning member 250 from the midsole 220 to define a cavity between the cushioning member 250 and the midsole 220. For example, when the internal space 102 receives the foot therein, the sidewalls and top surface 254 of the cushioning member 250 may cooperate to hold and support the foot on the cushioning member 250. In one configuration, the sidewalls may define an edge surrounding at least a portion of the periphery of the wavy top surface 254 of the cushioning member 250 to wrap around the foot during walking or running activities during use of the shoe 10. The edge may extend around the periphery of the midsole 220 when the cushioning member 250 is attached to the midsole 220.

[0103] Although the footwear 10 will be described and shown as including a cushioning member 250, the cushioning member 250 is optional. Therefore, the shoe plate 300 can be directly attached to both the midsole (i.e., the lining) 220 and the outsole 210 without having a cushioning member—such as the cushioning member 250—located between the plate 300 and either of the elements 210 or 220. Furthermore, although the cushioning member 250 will be described and shown as being located on both sides of the plate 300, the cushioning member 250 may be located only between the plate 300 and the upper 100, or alternatively between the plate 300 and the outsole 210.

[0104] In some examples, one or more protruding elements 215 (e.g., spikes or cleats) may extend from the ground surface 212 in a direction away from the sole structure 200 and the upper 100 to provide adhesion to soft surfaces, such as grass. For example, each protruding element 215 may be attached to the ground surface 212 of the outsole 210 and extend in a direction generally perpendicular to the longitudinal axis L of the sole structure 200. In the example shown, the protruding elements 215 include spikes extending from the outsole 210 at the forefoot portion 12. In other examples, cleats or spikes may extend from one or more of portions 12, 14, 16 in any arrangement.

[0105] In some configurations, the shoe plate 300 is disposed within the sole structure 210 to reduce energy loss at the MTP joint and simultaneously enhance foot roll as the shoe 10 rolls to engage the ground during running. In some configurations, the cushioning member 250 defines a sleeve / cavity 240 within the internal portion between the top surface 254 and the bottom surface 252. Figure 3The shoe plate 300 can be received within the cavity 240 and can be held in place between the top surface 254 and the bottom surface 22. In other configurations, the shoe plate 300 is disposed on the top surface 254 of the cushioning member 250 and below the midsole 220. In these configurations, the midsole 220 is optional and the shoe plate 300 can be fixed to the upper 100 to define an internal space 102 with or without an insole 260 disposed on top of the shoe plate 300. For example, the shoe plate 300 can be fixed to the upper 100 using adhesive. In some implementations, the shoe plate 300 is sandwiched between the top surface 254 of the cushioning member 250 and an additional cushioning member (not shown) located below the midsole 220. The shoe plate 300 can define at least a portion of the length extending through the sole structure 200. In some examples, the length of the plate 300 extends through the forefoot portion 12, midfoot portion 14, and heel portion 16 of the sole structure 200. In other examples, the length of the plate 300 extends through the forefoot portion 12 and midfoot portion 14, but is not present in the heel portion 16. In other configurations, the plate 300 is disposed within the footbed 224 of the midsole / padder 220 within the internal space 102 of the upper 100. Figure 3 The plate 300 is sandwiched between the footbed 224 of the midsole 220 and the bottom surface 252 of the cushioning member 250 within the internal space 102.

[0106] In some examples, the plate 300 includes a consistent local stiffness (e.g., tensile strength or flexural strength) across its entire surface area. The stiffness of the plate can be anisotropic, meaning that the stiffness in one direction differs from the stiffness in another. For example, the plate 300 can be formed from at least two mutually anisotropic fiber layers of fibers 450 to impart gradient stiffness and gradient load paths to the plate 300. In one configuration, the plate 300 provides a longitudinal stiffness (e.g., stiffness along the longitudinal axis L) greater than the lateral stiffness (e.g., stiffness in the direction transverse to the longitudinal axis L). In one example, the lateral stiffness is at least ten percent (10%) lower than the longitudinal stiffness. In another example, the lateral stiffness is about ten percent (10%) to about twenty percent (20%) of the longitudinal stiffness. In some configurations, the plate 300 is composed of one or more layers of fiber bundles 400 comprising at least one of carbon fiber, boron fiber, glass fiber, and polymer fiber. Figure 4The polymer fiber is formed and / or is formed from layers of fibers 450, including at least one of carbon fiber, boron fiber, glass fiber, and polymer fiber. The polymer fiber can be formed from a thermoplastic or thermosetting material. The polymer fiber may contain polyurethane, polyamide, polyester, polyether, polyurethane copolymer, polyamide copolymer, polyester copolymer, polyether copolymer, and any combination thereof. The polyurethane may be thermoplastic polyurethane (TPU). The polymer fiber may contain polyethylene terephthalate (PET). The polymer fiber may contain aromatic polyamide. The polymer fiber may contain poly(phenylene-2,6-benzodioxazole) (PBO).

[0107] In a particular configuration, fiber 450 comprises carbon fiber, or glass fiber, or a combination of both carbon fiber and glass fiber. The tow 400 of fiber 450 may be attached to a substrate. The tow 400 of fiber 450 may be attached by sewing and / or using an adhesive. Additionally or alternatively, the tow 400 of fiber 450 and / or the layers of fiber 450 may be bonded with a resin formed from a thermosetting polymeric material and / or a thermoplastic polymeric material. The tow of fiber 450 may be attached to a substrate or other base layer using any of the techniques disclosed in U.S. Provisional Application No. 62 / 364,594, filed July 20, 2016, and U.S. Provisional Application No. 62 / 364,585, filed July 20, 2016, the entire contents of which are incorporated herein by reference.

[0108] Therefore, plate 300 can have tensile or flexural strength in a transverse direction generally perpendicular to the longitudinal axis L. The stiffness of plate 300 can be selected for a specific wearer based on the wearer's tendon flexibility, calf muscle strength, and / or MTP joint flexibility. Furthermore, the stiffness of plate 300 can also be customized based on the athlete's running motion. In other configurations, plate 300 is formed from one or more layers / sheets of unidirectional strips. In some examples, each layer in the stack includes a different orientation than the layer disposed below. Plate 300 can be formed from unidirectional strips comprising at least one of carbon fiber, boron fiber, glass fiber, and polymer fiber. In some examples, one or more materials forming plate 300 have a Young's modulus of at least 70 gigapascals (GPa).

[0109] In some implementations, plate 300 has a generally uniform thickness, and the thickness of plate 300 can range from about 0.6 mm to about 3.0 mm. In one example, the thickness of the plate is approximately equal to 1.0 mm. In other implementations, the thickness of plate 300 is not uniform, such that the thickness of plate 300 defined in the midfoot portion 14 of sole structure 200 can be greater than the thickness defined in the forefoot portion 12 and / or heel portion 16.

[0110] The outsole 210 may include a ground surface 212 and an opposite inner surface 214. The outsole 210 may be attached to the upper 100. In some examples, the bottom surface 252 of the cushioning member 250 is attached to the inner surface 214 of the outsole 210. Figure 1 The example shows an outsole 210 attached to the upper 100 at the tip near the forefoot portion 12. The outsole 210 typically provides abrasion resistance and provides traction with the ground during use of the footwear 10. The outsole 210 can be formed of one or more materials that impart durability and abrasion resistance as well as enhanced traction with the ground. For example, rubber can form at least a portion of the outsole 210.

[0111] The midsole 220 may include a bottom surface 222 and a footbed 224 disposed on a side of the midsole opposite to the bottom surface 222. Stitches 226 or adhesives may secure the midsole 220 to the upper 100. The footbed 224 may be profiled to conform to the contours of the foot's bottom surface (e.g., the sole). The bottom surface 222 may be opposite the inner surface 214 of the outsole 210 to define a space between the bottom surface 222 and the inner surface 214 for receiving a cushioning member 250. Although element 220 is described as a midsole, element 220 may correspond to a padding that is sewn or otherwise secured to the upper 100.

[0112] Figure 2 An exploded view of footwear 10 is provided, showing an outsole 210, a cushioning member 250 disposed on the inner surface 214 of the outsole 210, and a generally rigid shoe plate 300 disposed between the top surface 254 of the cushioning member 250 and the bottom surface 222 of the midsole 220. The cushioning member 250 may be sized and shaped to occupy at least a portion of the empty space between the outsole 210 and the midsole 220. In some examples, the unoccupied space between the cushioning member 250 and the bottom surface 222 of the midsole 220 defines a cavity configured to receive the shoe plate 300. Thus, the cushioning member 250 and the plate 300 may substantially occupy the entire spatial volume between the bottom surface 222 of the midsole 220 and the inner surface 214 of the outsole 210. However, the cushioning member 250 may occupy the entire space between the midsole 220 and the outsole 210 and define a cavity 240. Figure 3 The cavity 240 is configured to receive the plate 300 therein, thereby embedding the plate 300 within the cushioning member 250. The cushioning member 250 can be elastically compressed between the midsole 220 and the outsole 210. In some configurations, the cushioning member 250 corresponds to a blank formed of polymer foam having a surface profile configured to receive the shoe plate 300 thereon.

[0113] The cushioning member 250 can be formed from any suitable material that elastically compresses under applied load. Examples of suitable polymeric materials for foam materials include ethylene vinyl acetate (EVA) copolymers, polyurethanes, polyether and olefin block copolymers. The foam may also comprise a single polymeric material or a blend of two or more polymeric materials including polyether block amide (PEBA) copolymers, EVA copolymers, thermoplastic polyurethane (TPU) and / or olefin block copolymers. The density of the cushioning member 250 may be about 0.05 g / cm³. 3 (approximately 0.20 g / cm³) 3 Within this range. In some examples, the density of the buffer element 250 is approximately 0.1 g / cm³. 3 Furthermore, the hardness of the buffer member 250 can be in the range of about eleven (11) Shore A to about fifty (50) Shore A. One or more materials forming the buffer member 250 can be adapted to provide at least sixty percent (60%) of energy return.

[0114] The length of the shoe plate 300 may extend between a first end 301 and a second end 302. The first end 301 may be located near the heel portion 16 of the sole structure 200, and the second end 302 may be located near the forefoot portion 12 of the sole structure 200. The first end 301 may also be referred to as the "rearmost point" of the plate 300, and the second end 302 may also be referred to as the "foremost point" of the plate. In some examples, the length of the shoe plate 300 is less than the length of the cushioning member 250. The shoe plate 300 may also include a thickness extending substantially perpendicular to the longitudinal axis L of the sole structure 200 and a width extending between the outer portion 18 and the inner portion 20. Thus, the length, width, and thickness of the plate 300 may substantially occupy the cavity 240 defined by the cushioning member 250 and the bottom surface 222 and may extend through the respective forefoot portion 12, midfoot portion 14, and heel portion 16 of the sole structure 100. In some examples, the peripheral edge of the shoe plate 300 is visible on the outer side 18 and / or the inner side 20 of the shoe 10.

[0115] Reference Figure 3 along Figure 1A partial cross-sectional view taken by line 3-3 shows the shoe plate 300 located within the cavity 240 defined by the cushioning member 250, which is disposed between the midsole 220 and the outsole 210. The insole 260 may be disposed on the footbed 224 within the internal space 120 under the foot. The cushioning member 250 may be defined with a greater thickness in the heel portion 16 of the sole structure 200 than in the forefoot portion 12. In other words, the gap or distance separating the outsole 210 and the midsole 220 decreases from the heel portion 16 toward the forefoot portion 12 along the longitudinal axis L of the sole structure 200. In some implementations, the top surface 254 of the cushioning member 250 is smooth, and the top surface 254 includes a surface profile contoured to match the surface profile of the shoe plate 300 such that the shoe plate 300 and the cushioning member 250 fit flush with each other. The thickness of the cushioning member 250 defined in the forefoot portion 12 of the sole structure can range from about seven (7) millimeters (mm) to about twenty (20) millimeters. In one example, the thickness of the cushioning member 250 in the forefoot portion 12 is about twelve (12) millimeters.

[0116] In some configurations, the cushioning member 250 may be omitted, and the plate 300 may be directly mounted on the top of the inner surface 214 of the outsole 210. Furthermore, a cushioning material associated with the same or a different cushioning member 250 may be provided between the plate 300 and the midsole 220, and the cushioning material accordingly extends through the forefoot portion 12, the midfoot portion 14, and the heel portion 16.

[0117] The shoe plate 300 includes a curved region 310 extending through the forefoot portion 12 and midfoot portion 14 of the sole structure 200. The terms "curved portion," "concave portion," and "circular portion" may also be used to describe the curved region 310. The shoe plate 300 may optionally include a generally flat region 312 extending from the curved region 310 of the plate 300 through the heel portion 16 to the rearmost point 301. The curved region 310 is associated with a radius of curvature near the MTP point 320 to define a forward curved portion 322 extending from one side of the MTP point 320 and a rear curved portion 324 extending from the other side of the MTP point 320. For example, the forward curved portion 322 extends between the MTP point 320 of the plate 300 and the foremost point (AMP) 302 (e.g., the second end 302), while the rear curved portion 324 extends between the MTP point 320 and a rear point 326 located at the junction of the curved region 310 and the flat region 312. In some examples, the front bend 322 and the rear bend 324 are associated with the same radius of curvature mirrored about MTP point 320. In other examples, the front bend 322 and the rear bend 324 are each associated with a different radius of curvature. In some configurations, a portion of the rear bend 324 is associated with the same radius of curvature as the front bend 322. Thus, the bends 322 and 324 may each have corresponding radii of curvature that may be the same as or different from each other. In some examples, the radii of curvature differ from each other by at least two percent (2%). The radii of curvature of the bends 322 and 324 may range from 200 mm to approximately 400 mm. In some configurations, the front bend 322 has a radius of curvature that continues the curvature of the rear bend 324, such that the bends 322 and 324 define the same radius of curvature and share the same vertex. Alternatively or additionally, the plate may define the radius of curvature connecting the rear bend 324 of the plate 300 to the generally flat region 312. As used in this paper, the term “generally flat” refers to a horizontal plane within five (5) degrees, that is, a flat area parallel to the ground within five (5) degrees 312.

[0118] MTP point 320 is the point on the plate 300 closest to the inner surface 214 of the outsole 210, while the rear points 326 and AMP 302 of the plate 300 are located further away from the outsole 210 than MTP point 320. In some configurations, the rearmost points 301 and AMP 302 are coplanar. In some examples, the MTP point 320 of the plate 300 is positioned directly below the MTP joint of the foot when the foot is received within the inner space 102 of the upper 100. In other examples, the MTP point 320 is located further away from the toe end of the sole structure 200 than the MTP joint. The forward flex portion 322 and the rear flex portion 324 of the flex region 310 respectively give the plate 300 the following longitudinal stiffness: this longitudinal stiffness reduces energy loss near the MTP joint of the foot and enhances foot rolling during running, thereby reducing lever arm distance and relieving stress on the ankle joint.

[0119] In some implementations, AMP 302 and back point 326 are located above MTP point 320 at the following distance / height H ( Figure 5 The distance / height H extends from MTP 320 along a direction generally perpendicular to the longitudinal axis L of the sole structure 200. The height H is in the range of about three (3) millimeters (mm) to about twenty-eight (28) millimeters (mm). In other examples, the height H is in the range of about three (3) millimeters to about seventeen (17) millimeters (mm). In one example, the height H is equal to about seventeen (17) millimeters (mm). Therefore, since the fore-bend portion 322 extends from MTP point 320 toward AMP 302 away from the outsole 210, the toes of the foot located above the fore-bend portion 322 will be biased upward. Alternatively or additionally, the length L of the fore-bend portion 322 is... A It can be approximately equal to the length L of the 324-degree bend after bending. P As used in this article, L A and L P Each is measured along a line extending approximately parallel to the longitudinal axis L between the corresponding point of MTP 320 and AMP 302 and the rear point 326. In other words, the length L A and L P Each is associated with the distance between MTP point 320 and the corresponding one of AMP 302 and back point 326. In some configurations, L A and L P Each of these regions is approximately 30% (thirty percent) of the total length of plate 300, while the length of the flat region 312 accounts for the remaining 40% (40%) of the total length of plate 300. In other configurations, L A Equal to approximately 25% to 35% (35%) of the total length of the 300mm plate, L PIt is equal to approximately 25% to approximately 35% (35%) of the total length of plate 300, and the length of the flat region 312 is equal to the remaining length. In other configurations, L A The lengths of Lp and the flat region 312 are approximately equal. Changing the radius of curvature of the curved region 310 results in a change in the length L. A The distance / height between Lp and / or the foremost point 302 and the rearmost point 306 changes relative to MTP point 320. For example, reducing the radius of curvature causes an increase in the angle between MTP point 320 and AMP 302, and also increases the height H of AMP 302 above MTP point 320. In configurations where curved portions 322 and 324 each have different radii of curvature, the corresponding lengths La and L... P And / or the height H from the MTP point 320 can be different. Therefore, the radius of curvature of the bending region 310 can vary for different shoe sizes, can vary depending on the intended use of the shoe 10, and / or can vary based on the anatomical characteristics of the foot on the wearer's basis.

[0120] In some implementations, the MTP point 320 is located at approximately thirty percent (30%) of the total length of the plate relative to AMP 302. The center of the radius of curvature of the curved region 310 may be located at the MTP point 320. In some examples, the curved region 310 (e.g., a concave portion) is associated with a constant radius of curvature extending from AMP 302 through the MTP point 320. In these examples, the constant radius of curvature may extend from AMP 302 through the MTP point 320 relative to AMP 302 for at least forty percent (40%) of the total length of the plate 300.

[0121] Figure 4 Is Figure 1 A top perspective view of the shoe plate 300 used in the footwear 10. The plate 300 defines a length extending between a first end 301 corresponding to the rearmost point and a second end 302 corresponding to the foremost point (PMP) of the plate 300. The terms "first end" and "rearmost point" are used interchangeably herein. The terms "second end" and "AMP" of the plate 300 are used interchangeably herein. Figure 4 A shoe plate 300 is shown, comprising a curved region 310 and a generally flat region 312.

[0122] In some implementations, the shoe plate 300 is generally rigid and formed of one or more composite materials. Compared to conventional composite plates formed from unidirectional tapes that only provide directional stiffness characteristics, the shoe plate 300 is formed from one or more strand portions 400 arranged in a selected pattern to impart anisotropic stiffness and gradient load paths throughout the plate 300. Each strand portion 400 may refer to a bundle of multiple fibers 450, a bundle of monofilaments, a bundle of yarns, or a polymer-prepreg bundle including a unidirectional tape or strip. Unless otherwise stated, this disclosure refers to each strand portion 400 as a bundle 400 of the corresponding fiber 450. As used herein, the term "bundle" refers to a bundle (i.e., multiple) of filaments (e.g., fibers 450) that may be twisted or untwisted, and each bundle may be specified with a dimension associated with the multiple fibers 450 contained in the corresponding bundle 400. For example, the size of at least one filament bundle 400 forming the shoe plate 300 can range from about 1,000 fibers per bundle to about 48,000 fibers per bundle. In some examples, the at least one filament bundle 400 comprises 3,000 fibers per bundle. In other examples, the at least one filament bundle 400 comprises 12,000 carbon fibers per bundle.

[0123] In some configurations, the fibers 450 associated with the at least one filament bundle 400 include at least one of carbon fibers, boron fibers, glass fibers, and polymer fibers. Additionally, at least a portion of the fibers 450 associated with the at least one filament bundle 400 may be formed of a first thermoplastic material. Fibers such as carbon fibers, aramid fibers, and boron fibers can provide high modulus, while glass fibers (e.g., glass filaments) and polymer fibers (e.g., synthetic fibers) provide medium modulus. The fibers may also include basalt fibers or a combination of carbon fiber / basalt fibers.

[0124] In some examples, the fiber density per unit area varies within a single bundle 400 of fiber 450. Alternatively or additionally, the type of fiber 450 forming the corresponding bundle 400 can vary on the plate 300 between the forefoot region 12 and the heel region 16, and between the outer portion 18 and the inner portion 20. In doing so, the plate 300 can be designed to have a stiffness gradient based on the anatomical features of the foot. For example, the stiffness of the plate 300 can increase from the forefoot portion 12 along the length of the plate 200 to the heel portion 16. In some examples, the pattern of each bundle 400 of fiber 450 provides a stiffness gradient between the outer portion 18 and the inner portion 20 of the plate 300 passing through at least one of portions 12, 14, and 16. For example, the stiffness of the plate 300 in the forefoot portion 12 can increase in the direction from the inner portion 20 to the outer portion 18. Therefore, one or more bundles 400 of fiber 450 may include paths with multiple curves to turn around space and / or change the orientation in the load path of plate 300, thereby adapting to anatomical features and enhancing the performance of shoe 10 for its intended use.

[0125] In some configurations, the shoe plate 300 has a stiffness of about 80 N / mm to about 90 N / mm in the forefoot region 12 and about 20 N / mm to about 55 N / mm in the midfoot region 14. In other configurations, the shoe plate 300 has a stiffness of about 80 N / mm to about 90 N / mm in the forefoot region 12 and about 75 N / mm to about 120 N / mm in the midfoot region 14. In yet another configuration, the plate 300 has a stiffness of about 75 N / mm to about 120 N / mm in the forefoot region 12 and about 60 N / mm to about 70 N / mm in the midfoot region 14. In still another configuration, the plate 300 has a stiffness of about 95 N / mm to about 105 N / mm in the forefoot region 12 and about 60 N / mm to about 70 N / mm in the midfoot region 14.

[0126] In some implementations, the shoe plate 300 has a stiffness of about 80 N / mm to about 90 N / mm in the forefoot region 12 and a stiffness of about 20 N / mm to about 30 N / mm in the heel region 16. In another implementation, the shoe plate 300 has a stiffness of about 80 N / mm to about 90 N / mm in the forefoot region 12 and a stiffness of about 50 N / mm to about 60 N / mm in the heel region 16.

[0127] In some configurations, plate 300 has a stiffness of about 60 N / mm to about 70 N / mm in the mid-leg region 14 and a stiffness of about 20 N / mm to about 30 N / mm in the heel region 16. In another configuration, plate 300 has a stiffness of about 60 N / mm to about 70 N / mm in the mid-leg region 14 and a stiffness of about 50 N / mm to about 60 N / mm in the heel region 16.

[0128] In some cases, the plate 300 has a stiffness of about 75 N / mm to about 120 N / mm in the forefoot region 12 and a stiffness of about 35 N / mm to about 45 N / mm in the heel region 16. In other cases, the plate 300 has a stiffness of about 95 N / mm to about 105 N / mm in the forefoot region 12 and a stiffness of about 35 N / mm to about 45 N / mm in the heel region 16.

[0129] In some configurations, plate 300 has a stiffness of about 20 N / mm to about 55 N / mm in the mid-leg region 14 and a stiffness of about 35 N / mm to about 45 N / mm in the heel region 16. In other configurations, plate 300 has a stiffness of about 75 N / mm to about 120 N / mm in the mid-leg region 14 and a stiffness of about 35 N / mm to about 45 N / mm in the heel region 16.

[0130] In some implementations, the plate 300 is formed by embroidering at least two bundles 400 of fibers 450 in a layered configuration and simultaneously attaching the at least two bundles 400 of fibers 450 to the same substrate, or by individually attaching the at least two bundles 400 of fibers 450 to their respective substrates and stacking the substrates such that the at least two bundles 400 of fibers 450 are embroidered in a layered configuration. As used herein, a substrate refers to any of a cover, support, or padding attached to and bonded to at least one bundle 400 of fibers 450. The substrate may be formed of a thermosetting polymer material or a thermoplastic polymer material, and the substrate may be a textile (e.g., knitted, woven, or nonwoven), injection-molded, organic sheet, or thermoplastic article. In some examples, the thermoplastic polymer material used to form the substrate includes spunbond nonwoven nylon 6-6 manufactured by Cerex Advanced Fabrics with a density ranging from about 10 g / m² to about 50 g / m². In one example, the nylon 6-6 used to form the substrate has a density of about 25 g / m².

[0131] Typically, it is difficult to manufacture a composite panel that is non-flat (e.g., curved / wavy) and substantially rigid in its final state from a prefabricated panel that is initially rigid and flat in shape. The implementation described herein involves an embroidered prefabricated section in which one or more bundles 400 of fibers 450 are attached to the same or different substrates, and heat is applied to mold the embroidered prefabricated section to form a shoe plate 300 with a desired shape and curvature. The plate 300 can then be cured to impart structural rigidity. In other words, both the substrate and each bundle 400 of the fibers 450 are thin and flexible to allow the embroidered prefabricated section to be positioned in a mold to impart a curved shape to the plate 300 while simultaneously allowing the finished plate 300 to have structural rigidity. In some examples, manufacturing the plate 300 involves injecting a liquid thermoplastic and / or liquid thermosetting material into the embroidered prefabricated section (e.g., attaching one or more bundles 400 of fibers 450 to the substrate) and forming the plate 300 using vacuum molding and / or compression molding techniques. The liquid thermoplastic and / or thermosetting materials may contain a resin having at least one of a polymerizable composition or a prepolymer material to assist in binding / attaching one or more filament bundles 400 to the substrate. Additional polymers / toughening agents (e.g., soft polymers, rubbers, and / or block copolymers) may be added to the liquid thermoplastic and / or liquid thermosetting materials to reduce the brittleness of the sheet 300. The thermoplastic / thermosetting materials may also contain at least one of epoxy resins, polyurethanes, and prepolymers.

[0132] In other examples, the substrate or a portion thereof is formed of a thermosetting polymer material and / or a thermoplastic polymer material. The thermoplastic polymer material has a melting point lower than the melting point of the filaments 400 of fiber 450 or a melting point lower than the degradation temperature of the filaments 400 of fiber 450. Here, instead of injecting liquid thermoplastic and / or liquid thermosetting materials into the embroidery preform to melt / inject the embroidery preform during vacuum molding and / or compression molding, thermoplastic and / or thermosetting polymer materials can be incorporated into the substrate. Additionally or alternatively, thermoplastic yarns can be mixed with one or more filaments 400 of fiber 450 to aid in melting / injecting the embroidery preform during vacuum molding or compression molding. Alternatively, the embroidered preform may be dynamically coated with a thermosetting polymer material and / or a thermoplastic polymer material, or the embroidered preform may be covered and / or impregnated with a thermosetting polymer material and / or a thermoplastic polymer material using injection molding technology.

[0133] Figure 5 Provided Figure 4A side view of the shoe plate 300 shows the MTP point 320, which is the point on the plate 300 closest to a horizontal reference plane RP extending generally parallel to the ground (not shown). For example, the MTP point 320 is tangent to the horizontal reference plane RP, and the MTP point 320 can be positioned directly below the MTP joint when the foot is received by the internal space 102 of the shoe 10. In other configurations, the MTP point 320 is positioned below and slightly rearward of the MTP joint of the foot, such that the forward flexion portion 322 is located below the MPT joint of the foot. The forward flexion portion 322 of the flexion region 310 can define a corresponding radius of curvature and a length L between the MTP point 320 and the AMP 302. A The rear-bend portion 324 of the bending region 310 can define the corresponding radius of curvature and the length Lp between the MTP point 320 and the rear point 326. As used herein, L... A and L P Each is measured along the horizontal reference plane RP between MTP point 320 and the corresponding one of AMP 302 and rear point 326. In some examples, the L of the front bend 322 is... A Approximately 30% (30%) of the length of the 200mm length of the sole structure, the rear flex portion 324 L P The generally flat portion 312 comprises approximately 30% (30%) of the length of the sole structure 200, and approximately 40% (40%) of the length of the sole structure 200. In other examples, the L-shaped forward bend of the forward bend 322... A Within approximately 25% to 35% (35%) of the length of the sole structure 200, the L-shaped rear flex portion 324... P Within the range of approximately 25% to approximately 35% (35%) of the length of the sole structure 200, and the generally flat area 312 has the remaining length of the sole structure 200.

[0134] The radius of curvature associated with the forward bend 322 causes AMP 302 to extend from MTP point 320 relative to the horizontal reference plane RP at an angle α. Therefore, the forward bend 322 allows the toe segment 362 of plate 300 to offset the toes of the foot in a direction away from the ground. Angle α can have a value ranging from about 12 degrees to about 35 degrees. In one example, angle α has a value approximately equal to 24 degrees. Similarly, the radius of curvature associated with the rear bend 324 causes the rear point 326 to extend from MTP point 320 relative to the horizontal reference plane RP at an angle β. Angle β can have a value ranging from about 12 degrees to about 35 degrees. In one example, angle β has a value approximately equal to 24 degrees. In some configurations, angles α and β are approximately equal to each other, such that the radii of curvature are equal and share the same vertex. In other configurations, angles α and β are different from each other.

[0135] In some implementations, the rear point 326 is positioned along the blending portion 328—which runs along the curved region 310 of the plate 300—wherein the blending portion 328 has a radius of curvature configured to join the curved region 310 to the generally flat region 312 at the rear curved portion 324. Thus, the blending portion 328 is positioned between the curved region 310 and the generally flat region 312 and connects the constant radius of curvature of the curved region 310. In some examples, the blending portion 328 has a generally constant radius of curvature. The blending portion 328 may allow the generally flat region 312 of the plate 300 to extend between the first end 301 (the rearmost point) and the rear point 326 in a direction generally parallel to the horizontal reference plane RP (and the ground). Due to the radius of curvature of the rear curved portion 324 and the radius of curvature of the blending portion 328, the rear point 326 may have a positional height H above the MTP point 320. As used herein, the position height H of the rear point 326 corresponds to the separation distance extending between the rear point 326 and the reference plane RP in a direction generally perpendicular to the horizontal reference plane RP. In some examples, the position height H may have a value ranging from about 3 mm to about 28 mm, while in other examples, the position height H may have a value ranging from about 3 mm to about 17 mm. In one example, the position height H is equal to about 17 mm. In some implementations, the rearmost point 301 and AMP 302 are coplanar at the junction of the blending portion 328 and the generally flat region 312. The shoe plate 300 may include any geometry of the shoe plate geometry disclosed in U.S. Provisional Application Serial No. 62 / 474,030, filed March 20, 2017, U.S. Patent Application No. 15 / 248,051, filed August 26, 2016, and U.S. Patent Application No. 15 / 248,059, filed August 26, 2016, the entire contents of which are incorporated herein by reference.

[0136] Figure 6 Provided Figure 4 A top view of the shoe plate 300 shows its shape. The shoe plate 300 is segmented in length to define a toe section 362, an MTP section 364, a bridging section 366, and a heel section 368. The toe section 362 corresponds to the toes of the foot, and the MTP section 364 corresponds to the MTP joint connecting the metatarsals and phalanges of the foot. The toe section 362 and the MTP section 364 of the plate 300 may correspond to... Figures 1 to 3The forefoot portion 12 of the sole structure 200. A bridging segment 366 corresponds to the arch region of the foot and connects the MTP segment 364 to the heel segment 368. When the plate 300 is incorporated into the sole structure 200, the bridging segment 366 may correspond to the midfoot portion 14, and the heel segment 368 may correspond to the heel portion 16. An MTP point 320 may be located within the MTP segment 364 that engages the toe segment 362 to the bridging segment 366. A rear point 326 may be provided within the bridging segment 366 near the engagement point of the bridging segment 366 and the heel segment 368. For example, a hybrid portion 328 ( Figure 5 The radius of curvature of the section can seamlessly join the bridging section 366 associated with the rear bend 324 to the heel section 368 associated with the flat area 312 of the plate 300.

[0137] Reference Figure 7 and Figures 8A to 8E The shoe plate 300 is shown as being formed by using a series of stacked prepreg fiber sheets 600a to 600e. The prepreg fiber sheets 600a to 600e can be formed from the same or different materials. For example, each of the sheets 600a to 600e can be a unidirectional tape or a multiaxial fabric having a series of resin-impregnated fibers 602. The resin can comprise a two-component epoxy-amine resin manufactured by Applied Poleramics, trademarked CR-157A / DD3-76-6B. The resin concentration can be in the range of about 25% to about 45%, and more preferably from about 30% to about 35%. The fibers 602 can include at least one of carbon fibers, aramid fibers, boron fibers, glass fibers, and other polymer fibers forming the unidirectional sheet or multiaxial fabric. Fibers such as carbon fiber, aramid fiber, and boron fiber can provide high Young's modulus, while glass fiber (e.g., glass filament) and other polymer fibers (e.g., synthetic fibers such as polyamides other than aramids, polyesters, and polyolefins) provide medium modulus. Alternatively, some of the sheets 600a to 600e may be unidirectional tapes, while others are multiaxial fabrics. Furthermore, each of the sheets 600a to 600e may include fibers 602 formed of the same material, or alternatively, one or more of the sheets 600a to 600e may include fibers 602 formed of a material different from the fibers 602 of the other sheets 600a to 600e.

[0138] During the manufacture of the shoe plate 300, a unidirectional or multiaxial fabric is provided and cut into fiber sheets. Each sheet is cut at an angle relative to each other, and the shapes of the individual sheets 600a to 600e are cut from the stacked sheets. Figures 8A to 8EThe shape is shown in the figure. In doing so, the sheets 600a to 600e comprise fibers 602 formed at different angles relative to each other, such that: once cut, the longitudinal axis of the fibers 602 of the unidirectional tape or multiaxial fabric is positioned at an angle (Φ) relative to the longitudinal axis (L) of each sheet 600a to 600e. Therefore, when the sheets 600a to 600e are stacked on top of each other, the longitudinal axis of the fibers 602 is positioned at different angles relative to the longitudinal axis of the plate 300.

[0139] In one configuration Figure 8A The angle (Φ) shown is 0 degrees (0°). Figure 8B The angle (Φ) shown is -15 degrees (-15°). Figure 8C The angle (Φ) shown is -30 degrees (-30°). Figure 8D The angle (Φ) shown is 15 degrees (15°), and Figure 8E The angle (Φ) shown is 30 degrees (30°). When manufacturing the shoe plate 300, the layers are stacked such that when sheets 600a to 600e are cut from the stacked layers, the sheets 600a to 600e have… Figures 8A to 8E The shape shown and the sheet 600a to 600e are as follows Figure 7The stacking order is shown. In other words, the bottom sheet 600c includes fibers 602 positioned at -30° relative to the longitudinal axis (L), the next sheet 600d includes fibers positioned at 15° relative to the longitudinal axis (L), the next two sheets 600a include fibers positioned at 0° relative to the longitudinal axis (L), the next sheet 600b includes fibers positioned at -15° relative to the longitudinal axis (L), and the top and last sheet 600e includes fibers 602 positioned at 30° relative to the longitudinal axis (L). Although the bottom sheet 600c is described as positioned at an angle (Φ) of -30° relative to the longitudinal axis (L) and the top sheet 600e is described as positioned at an angle (Φ) of 30° relative to the longitudinal axis (L), the bottom sheet 600c may alternatively be positioned at an angle (Φ) of -15° relative to the longitudinal axis (L) and the top sheet 600e may alternatively be positioned at an angle (Φ) of 15° relative to the longitudinal axis (L). Furthermore, although two (2) sheets 600a are described as being positioned at an angle (Φ) of 0° relative to the longitudinal axis (L), more than two sheets 600a may be provided at an angle (Φ) of 0°. For example, eight (8) sheets 600a may be provided. In one configuration, three (3) sheets 600a positioned at an angle (Φ) of 0° relative to the longitudinal axis (L) are configured as three intermediate layers, while the bottom sheet 600c is positioned at an angle (Φ) of -15° or -30° relative to the longitudinal axis (L) and the top sheet 600e is positioned at an angle (Φ) of 15° or 30° relative to the longitudinal axis (L). In this configuration, the finished shoe plate 300 is formed by seven (7) sheets / layers stacked in a layered configuration.

[0140] Once the layers are stacked and cut into sheets 600a to 600e, the stacked pieces are subjected to heat and pressure to impart a specific shape of the shoe plate 300 to the stacked sheets 600a to 600e, as will be described below. Figure 20 and Figure 21 As described in detail herein. Additionally, when using pre-impregnated resin fibers, subjecting the stack to heat and pressure can melt or soften the pre-impregnated resin, attaching the layers together and holding them in a specific shape. Alternatively or additionally, liquid resin can be applied to the layers to attach the sheets together and, in some cases, to consolidate the fibers, thereby increasing the tensile strength of the sheets upon resin curing. The pre-impregnated resin may include a two-component epoxy-amine resin, trademarked CR-157A / DD3-76-6B, manufactured by Applied Poleramics. The resin concentration may range from about 25% to about 45%, and more preferably from about 30% to about 35%.

[0141] Reference Figure 9 and Figures 10A to 10EThe shoe plate 300 is shown to be formed by attaching fiber strands 702 to a base 704. In other words, the shoe plate 300 is formed from one or more fiber strands 702 arranged in a selected pattern to impart anisotropic stiffness and gradient load paths to the shoe plate 300. The fiber strands 702 may be attached to the same base 704 or separate bases 704 and embroidered in a layered configuration. If the fiber strands 702 are applied to separate bases 704, the individual bases 704 are stacked on top of each other as each base 704 is supplied with fiber strands 702. On the other hand, if only one base 704 is used when forming the shoe plate 300, the first fiber strand 702 is applied to the base 704, while additional fiber strands (i.e., layers) 702 are applied on top of the first fiber strand 702. Finally, the shoe plate 300 can be formed using a single continuous strand 702 of fiber, whereby the strand 702 is first applied and attached to the base 704 and then layered on top of the strand 702 itself to form Figure 9 The layered configuration is shown. Although each of the above processes can be used to form the shoe plate 300, the following process will be described as forming it using a single substrate 704 together with the individual strands 702 of the applied fibers. Figure 9 The configuration shown indicates that each strand 702a to 702e forms a preformed plate—that is, Figures 1 to 6 The shoe plate 300-700a to 700e.

[0142] Individual strands 702a to 702e may refer to bundles of multiple fibers, bundles of monofilaments, bundles of yarns, or polymer-prepreg bundles. For example, strand 702 may include multiple carbon fibers and multiple resin fibers that are cured upon activation to hold the carbon fibers in a desired shape and to position the multiple carbon fibers and resin fibers relative to each other. As used herein, the term "bundle" refers to a bundle (i.e., multiple) of filaments (e.g., fiber 450) that may be twisted or untwisted, and each bundle may be specified with a size associated with the multiple 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. As used herein, substrate 704 refers to any of the shielding, support, or padding to which at least one strand 702 of fiber is attached. The substrate 704 can be formed from a thermosetting polymer material or a thermoplastic polymer material, and can be a textile (e.g., knitted, woven, or nonwoven), injection-molded, organic sheet, or thermoplastic product. In some configurations, the fiber associated with each strand 702 includes at least one of carbon fiber, boron fiber, glass fiber, and polymer fiber. Fibers such as carbon fiber, aramid fiber, and boron fiber can provide high Young's modulus, while glass fiber (e.g., glass filament) and polymer fiber (e.g., synthetic fiber) provide medium modulus.

[0143] When forming plate 300, the first strand 702c can be applied to substrate 704. In other words, the first strand 702c can be applied directly to substrate 704 and the first strand 702c can be sewn to substrate 704 to hold the first strand 702c in the desired position. In one configuration, the first strand 702c is applied to substrate 704 such that the strand 702c is positioned such that... Figure 10C The diagram shows the positioning at an angle (Φ) of -30 degrees (-30°) relative to the longitudinal axis (L) of the substrate 704. For example, a second thread or second thread 702d can be applied to the first thread 702c via a suture, and the second thread or second thread 702d can be positioned at... Figure 10D The diagram shows the formation at an angle (Φ) of 15 degrees (15°) relative to the longitudinal axis (L) of the substrate 704. In some examples, the first thread 702c is attached to the substrate 704 via a first suture that crosses the first thread 702c and penetrates the substrate 704 at a first attachment position spaced apart from the first thread. A third thread 702a can be used in... Figure 10A The second strand is shown to be applied at an angle (Φ) of zero degrees (0°) relative to the longitudinal axis (L) of the substrate 704. The fourth strand 702b can be applied in... Figure 10BThe diagram shows an angle (Φ) of -15 degrees (L) relative to the longitudinal axis (L) of the base 704 applied to the third strand. The fifth and final strand 702e can be applied at... Figure 10E The second strand is shown to be applied at an angle (Φ) of 30 degrees (30°) relative to the longitudinal axis (L) of the substrate 704. Although the first strand 702c is shown and described as being applied at... Figure 10C The fifth strand 702e is shown and described as being applied at an angle (Φ) of -30 degrees (-30°) relative to the longitudinal axis (L) of the substrate 704, and is shown and described as being applied at an angle (Φ) of -30 degrees (-30°) relative to the longitudinal axis (L) of the substrate 704. Figure 10E The figure shows that the angle (Φ) is applied at 30 degrees (30°) relative to the longitudinal axis (L) of the substrate 704, but these angles (Φ) can alternatively be -15 degrees (-15°) and 15 degrees (15°).

[0144] The strands 702a to 702e form the various layers 700a to 700e of the preformed plate 300. During the formation of layers 700a to 700e, layers 700a to 700e are subjected to heat and pressure to activate the pre-impregnated resin of each strand 702a to 702e and further impart a specific shape to layers 700a to 700e of the plate 300, as will be described below. Figure 20 and Figure 21 As described in detail in [the text].

[0145] As described above, the shoe plate 300 is formed using carbon fiber sheet (CFP) processing, which involves one less layer compared to forming the plate 300 via prepreg fiber sheets 600a to 600e. In other words, CFP processing can utilize only those layers with… Figure 10A The image shows a single layer 700a at an angle (Φ) of zero degrees (0°) relative to the longitudinal axis (L) of the substrate 704. Although the CFP process uses one less layer when forming the plate 300, the resulting plate 300 has approximately the same properties as the plate 300 when using prepreg fiber sheets (i.e., stiffness, thickness, etc.). However, in other configurations, the CFP process can utilize two (2) or more layers 700a arranged at an angle (Φ) of 0° relative to the longitudinal axis (L) to form the shoe plate 300 by means of six (6) or more layers 700a to 700e formed by strands of fiber 702a to 702e.

[0146] Figure 11 and Figure 12A top view is provided of the first strands / tows 400, 410 of fiber 450 that can form layer 1100 of shoe plate 300. The pattern of the first tows 410 of fiber 450 is shown relative to the peripheral edge P of the finished shoe plate 300. In some examples, the first tows 410 are attached to / attached to a base layer including a corresponding substrate 500, such as substrate 704. In other examples, the first tows 410 are attached / attached on top of a base layer comprising sheets 600a to 600e of fibers in a layered configuration, all of which are attached / attached to a single substrate 500. Figure 7 (e.g., unidirectional band) or layers 700a to 700e ( Figure 9 (e.g., strands / tows). For example, one or more layers 1100 formed by the first tow 410 of fibers 450 can replace... Figure 7 One or more of the sheet material 600a or 600e Figure 9 One or more of layers 700a to 700e are used to form the finished shoe plate 300. Therefore, from Figure 11 and Figure 12 The example shown omits any layers 700a to 700e / sheets 600a to 600e of the fibers located below or above the layer 1100 associated with the first bundle 410 of the fiber 450.

[0147] In some examples, the first filament bundle 410 is formed from corresponding continuous strands of fiber 450. However, in other configurations, the first filament bundle 410 is formed from two or more strands of fiber 450. The size of the first filament bundle 410 can range from about 1,000 fibers per bundle to about 48,000 fibers per bundle. In some examples, the first filament bundle 410 includes 12,000 fibers per bundle. The first filament bundle 410 may include the same or different fiber type as the fiber type of the layers 700a to 700e / sheets 600a to 600e of the fibers formed in a layered configuration below or above the first filament bundle to form the finished shoe plate 300. For example, the first filament bundle 410 may include at least one of carbon fiber, boron fiber, glass fiber, and polymer fiber. Fiber 450 may be mixed with thermosetting polymer materials and / or thermoplastic polymer materials to assist in attaching the first filament bundle 410 to the substrate 500 and / or any layer 700a to 700e / sheet 600a to 600e of the fiber located below or above the first filament bundle 410 of fiber 450 to form plate 300.

[0148] Figure 11A first filament bundle 410 of fiber 450, including an annular portion 415, is shown. The annular portion 415 is disposed outside the peripheral edge P of the shoe plate 300 or base 500 for connecting adjacent courses 412, 414, 418 of the first filament bundle 410. The annular portion 415 can be consolidated when the first filament bundle 410 and other layers 700a to 700e / sheets 600a to 600e are subjected to heat and pressure, thereby consolidating the fiber 450 and forming the shoe plate 300. In some cases, the annular portion 415 extending outside the peripheral edge P creates a pinch point when the layered configuration is subjected to pressure (e.g., molding) to consolidate the fiber 450 to form the shoe plate 300. Therefore, Figure 12 The following first filament bundle 410 of fiber 450 is shown: the first filament bundle 410 of fiber 450 is cut along the peripheral edge P of shoe plate 300 to remove the annular portion 415, thereby removing the present compression point when pressure is applied to form the finished shoe plate 300.

[0149] In some configurations, a first bundle 410 of fibers is attached to a substrate 500 via a stitch 416. For example, the stitch 416 may zigzag across the first bundle 410 between first attachment sites located on or beneath the substrate 500, in layers of fibers (e.g., strands or unidirectional tape). Here, the attachment sites may be spaced apart from the first bundle 410 along the peripheral edge P of the finished shoe plate 300. The stitch 416 may be formed of the same material as the substrate 500, or it may be formed of a different material than the material forming the substrate 500, such that the stitch 416 is associated with a higher melting point than the substrate 500. Having a higher melting point than the substrate 500 allows the stitch 416 to melt after the substrate 500 when heat is applied, thus allowing the stitch 416 to melt after the substrate 500 begins to melt. In some examples, the stitch 416, or at least a portion thereof, is formed of resin. In some configurations, sheets of fibers 602 and 702 are 600a to 600e. Figure 7 (e.g., unidirectional band) or layers 700a to 700e ( Figure 9A thread 416 (e.g., strands / tows) is disposed between the substrate 500 and the first filament bundle 410, and the thread 416 may zigzag across the first filament bundle 410 between attachment sites located on the substrate 500. In these configurations, the thread 416 may penetrate the substrate 500 at the attachment sites and / or the thread 416 may extend through the sheets 600a to 600e / layers 700a to 700e of fibers 602, 702 disposed on the substrate 500 and below the first filament bundle 410. For example, the thread 416 may attach the first filament bundle 410 of fiber 450 to the substrate 500 by crossing the first filament bundle 410 of fiber 450 at the attachment sites, extending through the sheets 600a to 600e / layers 700a to 700e of fibers 602, 702 and penetrating the substrate 500.

[0150] The first filament bundle 410 of fiber 450 includes a plurality of outer portions / segments 412, a plurality of inner portions / segments 414, and a plurality of inner portions / segments 418. The outer portions 412 may be arranged adjacent to each other and generally parallel to each other. Each outer portion 412 has a corresponding length extending between a corresponding first end and a corresponding second end, wherein the corresponding first end is located near the peripheral edge P at the outer portion 18 in the forefoot region 12 or midfoot region 14, and the corresponding second end is located near the peripheral edge P at the outer portion 18 in the heel region 16 or midfoot region 14. Furthermore, each outer portion 412 of the first filament bundle 410 traverses the shoe plate 300 in a “C” shape, such that a portion along the length of each outer portion 412 extends along the midfoot region 14 of the shoe plate 300 into the inner region. Here, these portions of the segments 412 may extend in the midfoot region 14 in a direction generally parallel to the longitudinal axis L of the shoe plate 300. Figure 11 and Figure 12 The spacing between each adjacent lateral segment 412 is shown, which is smaller in the midfoot region 14 than in the forefoot region 12 and / or the heel region 16. In other words, the distance separating adjacent lateral segments 412 decreases as the segments 412 move away from the outer portion 18 of the shoe plate 300 and traverse towards the inward region.

[0151] On the other hand, each inner segment 418 has a corresponding length extending between a corresponding first end and a corresponding second end, wherein the corresponding first end is located near the peripheral edge P at the inner portion 20 in the forefoot region 12 or the midfoot region 14, and the corresponding second end is located near the peripheral edge P at the inner portion 20 in the heel region 16 or the midfoot region 14. Here, the inner segments 418 of the first filament bundle 410 define a shape opposite to that of the outer segment 412, such that each inner segment 418 traverses the shoe plate 300 in an "opposite C" shape. Thus, a portion along the length of each inner segment 418 extends along the midfoot region 14 of the shoe plate 300 into the inner region. Like the outer segment 412, these portions of the inner segments 418 can extend in the midfoot region 14 in a direction generally parallel to the longitudinal axis L of the shoe plate 300. Figure 11 and Figure 12 The spacing between each adjacent medial segment 418 is shown, which is smaller in the midfoot region 14 than in the forefoot region 12 and / or heel region 16. In other words, the distance separating adjacent medial segments 418 decreases as the segments 412 move away from the medial portion 20 of the shoe plate 300 and traverse towards the inner region.

[0152] An inner segment 414 of the first filament bundle 410 of fiber 450 is disposed between the outer segment 412 and the inner segment 418 and defines a corresponding length extending along the length of the shoe plate 300 between the first end 301 and the second end 302. The inner segments 414 may be arranged adjacent to each other and generally parallel, traversing the shoe plate 300 in an "S" shape and passing through the inner region of the plate 300. Similar to the outer segment 412 and the inner segment 418, the spacing between each adjacent inner segment 414 is smaller in the midfoot region 14 than in the forefoot region 12 and the heel region 16. Therefore, the distance separating adjacent inner segments 414 decreases as the segments 414 extend in opposite directions toward the forefoot region 12 and the heel region 16, respectively.

[0153] Because the spacing between adjacent segments 412, 414, 418 of the first bundle 410 of fiber 450 in the midfoot region 14 is smaller than the corresponding spacing in the forefoot region 12 and the heel region 16, segments 412, 414, 418 collectively provide a greater concentration / density of fiber 450 in the midfoot region 14 compared to the corresponding fiber concentration / density in the forefoot region 12 and the heel region 16. Therefore, the first bundle 410 of fiber 450 makes the shoe plate 300 more stiff in the midfoot region 14 than it is in either the forefoot region 12 or the heel region 16.

[0154] In one configuration, the layer 1100 associated with the first bundle 410 of fiber 450 is configured to... Figure 7The stacked prepreg sheets 600a to 600e shown are the top and last layer of the stacked sequence. Here, the first bundle 410 of fiber 450 may be attached / attached to the underlying sheet 600e, which includes fiber 602, positioned at an angle (Φ) of 30° or 15° relative to the longitudinal axis (L) to form the shoe plate 300 from seven (7) sheets / layers. In another configuration, the layer 1100 associated with the first bundle 410 of fiber 450 is configured to form a... Figure 9 The layers 700a to 700e shown in the sequential stacking are the top and last layers of strands 702a to 702e. Here, the first bundle 410 of fiber 450 may be attached (e.g., via stitch 416) to the underlying layer 700e to form the shoe plate 300, wherein the layer 700e includes a fifth strand 702e of fiber positioned at an angle (Φ) of 30° or 15° relative to the longitudinal axis (L).

[0155] Figure 13 and Figure 14 A top view is provided of the second strands / tows 400, 420 of fiber 450 that can form layer 1300 of shoe plate 300. The pattern of the second tows 420 of fiber 450 is shown relative to the peripheral edge P of the finished shoe plate 300. In some examples, the second tows 420 are attached to / attached to a base layer including a corresponding substrate 500, such as substrate 704. In other examples, the second tows 420 are attached to / attached on top of a base layer comprising sheets 600a to 600e of fibers 602, 702, all attached / attached in a layered configuration to a single substrate 500. Figure 7 (e.g., unidirectional strip) or layers 700a to 700e ( Figure 9 (e.g., strands / tows). For example, one or more layers 1300 formed by a second filament bundle 420 of fiber 450 can replace... Figure 7 One or more of the sheet material from 600a to 600e or Figure 9 One or more of layers 700a to 700e are used to form the finished shoe plate 300. Therefore, from Figure 13 and Figure 14 The example shown omits any layers 700a to 700e / sheets 600a to 600e of fibers 602, 702 located below or above layer 1300 associated with the second bundle 420 of fiber 450.

[0156] and Figure 11 and Figure 12Similar to the first bundle 410 of fiber 450, the second bundle 420 of fiber 450 may be formed from corresponding continuous strands of fiber 450 or two or more strands of fiber 450, and the second bundle 420 may include at least one of carbon fiber, boron fiber, glass fiber, and polymer fiber. The fibers 450 of the second bundle 420 may also be blended with thermosetting polymer materials and / or thermoplastic polymer materials. Similar to the annular portion 415 associated with the first bundle 410, Figure 13 A second filament bundle 420 is shown, including a corresponding annular portion 425, wherein the annular portion 425 is disposed outside the peripheral edge P of the plate / base 300, 500 for connecting adjacent segments 422, 428 of the second filament bundle 420. This is to eliminate compression points present when the second filament bundle 420 is subjected to pressure (e.g., molding) to form the shoe plate 300. Figure 14 The following second filament bundle 420 of fiber 450 is shown: the second filament bundle 420 of fiber 450 is cut along the peripheral edge P to remove the annular portion 425 extending outside the peripheral edge P.

[0157] In some configurations, the second bundle 420 of the fibers is attached via stitch 426 to the substrate 500 or the sheet 600a to 600e of the underlying fibers 602, 702. Figure 7 (e.g., unidirectional band) or layers 700a to 700e ( Figure 9 (e.g., strands / tows). For example, stitch 426 may zigzag across the second tow 420 between attachment sites on the strands 600a to 600e / layers 700a to 700e of the fibers 602, 702 located on the base 500 or below. Here, the attachment sites may be spaced apart from the second tow 420 along the peripheral edge P of the finished shoe plate 300. Stitch 426 may be formed by... Figure 11 and Figure 12 The suture 426 is formed of the same material (e.g., resin) as the suture 416, allowing the suture 426 to melt after the substrate 500 begins to melt upon application of heat. In some examples, the suture 426 may penetrate the substrate 500 at the attachment location and / or may also extend through the sheets 600a to 600e / layers 700a to 700e of fibers 602, 702 disposed on the substrate 500 and located below the second filament bundle 420. For example, the suture 426 may attach the second filament bundle 420 of fiber 450 to the substrate 500 by crossing the second filament bundle 420 of fiber 450 at the attachment location, extending through the sheets 600a to 600e / layers 700a to 700e of fibers 602, 702 and penetrating the substrate 500.

[0158] The second bundle 420 of fiber 450 includes a plurality of outer portions / segments 422 and a plurality of inner portions / segments 428, which are interwoven or overlapped within an inner region 429 of the midfoot region 14 of the shoe plate 300. In some configurations, the outer portions / segments 422 and inner portions / segments 428 are associated with separate toe portions of fiber 420. The outer portions 422 may be arranged adjacent to each other and generally parallel to each other, such that each outer portion 422 has a corresponding length extending between a corresponding first end and a corresponding second end, wherein the corresponding first end is near the peripheral edge P at the outer portion 18 in the forefoot region 12, and the corresponding second end is near the peripheral edge P at the outer portion 18 in the heel region 16. The outer portions 422 traverse the shoe plate 300 in a “C” shape such that a portion along the corresponding length of each outer portion 412 extends into the inner region 429. Here, these portions of the outer segment 422 extend in the inner region 429 in a direction generally parallel to the longitudinal axis L of the shoe plate 300. In some implementations, the spacing between each adjacent outer segment 422 is generally consistent along the length of the outer segment 422.

[0159] On the other hand, each inner segment 428 has a corresponding length extending between a corresponding first end and a corresponding second end, wherein the corresponding first end is located near the peripheral edge P at the inner portion 20 in the forefoot region 12, and the corresponding second end is located near the peripheral edge P at the inner portion 20 in the heel region 16. The shape of the inner segment 428 is reversed relative to the shape of the outer segment 422, and thus the inner segment 428 traverses the shoe plate 300 in an "opposite C" shape, such that portions along the corresponding lengths of each inner segment extend into the inner region 429. Here, these portions of the inner segment 428 extend in the inner region 429 in a direction generally parallel to the longitudinal axis L of the shoe plate 300.

[0160] The inner segments 428 extending into and from the inner region 429 may intersect, overlap, and / or interweave with one or more of the outer segments 422 extending into and from the inner region 429. Although the spacing between each adjacent inner segment 428 may be substantially consistent in length, each inner segment 428 may be arranged alternately between two corresponding outer segments 422 within the inner region 429. Thus, the outer segments 422 and inner segments 428 of the second filament bundle 420 may extend substantially parallel to the longitudinal axis L within the inner region 429, and the outer segments 422 and inner segments 428 are separated from each other as they extend toward the respective ends of the outer segments 422 and inner segments 428, respectively, at one of the outer portions 18 and the inner portions 20. In some implementations, the second filament bundle 420 provides layer 1300 with a higher concentration / density of fibers 450 within the inner region 429 than the concentration / density of fibers outside the inner region 429, thereby increasing the stiffness of the shoe plate 300 within the inner region 429. In some examples, the stitch 426 zigzags across the outer segment 422 within the inner region 429 to attach the outer segment 422 to the substrate 500, and the stitch 426 also zigzags across the inner segment 428 within the inner region 429 to attach the inner segment 428 to the substrate 500 at the corresponding attachment position within the inner region 429. In some configurations, the seam 426 can attach the outer segment 422 and the inner segment 428 to the base 500 by zigzagging across one of the outer segment 422 and the inner segment 428 within the inner region 429, extending zigzag through the other of the outer segment 422 and the inner segment 428 within the inner region 429, and penetrating the base 500 at the attachment location within the inner region 429. Furthermore, the fibers 450 of the second filament bundle 420, mixed with thermosetting polymer materials and / or thermoplastic polymer materials, can facilitate bonding between the corresponding layers 1300, the base 500, and / or any other sheets 600a to 600e / layers 700a to 700e located below or above layer 1300 associated with the second filament bundle / strands 400, 420 of the fibers 450, to form the shoe plate 300 when heat and pressure are applied.

[0161] Although the first bundle 410 of fiber 450 includes an inner segment 414 extending along the length of plate 300, the second bundle 420 of fiber 450 defines a space 421 in the forefoot region 12 and a space 423 in the heel region 16, where fiber 450 is absent. In some examples, spaces 421, 423 expose one or more layers 700a to 700e / sheets 600a to 600e located beneath the layer 1300 associated with the second bundle 420 of fiber 450. When combined in a layered configuration to form the shoe plate 300, the layer 1300 associated with the second bundle 420 does not impart any stiffness properties to the areas in the forefoot region 12 and heel region 16 where spaces 421 and 423 are formed.

[0162] Figure 15 and Figure 16 A top view is provided of the third filaments / strands 400, 430 of fiber 450 that can form layer 1500 of shoe plate 300. The pattern of the third filaments 430 of fiber 450 is shown relative to the peripheral edge P of the finished shoe plate 300. In some examples, the third filaments 430 are attached / attached to a base layer including a corresponding substrate 500. In other examples, the third filaments 430 are attached / attached on top of a base layer comprising sheets 600a to 600e of fibers 602, 702, all attached / attached in a layered configuration to a single substrate 500. Figure 7 (e.g., unidirectional band) or layers 700a to 700e ( Figure 9 (e.g., strands / tows). For example, one or more layers 1500 formed by the third filament bundle 430 of fiber 450 can replace... Figure 7 One or more of the sheet material 600a or 600e Figure 9 One or more of layers 700a to 700e are used to form the finished shoe plate 300. Therefore, from Figure 15 and Figure 16 The example shown omits any layers 700a to 700e / sheets 600a to 600e of the fibers located below or above the layer 1500 associated with the third bundle 430 of fiber 450.

[0163] In some configurations, the third bundle 430 of fiber 450 is attached to the substrate 500 or to the sheets 600a to 600e or layers 700a to 700e of the underlying fibers 602, 702 via stitch 437. For example, stitch 437 may zigzag across the third bundle 430 between first attachment positions on the substrate 500 or on the strands 600a to 600e / layers 700a to 700e of the underlying fibers 602, 702. Here, the attachment positions may be spaced apart from the third bundle 430 along the peripheral edge P of the finished shoe plate 300. Stitch 437 may be formed by... Figures 11 to 14 The sutures 416 and 426 are formed of the same material (e.g., resin) to allow suture 437 to melt after the substrate 500 begins to melt upon application of heat. In some examples, suture 437 may penetrate the substrate 500 at the attachment location and / or may also extend through the sheets 600a to 600e / layers 700a to 700e of fibers 602, 702 disposed on the substrate 500 and below the third filament bundle 430. For example, suture 437 may attach the third filament bundle 430 of fiber 450 to the substrate 500 by crossing the third filament bundle 430 of fiber 450 at the attachment location, extending through the sheets 600a to 600e / layers 700a to 700e of fibers 602, 702 and penetrating the substrate 500. Furthermore, the fibers 450 of the second filament bundle 430, which are mixed with thermosetting polymer materials and / or thermoplastic polymer materials, can promote bonding between the corresponding layers 1500, substrate 500, and / or any other sheets 600a to 600e / layers 700a to 700e located below or above the third filament bundle / strand 400, 430 of the fibers 450, to form the shoe plate 300 when heat and pressure are applied.

[0164] and Figures 11 to 14 Like the first bundle 410 and the second bundle 420 of fiber 450, the third bundle 430 of fiber 450 may be formed from corresponding continuous strands of fiber 450 or two or more strands of fiber 450, and the third bundle 430 may include at least one of carbon fiber, boron fiber, glass fiber and polymer fiber. Figure 15 The diagram shows a third filament bundle 430 including corresponding annular portions 435 for connecting adjacent segments 432, 434, 436, and 438. The annular portions 435 located in the forefoot region 12 are positioned inside the peripheral edge P of the plate / base 300, 500, while the annular portions 435 near the heel region 16 are positioned outside the peripheral edge P. This is to eliminate pressure points present when the third filament bundle 430 is subjected to pressure (e.g., molding) to form the shoe plate 300. Figure 16The following third filament bundle 430 of fiber 450 is shown: the third filament bundle 430 of fiber 450 is cut along the peripheral edge P to remove the annular portion 435 extending outside the peripheral edge P.

[0165] and Figures 11 to 14 Compared to the first and second filament bundles 420 of fiber 450, the third filament bundle 430 of fiber 450 provides a greater variation in stiffness along the length of the shoe plate 300. A segment / part of the third filament bundle 430 of fiber 430 located within the inner region of the shoe plate 300 extends from the heel region 16 generally parallel to the longitudinal axis (L) to the midfoot region 14, while segments / filament bundles along the outer portion 18 and the inner portion 20 converge toward the inner region of the shoe plate 300 as they extend from the heel region 16 to the midfoot region 14. Therefore, the third filament bundle 430 of fiber 450 has a spacing between adjacent segments / parts in the heel region 16, which decreases as the segments / parts extend into the midfoot region 14, thus the midfoot region 14 of the shoe plate 300 is associated with a narrower width compared to the heel region 16. As used herein, the width of the shoe plate 300 corresponds to the distance between the peripheral edge P at the outer side 18 and the peripheral edge P at the inner side 20 in a direction approximately perpendicular to the longitudinal axis (L).

[0166] In some configurations, the third filament bundle 430 of fiber 450 branches into four separate segment groups 432, 434, 436, and 438 as it extends from the midfoot region 14 toward the annular portion 435 disposed in the forefoot region 12 of the plate / base 300, 500. For example, the outer segment group 432 generally follows the peripheral edge P of the shoe plate 300 at the outer portion 18, while the inner segment group 438 generally follows the peripheral edge P of the shoe plate 300 at the inner portion 20. Furthermore, the first inner segment group 434 is adjacent to and spaced inward from the outer segment group 432, and the second inner segment group 436 is adjacent to and spaced inward from the inner segment group 438. In the example shown, the first inner group 434 and the second inner group 436 are also spaced apart from each other. Therefore, the third bundle 430 of fiber 450 forms multiple regions between the separate groups 432, 434, 436, 438 of fiber 450, where fiber 340 is absent, thereby exposing one or more layers 700a to 700e / sheets 600a to 600e beneath the third bundle 430 of fiber in the forefoot region 12 of shoe plate 300. Here, the layer 1500 associated with the third bundle 430 does not impart any stiffness characteristics to the region in the forefoot region 12 where fiber 450 is absent. Each group 432, 434, 436, 438 of the third bundle 430 of fiber 450 corresponds to a corresponding "tendon": the "tendon" imparts stiffness characteristics based on the number of segments and / or the spacing between adjacent segments in each separate group 432, 434, 436, 438. More specifically, the separate groups 432, 434, 436, and 438 of the third bundle 430 of fiber 450 cooperate to impart anisotropic stiffness and gradient load paths throughout the forefoot region 12 of the entire shoe plate 300. For example, the longitudinal and lateral stiffness obtained at different locations in the forefoot region 12 can alternate between a certain degree of stiffness provided by the concentration of fiber 450 in the corresponding groups 432, 434, 436, and 438 and no stiffness in the absence of fiber 450.

[0167] In some examples, the outer segment group 432 is longer than the first inner segment group 434, the first inner segment group 434 is longer than the second inner segment group 436, and the second inner segment group 436 is longer than the inner segment group 438. In these examples, the annular portion 435 corresponding to the outer segment group 432 is positioned closer to the second end 302 of the shoe plate 300 than the annular portion 435 corresponding to the inner segment group 438. In some configurations, at least one of the segment groups 432, 434, 436, and 438 includes a different number of segments than the other groups 432, 434, 436, and 438. In other configurations, each segment group 432, 434, 436, and 438 includes the same number of segments as the other groups 432, 434, 436, and 438. Increasing the number of segments in a corresponding group provides a higher concentration of fibers 450 and thus imparts greater stiffness to that corresponding group.

[0168] In some implementations, the spacing between adjacent segments of at least one of groups 432, 434, 436, and 438 varies along the length of plate 300 between the annular portion 435 in the middle leg region 14 and the front leg region 12. For example, the spacing between adjacent segments of at least one of groups 432, 434, 436, and 438 may increase as the segment crosses from the middle leg region 14 into the front leg region 12, and then the spacing may gradually decrease until the segment terminates at the corresponding annular portion 435 in the front leg region 12. In other implementations, the spacing between adjacent segments of at least one of groups 432, 434, 436, and 438 is substantially consistent along the length of plate 300 between the annular portion 435 in the middle leg region 14 and the front leg region 12.

[0169] Because the spacing between adjacent segments of the third filament bundle 430 of fiber 450 in the midfoot region 14 is smaller than that in the heel region 16, the third filament bundle 430 collectively provides a greater concentration / density of fiber 450 in the midfoot region 14 compared to the concentration / density of fiber 450 in the heel region 16. Furthermore, because the third filament bundle 430 of fiber 450 is divided into four separate groups 432, 434, 436, and 438 as it traverses the shoe plate 300 from the midfoot region 14 to the forefoot region 12, the concentration / density of fiber 450 in the midfoot region 14 is greater than that in the forefoot region 12. In the forefoot region 12, there is no fiber 450 in the area between each of the separate segment groups 432, 434, 436, and 438. Therefore, the third filament bundle 430 of fiber 430 imparts different stiffness characteristics to the shoe plate 300 in each of the forefoot region 12, midfoot region 14 and heel region 16. Figure 17A top view is provided of the fourth filament / strand 400, 440 of fiber 450 that can form layer 1700 of shoe plate 300. The pattern of the fourth filament 440 of fiber 450 is shown relative to the peripheral edge P of the finished shoe plate 300. In some examples, the fourth filament 440 is attached to / attached to a base layer including a corresponding substrate 500. In other examples, the fourth filament 440 is attached / attached on top of a base layer comprising sheets 600a to 600e of fibers in a layered configuration, all of which are attached / attached to a single substrate 500. Figure 7 (e.g., unidirectional band) or layers 700a to 700e ( Figure 9 (e.g., strands / tows). For example, one or more layers 1700 formed by the fourth filament bundle 440 of fiber 450 can replace... Figure 7 One or more of the sheet material 600a or 600e Figure 9 One or more of layers 700a to 700e are used to form the finished shoe plate 300. Therefore, from Figure 7 The example shown omits any layers 700a to 700e / sheets 600a to 600e of the fiber located below or above the layer 1700 associated with the fourth filament bundle 440 of fiber 450. The fourth filament bundle / strand 440 of fiber 450 can be attached to the substrate 500 by a serrated suture across the fourth filament bundle 440 of fiber 450 at the attachment location and through the substrate 500. In some examples, the suture may also extend through and penetrate the underlying layers 700a to 700e / sheets 600a to 600e of the fiber.

[0170] The fourth filament bundle 440 of fiber 450 and Figure 15 and Figure 16The arrangement of the third filament bundle 430 of fiber 450 is generally similar, except that segments / parts 442, 444, 446, 448 of the fourth filament bundle 440 of fiber 450 are shorter than the corresponding segments / parts 432, 434, 436, 438 of the third filament bundle 430 of fiber 450. For example, the fourth filament bundle 440 of fiber 450 defines a shortened length along the length of the shoe plate 300, thereby eliminating the presence of fibers in most of both the heel region 16 and the forefoot region 12. Similar to the third filament bundle 430 of fiber 450, segments / parts of the fourth filament bundle 440 of fiber 450 in the inner region of the shoe plate 300 extend approximately parallel to the longitudinal axis (L) from the corresponding annular portion 445 provided in the heel region 16, while segments / parts near the outer portion 18 or the inner portion 20 converge toward the inner region of the shoe as they extend from the corresponding annular portion 445 provided in the heel region 16. However, compared to the third filament bundle 430 of fiber 450, which has adjacent segments extending in the midfoot region 14 across the width of the shoe plate 300, the segments corresponding to the fourth filament bundle 440 of fiber 450 are concentrated in the midfoot region 14 toward the interior region of the plate 300 and simultaneously define a gap along the peripheral edge P where no fiber is present and therefore no stiffness is imparted.

[0171] Similar to the third filament bundle 430 of fiber 450, the fourth filament bundle 440 of fiber 450 also branches into four separate segment groups 442, 444, 446, and 448 as it extends from the midfoot region 14 toward the annular portion 445 disposed in either the forefoot region 12 or the midfoot region 14. For example, the outer segment group 442 generally follows the peripheral edge P of the shoe plate 300 at the outer portion 18 and terminates at the forefoot region 12, while the inner segment group 448 generally follows the peripheral edge P of the shoe plate 300 at the inner portion 20 and terminates at the midfoot region 14. Furthermore, the first inner segment group 444 is adjacent to the outer segment group 442 and spaced inward from the outer segment group 442, and the second inner segment group 446 is adjacent to the inner segment group 448 and spaced inward from the inner segment group 448. Here, the layer 1700 associated with the fourth filament bundle 440 does not impart any stiffness characteristics to the region between groups 442, 444, 446, and 448 of fibers 450 in the foreleg region 12. However, the separated segments 442, 444, 446, and 448 of the fourth filament bundle 440 of fibers 450 cooperate to impart anisotropic stiffness and gradient load paths to the region extending toward the foreleg region 12 and away from the middle leg region 14 of high-concentration / density fibers 450, where the stiffness is greatest.

[0172] In some examples, the outer segment group 442 is longer than the first inner segment group 444, the first inner segment group 444 is longer than the second inner segment group 446, and the second inner segment group 446 is longer than the inner segment group 448. In these examples, the annular portion 445 corresponding to the outer segment group 442 is positioned closer to the second end 302 of the shoe plate 300 than the annular portion 445 corresponding to the inner segment group 448. Each segment group 442, 444, 446, 448 of the fourth filament bundle 440 can be positioned closer than... Figure 15 and Figure 16 Each corresponding segment group 432, 434, 436, 438 of the third filament bundle 430 is further away from the second end 302 of the plate 300. In some configurations, at least one of the segment groups 442, 444, 446, 448 includes a different number of segments than the other groups 442, 4434, 446, 448. In other configurations, each segment group 442, 444, 446, 448 includes the same number of segments as the other groups 442, 444, 446, 448. Increasing the number of segments in a corresponding group provides a greater concentration of fibers 450 and thus gives the corresponding group greater stiffness. In addition, the spacing between adjacent segments in at least one of the groups 442, 444, 446, 448 may vary as the segments traverse toward the front foot region 12 of the plate 300 or may be substantially uniform. For example, the interval between segments in at least one of groups 442, 444, 446, and 448 may first increase as the segment begins to traverse from the middle foot region 14 toward the front foot region 12, and then the interval may gradually decrease until the segment terminates at the corresponding annular portion 435 in the front foot region 12 or until the segment terminates at a position in the middle foot region 14 near the front foot region 12.

[0173] Figure 18 A top view is provided of the fifth strand / tow 400, 460 of fiber 450 that can form layer 1800 of shoe plate 300. The pattern of the fifth tow 450 of fiber 450 is shown relative to the peripheral edge P of the finished shoe plate 300. In some examples, the fifth tow 460 is attached to / attached to a base layer including a corresponding substrate 500, such as substrate 704. In other examples, the fifth tow 460 is attached / attached on top of a base layer comprising sheets 600a to 600e of fibers in a layered configuration, all of which are attached / attached to a single substrate 500. Figure 7 (e.g., unidirectional band) or layers 700a to 700e ( Figure 9 (e.g., strands / tows). For example, one or more layers 1800 formed by the fifth filament bundle 460 of fiber 450 can replace... Figure 7 One or more of the sheet material 600a or 600e Figure 9One or more of layers 700a to 700e are used to form the finished shoe plate 300. Therefore, from Figure 18 The example shown omits any layers 700a to 700e / sheets 600a to 600e of the fiber located below or above the layer 1800 associated with the fifth filament bundle 460 of fiber 450. The fifth filament bundle / strand 460 of fiber 450 can be attached to the substrate 500 by a serrated suture across the fifth filament bundle 460 of fiber 450 at the attachment location and through the substrate 500. In some examples, the suture may also extend through and penetrate the underlying layers 700a to 700e / sheets 600a to 600e of the fiber.

[0174] and Figure 11 and Figure 12 Similar to the first bundle 410 of fiber 450, the fifth bundle 460 of fiber 450 may be formed from a continuous strand of fiber 450 or two or more strands of fiber 450, and the size of the fifth bundle 460 may range from about 1,000 fibers per bundle to about 48,000 fibers per bundle. The fifth bundle 460 includes at least one of carbon fiber, boron fiber, glass fiber, and polymer fiber, and the fifth bundle 460 may be blended with thermosetting polymer materials and / or thermoplastic polymer materials. Here, using thermosetting polymer materials and / or thermoplastic polymer materials to bond the fibers 450 of the fifth filament bundle 460 can promote bonding between the corresponding layers 1800, substrate 500, and / or any other sheets 600a to 600e / layers 700a to 700e located below or above the fifth filament bundle / strand 400, 460 of the fibers 450, to form the shoe plate 300 when heat and pressure are applied.

[0175] Figure 18A fifth filament bundle 460 of fiber 450, comprising multiple segments of equal length, is shown and extends between a first position 462 in the forefoot region 12 and a second position 464 in the heel region 16. The fifth filament bundle 460 of fiber 450 includes an annular portion 465 at the first and second positions 462 for connecting adjacent segments of the fifth filament bundle 460. In the example shown, the segments of the fifth filament bundle 460 near the outer side 18 of the plate 300 and within the plate 300 extend substantially parallel to each other and substantially parallel to the axial axis (L) between the first and second positions 462 and 464. However, the segments of the fifth filament bundle 460 near the inner side 20 of the plate 300 converge toward the interior of the plate 300 as they extend from the second position 464 toward the inner region 14, and then separate and fan out in a fan shape away from the interior of the plate 300 as they extend from the inner region 14 to the first position 462. Therefore, the segments near the inner side 20 generally follow the curvature of the peripheral edge P of the plate 300 at the inner side 20. The convergence of the segments near the inner side 20 toward the interior of the plate 300 reduces the spacing between adjacent segments in the inner region 14 of the plate, and thus provides greater stiffness in the middle leg region 14 due to the corresponding increase in the concentration / density of the fibers 450. Furthermore, the spacing between adjacent segments of the fifth filament 460 near the first position 462 in the front leg region 12 is larger than the spacing between adjacent segments near the second position in the heel region 16. Therefore, the fifth filament 460 of the fibers 450 provides less stiffness to the heel region 16 than to the middle leg region 14 and more stiffness to the front leg region 12. In other configurations, the spacing between adjacent segments of the fifth filament 460 of the fibers 450 is approximately consistent in length between the first position 462 and the second position 464.

[0176] Figure 19 A top view is provided of the sixth strand / tow 400, 470 of fiber 450 that can form layer 1900 of shoe plate 300. The pattern of the sixth tow 470 of fiber 450 is shown relative to the peripheral edge P of the finished shoe plate 300. In some examples, the sixth tow 470 is attached to / attached to a base layer including a corresponding substrate 500, such as substrate 704. In other examples, the sixth tow 470 is attached / attached on top of a base layer comprising sheets 600a to 600e of fibers in a layered configuration, all of which are attached / attached to a single substrate 500. Figure 7 (e.g., unidirectional band) or layers 700a to 700e ( Figure 9 (e.g., strands / tows). For example, one or more layers 1900 formed by the sixth tow 470 of fiber 450 can replace... Figure 7One or more of the sheet material from 600a to 600e or Figure 9 One or more of layers 700a to 700e are used to form the finished shoe plate 300. Therefore, from Figure 19 The example shown omits any layers 700a to 700e / sheets 600a to 600e of the fiber located below or above layer 1900 associated with the fifth filament bundle 460 of fiber 450. The sixth filament bundle / strand 470 of fiber 450 can be attached to the substrate 500 by serrulating across the sixth filament bundle 470 of fiber 450 at the attachment location and penetrating the substrate 500. In some examples, the suture may also extend through and penetrate the underlying layers 700a to 700e / sheets 600a to 600e of the fiber.

[0177] In the example shown, the sixth filament bundle 470 of fiber 450 is formed from continuous strands of fiber 450. However, in other examples, the sixth filament bundle 470 may be formed from two or more strands of fiber 450. The size of the sixth filament bundle 470 may range from about 1,000 fibers per bundle to about 48,000 fibers per bundle, and the sixth filament bundle 470 includes at least one of carbon fiber, boron fiber, glass fiber, and polymer fiber, and the sixth filament bundle 470 may be blended with thermosetting polymer materials and / or thermoplastic polymer materials. Here, the sixth filament 470 of fiber 450, which is mixed with thermosetting polymer material and / or thermoplastic polymer material, can facilitate bonding between the corresponding layer 1900, substrate 500 and / or any other sheet 600a to 600e / layer 700a to 700e located below or above layer 1900 associated with the sixth filament / strand 400, 470 of fiber 450, to form shoe plate 300 when heat and pressure are applied.

[0178] Figure 19A sixth filament bundle 470 of fiber 450, having multiple segments 472, 474, and 478, is shown. Each segment 472, 474, and 478 extends along the length of the plate 300 from a first position 479 disposed in the heel region 16 to a corresponding second position 471, 473, or 477 disposed in the forefoot region 12 of the shoe plate 300. For example, the outer segment 472 extends between the first position 479 and the corresponding second position 471, while the inner segment 478 extends between the first position 479 and the corresponding second position 477, wherein the corresponding second position 477 is positioned closer to the second end 302 of the shoe plate 300 than the second position 471 corresponding to the outer segment 472. Additionally, an inner segment 474 disposed between the outer segment 472 and the inner segment 478 extends between the first position 479 and the corresponding second position 473. In the example shown, the second position 473 corresponding to the inner segment 474 is positioned closer to the second end 302 of the shoe plate 300 than the second position 471 corresponding to the outer segment 472 and farther away from the second end 302 of the shoe plate 300 than the second position 477 corresponding to the inner segment 478. The sixth filament bundle 470 of the fiber 450 includes an annular portion 475 disposed at the first position 479 and the second positions 471, 473, 477 for connecting adjacent segments of the sixth filament bundle 470.

[0179] In some implementations, the corresponding second positions 471, 473, 477 correspond to define the end portion of the sixth filament bundle 470 of fiber 450 in the forefoot region 12, said end portion being aligned with the anatomical features of the foot when the foot is received within the internal space 102 of the footwear 10 on the shoe plate 300. In some examples, the anatomical features include the curvature of all the toes of the foot. This curvature may extend through the metatarsophalangeal (MTP) joint of the foot, at which the proximal phalanges of the toes engage with the corresponding metatarsals of the foot. Thus, each segment 472, 474, 478 can impart stiffness to the plate 300 under the wearer's foot up to the MTP joint, without imparting any stiffness to the area of ​​the plate 300 where the toes of the foot reside, in order to provide the desired flexibility during the athlete's movement.

[0180] The outer segments 472 may be arranged adjacent to each other and generally parallel to each other along the longitudinal axis L of the shoe plate 300, near the peripheral edge P of the outer portion 18. In some examples, the spacing between each adjacent outer segment 472 is generally consistent along the length of the outer segment 472 between the first position 479 and the second position 471. In other examples, the spacing between each adjacent outer segment 472 varies along this length, such that the spacing between each adjacent outer segment 472 within the midfoot region 14 is smaller than the corresponding spacing within the forefoot region 12 and the heel region 16. Providing a narrower spacing between adjacent segments provides a greater concentration / density of the fibers 450, thereby increasing the stiffness of the shoe plate 300.

[0181] The inner segments 478 may be arranged adjacent to each other and substantially parallel to each other along the longitudinal axis L of the shoe plate 300, near the peripheral edge P of the inner portion 20. In some examples, the spacing between each, adjacent inner segments 478 is substantially consistent along the length of the inner segment 478 between the first position 479 and the second position 477. In other examples, the spacing between each adjacent inner segment 478 varies along this length, such that the spacing between each adjacent inner segment 478 in the midfoot region 14 is smaller than the corresponding spacing in the forefoot region 12 and the heel region 16. Within the inner region of the shoe plate 300, the inner segments 474 may be arranged adjacent to each other and substantially parallel to each other along the longitudinal axis L of the shoe plate 300. Similar to the outer segments 472 and the inner segments 478, the spacing between each adjacent inner segment 474 may be substantially consistent or may vary along the length of the inner segment 474 between the first position 479 and the second position 473.

[0182] In some configurations, segments 472, 474, and 478 of the sixth filament bundle 470 of the fiber are arranged adjacent to each other and generally parallel to each other in the midfoot region 14 and the heel region 16, respectively, and then diverge from each other as they extend from the midfoot region 14 to each corresponding second position 471, 473, and 477 in the forefoot region 12. For example, the outer segment 472 may generally follow the outline of the peripheral edge P of the shoe plate 300 at the outer portion 18, the inner segment 478 may generally follow the outline of the peripheral edge P of the shoe plate 300 at the inner portion 20, and the inner segment 474 may extend generally parallel to the longitudinal axis L as the outer segments 472 and the inner segments 478 diverge outward and leave the inner segment 474. Here, the layer 1900 associated with the sixth filament bundle 470 does not impart any stiffness characteristics to the region of the foreleg region 12 where there are no fibers 450 between segments 472, 474, and 478. However, the spread of segments 472, 474, and 478 of the sixth filament bundle 470 imparts anisotropic stiffness and gradient paths to the region of high-concentration / density fibers 450 extending into the foreleg region 12 and away from the middle leg region 14, where the stiffness is greatest.

[0183] As described above, the corresponding bundles 410, 420, 430, 440, 460, and 470 of each free fiber 450 are formed Figures 11 to 19 At least one or more of layers 1100, 1300, 1500, 1700, 1800, and 1900 can be combined with Figure 7 A series of stacked prepreg fiber sheets 600a to 600e or formed separately Figure 9 In the individual strands 702a to 702e of layers 700a to 700e, the stiffness characteristics imparted by the finished shoe plate 300 are adjusted. In other words, it is set to... Figure 7 The two intermediate layers of the sequentially stacked prepreg sheets 600a to 600e shown, and one or more sheets 600a having a 0° angle (Φ) relative to the longitudinal axis (L), can be replaced by at least one of layers 1100, 1300, 1500, 1700, 1800, and 1900 to adjust the stiffness characteristics in the midfoot region 14 of the shoe plate 300 while maintaining substantially consistent stiffness in the forefoot region 12 and / or the heel region 16. Similarly, configured to... Figure 9 The intermediate layer of the multiple sequentially stacked layers 700a to 700e shown, and the layer 700a having a 0° angle (Φ) relative to the longitudinal axis (L), can be replaced by at least one of layers 1100, 1300, 1500, 1700, 1800, and 1900 to adjust the stiffness characteristics in the midfoot region 14 of the shoe plate 300.

[0184] Reference Figure 7, Figures 8A to 8E as well as Figure 12 In a configuration, Figure 7 One (1) or two (2) intermediate sheets 600a of the stacked prepreg sheets 600a to 600e having a 0° angle (Φ) relative to the longitudinal axis (L) of the shoe plate 300 are replaced by two (2) layers 1100 of the first bundle 410 of the fiber 450. Therefore, the configuration includes: a bottom sheet 600c, which includes fibers 602 positioned at -15° (or alternatively -30°) relative to the longitudinal axis (L); a next sheet 600d, which includes fibers 602 positioned at 15° relative to the longitudinal axis (L); two (2) layers 1100 formed by a first bundle 410 of fibers 450; a next sheet 600b, which includes fibers 602 positioned at -15° relative to the longitudinal axis (L); and a top and last sheet 600e, which includes fibers 602 positioned at 15° (or alternatively 30°) relative to the longitudinal axis (L).

[0185] The two (2) layers 1100 formed by the first bundle 410 of fiber 450 are compared with the two (2) layers 1100 formed by the first bundle 410 of fiber 450. Figure 7 The sequentially stacked fiber sheets 600a to 600e shown increase the stiffness of the shoe plate 300 in the midfoot region 14 while substantially maintaining the stiffness in the forefoot region 12 (and the heel region 16). For example, when two (2) layers 1100 formed by the first filament bundle 410 replace two (2) intermediate sheets 600a with a 0° angle (Φ) relative to the longitudinal axis (L), the stiffness in the midfoot region 14 can be increased from about 35.4 N / mm to about 91.7 N / mm. The stiffness in the heel region 16 can also be substantially maintained. In the example, when two (2) layers 1100 formed from the first filament bundle 410 replace the two (2) intermediate sheets, the stiffness of the heel region is about 15% (15%) to about 35% (35%) or about 20% (20%) to about 30% (30%) of the stiffness of the mid-leg region, and the stiffness of the foreleg region is about 40% (40%) to about 60% (60%) or about 45% (45%) to about 55% (55%) of the stiffness of the mid-leg region. In some examples, three (3) layers 1100 formed from the first filament bundle 410 of fiber 450 are used instead of three (3) intermediate sheets 600a to increase the stiffness in the mid-leg region 14 from about 63.0 N / mm to about 115.5 N / mm. Therefore, replacing the intermediate sheets 600a with one or more layers 1100 formed from the first filament bundle 410 of fiber 450 provides a stacking configuration that uses the same stiffness as that of the mid-leg region. Figure 7The stacked fiber sheets 600a to 600e provide approximately the same number of fibers 602. However, by replacing the intermediate sheet 600a with a layer 1100 formed of the first bundle 410 of fibers 450, the variation in the spacing and pattern of the segments 412, 414, 418 of the first bundle 410 results in a higher concentration / density of fibers 450 in the middle leg region 14 of the plate 30 than in the front leg region 12 and rear heel region 16 of the plate 300. As described above, other configurations may include placing the first bundle 410 of fibers 450 on the top sheet 600e as a... Figure 7 The fiber sheets 600a to 600e are stacked sequentially as shown, with the top and last layer 1100.

[0186] Reference Figure 9 , Figures 10A to 10E as well as Figure 11 and Figure 12 In a configuration, with Figure 9 The intermediate layer 700a, which has a 0° angle (Φ) relative to the longitudinal axis (L) among the multiple layers 700a to 700e in the sequential stacking shown, is replaced by two (2) layers 1100 formed by the first bundle 410 of fiber 450, in order to increase the stiffness of the shoe plate 300 in the midfoot region 14 while substantially maintaining the stiffness in the forefoot region 12 (and the heel region 16). The configuration includes: a bottom strand 702c, which is applied to the base 704, 500 such that the strand 702c is positioned at an angle (Φ) of -15° (or alternatively -30°) relative to the longitudinal axis (L); a second strand 702d, which is applied to the first strand 702c, for example via a stitch, and is positioned at an angle (Φ) of 15° relative to the longitudinal axis (L); two (2) layers 1100 formed by the first bundle 410 of fibers 450; a fifth layer including strand 702b, which is applied to the underlying layer 1100 at an angle (Φ) of -15° relative to the longitudinal axis (L); and a sixth and final layer including strand 702e, which is applied to the underlying strand 702b at an angle (Φ) of 15° (or alternatively 30°) relative to the longitudinal axis (L). In some implementations, each bundle 410 or strand 702 in each layer comprises 12,000 carbon fibers per bundle and is mixed with thermoplastic and / or thermosetting materials.

[0187] In another configuration, three (3) layers 1100 formed by the first bundle 410 of fibers 450 are used instead of the intermediate layer 700a, which has a 0° angle (Φ) relative to the longitudinal axis (L), to further increase the stiffness in the midfoot region 14. The stiffness in the heel region 16 can also be substantially maintained. Thus, replacing the intermediate layer 700a with one or more layers 1100 formed by the first bundle 410 of fibers 450 provides a layered configuration that uses the same... Figure 9 The fiber strands 702a to 702e of the layers 700a to 700e have approximately the same number of fibers. However, by replacing the intermediate layer 700a with a layer 1100 formed of the first bundle 410 of fibers 450, the variation in the spacing and pattern of the segments 412, 414, 418 of the first bundle 410 provides a higher concentration / density of fibers 450 in the middle foot region 14 of the plate 300 than the concentration / density of fibers provided in the front foot region 14 and the rear heel region 16 of the plate 300. As described above, other configurations may include placing the first bundle 410 of fibers 450 on the top layer 700e as a... Figure 9 The sequentially stacked layers 700a to 700e shown are on top of and the last layer 1100.

[0188] Refer to 7. Figures 8A to 8E and Figure 17 In another configuration, Figure 7 Two (2) intermediate sheets 600a of the stacked prepreg sheets 600a to 600e having a 0° angle (Φ) relative to the longitudinal axis (L) of the shoe plate 300 are made of Figure 17 The two (2) layers 1700 formed by the fourth filament bundle 440 of fiber 450 are replaced. The two (2) layers 1700 formed by the fourth filament bundle 440 of fiber 450 are compared with the two (2) layers 1700 formed by the fourth filament bundle 440 of fiber 450. Figure 7 The sequentially stacked fiber sheets 600a to 600e shown increase the stiffness of the shoe plate 300 in the midfoot region 14 while substantially maintaining the stiffness in the forefoot region 12 (and heel region 16). For example, when two (2) layers 1700 formed by the fourth filament bundle 440 replace the two (2) intermediate sheets 600a with a 0° angle (Φ) relative to the longitudinal axis (L), the stiffness in the midfoot region 14 can be increased from about 35.4 N / mm to about 76.1 N / mm.

[0189] Reference Figure 9 , Figures 10A to 10E as well as Figure 17 In a configuration, with Figure 9The intermediate layer 700a, which has a 0° angle (Φ) relative to the longitudinal axis (L) among the multiple layers 700a to 700e in the sequential stacking shown, is replaced by two (2) layers 1700 formed by the fourth filament bundle 440 of fiber 450, in order to increase the stiffness of the shoe plate 300 in the midfoot region 14 while substantially maintaining the stiffness in the forefoot region 12 (and the heel region 16).

[0190] Reference Figure 7 , Figures 8A to 8E as well as Figures 15 to 17 In another configuration, Figure 7 The stacked prepreg sheets 600a to 600e have two (2) intermediate sheets 600a at a 0° angle (Φ) relative to the longitudinal axis (L) of the shoe plate 300, made of... Figure 15 and Figure 16 The third bundle 430 of fiber 450 forms a (1) layer 1500 and is composed of Figure 17 The third filament 430 of the fiber 450 is replaced by two (2) layers 1700 formed by the fourth filament 440 of the fiber 450. In other words, the third filament 430 of the fiber 450 is set as the intermediate layer 1500, and each of the two (2) layers 1700 formed by the fourth filament 440 of the fiber 450 is arranged on opposite sides of the intermediate layer 1500 to sandwich the third filament 430 of the fiber 450 between the layers 1700. Here, the segments 432, 434, 436, and 438 of the third filament bundle 430 of fiber 450 correspond to the "long ribs," and the segments 442, 444, 446, and 448 of the fourth filament bundle 440 of fiber 450 correspond to the "short ribs." The "short ribs" extend less toward or within the front foot region 12 than the "long ribs" 432, 434, 436, and 438 of the intermediate layer 1500 corresponding to the third filament bundle 430 of fiber 450 (farther from the second end 302 of the plate 300). The two (2) layers 1700 sandwiched between the intermediate layer 1500 formed by the fourth filament bundle 440 of fiber 450 and the intermediate layer 1500 formed by the third filament bundle 430 are... Figure 7 The sequentially stacked fiber sheets 600a to 600e shown increase the stiffness of the shoe plate 30 in the midfoot region 14 while substantially maintaining the stiffness in the forefoot region 12 (and heel region 16). For example, when an intermediate layer 1500 formed by a third filament bundle 430 is disposed between the two (2) layers 1700 formed by a fourth filament bundle 440 instead of the two (2) intermediate sheets 600a having a 0° angle relative to the longitudinal axis (L), the stiffness in the midfoot region 14 can be increased from about 35.4 N / mm to about 99.6 N / mm.

[0191] Reference Figure 9 , Figures 10A to 10E as well as Figures 15 to 17 In a configuration, with Figure 9 The intermediate layer 700a, which has a 0° angle (Φ) relative to the longitudinal axis (L) among the multiple layers 700a to 700e in the sequential stacking shown, is made of... Figure 15 and Figure 16 The third bundle 430 of fiber 450 forms a (1) layer 1500 and is composed of Figure 17 The third filament 430 of fiber 450 is replaced by two (2) layers 1700 formed by the fourth filament 440 of fiber 450. In other words, the third filament 430 of fiber 450 is set as the intermediate layer 1500, and each of the two (2) layers 1700 formed by the fourth filament 440 of fiber 450 is arranged on opposite sides of the intermediate layer 1500 to sandwich the third filament 430 of fiber 450 between the layers 1700. The two (2) layers 1700 formed by the fourth filament 440 of fiber 450 sandwiching the intermediate layer 1500 formed by the third filament 430 are replaced by two (2) layers 1700 formed by the fourth filament 440 of fiber 450. Figure 9 The sequentially stacked layers 700a to 700e shown can increase the stiffness of the shoe plate 300 in the midfoot region 14 while maintaining approximately the same stiffness in the forefoot region 12 (and heel region 16).

[0192] Reference Figure 20 and Figure 21 The formation of the shoe plate 300 is described in conjunction with mold 800. Mold 800 includes a first half-mold 802 and a second half-mold 804. Half-molds 802 and 804 include a cavity 806 having the shape of the shoe plate 300 to allow mold 800 to impart the desired shape of a particular plate 300 to stacked sheets 600a to 600e or layers 700a to 700e, the sheets 600a to 600e or layers 700a to 700e comprising corresponding bundles 410, 420, 430, 440, 460, and 470 of each free fiber 450. Figures 11 to 19 At least one or more of layers 1100, 1300, 1500, 1700, 1800 and 1900.

[0193] After forming the stacked sheets 600a to 600e or layers 700a to 700e, the sheets 600a to 600e or layers 700a to 700e are inserted into the mold cavity 806 between the half molds 802 and 804. At this time, the mold 800 closes by moving the half molds 802 and 804 toward each other or by moving one of the half molds 802 and 804 toward the other. Once closed, the mold 800 applies heat and pressure to the stacked sheets 600a to 600e or layers 700a to 700e disposed in the mold cavity 806 to activate the resin associated with the stacked sheets 600a to 600e or layers 700a to 700e. The heat and pressure applied to the stacked sheets 600a to 600e or layers 700a to 700e cause the specific shape of the mold cavity 806 to be applied to the stacked sheets 600a to 600e or layers 700a to 700e, and once cured, the resin associated with the stacked sheets 600a to 600e or layers 700a to 700e causes the stacked sheets 600a to 600e or layers 700a to 700e to harden and maintain the desired shape.

[0194] It should be noted that although sheets 600a to 600e and layers 700a to 700e are described as including resin material, sheets 600a to 600e and layers 700a to 700e may additionally be provided with resin injected into mold 800. The injected resin may supplement the resin impregnating sheets 600a to 600e and layers 700a to 700e, or alternatively, the injected resin may be used in place of the impregnating resin. In some examples, at least the second half mold 804 is heated to approximately 160 degrees Fahrenheit (F) to approximately 165 degrees Fahrenheit, and resin is poured onto the stack to impregnate the stacked sheets 600a to 600e or layers 700a to 700e, and mold 800a is closed to apply pressure for a period of time within the resin gel profile range, i.e., between approximately 7.5 minutes and approximately 8.5 minutes, in the range of 75 psi to approximately 100 psi. After the plate 300 has fully cured for about 30 minutes, the formed plate 300 can be removed from the mold 800a.

[0195] Reference Figure 22 and Figure 23 A footwear article 10a is provided, comprising an upper 100a and a sole structure 200a attached to the upper 100a. Given the substantial structural and functional similarity of the components associated with the footwear article 10a with respect to the footwear article 10a, the same reference numerals are used hereinafter and in the accompanying drawings to identify the same components, while the same reference numerals including letter extensions are used to identify those components that have been modified.

[0196] During the use of footwear 10a, the upper defines an internal space 102 for receiving and securing the foot to support it on the sole structure 200a. An ankle opening facilitates entry into and removal of the foot from the internal space, and the upper 100a can be formed of an elastic material to conform to the shape of the foot when it is received within the internal space. Figures 1 to 3 Like the upper 100 of the footwear 10, the upper 100a may include openings such as eyelets and / or other engagement features such as fabric or mesh loops for receiving fasteners, such as shoelaces, straps, cords, hooks and loops or any other suitable type of fastener.

[0197] In some implementations, the sole structure 200a includes an outsole 210a, a cushioning member 250a, a pair of fluid-filled chambers 270 and 272, a stylopodium 300a, and a strobel 220 arranged in a layered configuration. Given the substantial structural and functional similarity of the components associated with the stylopodium 300 with respect to the stylopodium 300a, the same reference numerals are used hereinafter and in the figures to identify the same components, while the same reference numerals including letter extensions are used to identify those components that have been modified. The sole structure 200a (e.g., outsole 210a, cushioning member 250a, fluid-filled chambers 270 and 272, stylopodium 300a, and strobel 220) defines a longitudinal axis L. For example, the outsole 210a engages with the ground during use of the footwear 10a, the padding 220 is attached to the upper 100a, and a cushioning member 250a is disposed in the heel region 16 between the padding 220 and the outsole 210a to separate the padding 220 from the outsole 210a. For example, the cushioning member 250a defines a bottom surface 252a opposite to the outsole 210a and a top surface 254 disposed on the side of the cushioning member 250a opposite to the bottom surface 252a and opposite to the padding 220. The top surface 254 may be contoured to conform to the bottom surface of the foot (e.g., the sole) within the internal cavity 102. In some implementations, the shoe plate 300a is located within a cavity 240a defined by the cushioning member 250a. In the example shown, the bottom surface 252a of the cushioning member 250a is contoured to extend through a portion of the midfoot region 14 and a portion of the forefoot region 12 to define a gap 242 that operates to expose the MTP point 320 of the shoe plate 300a, as well as a portion of the forefoot bend 322 extending from one side of the MTP point 320 and a portion of the rearfoot bend 324 extending from the other side of the MTP point 320. The pair of fluid-filled chambers 270, 272 may be disposed within the gap 242 defined by the bottom surface 252a of the cushioning member 252a between the exposed portions of the shoe plate 300a. For example, the pair of fluid-filled chambers 270, 272 may be attached directly to the plate 300 within the gap 242 and below the MTP joint that connects the metatarsals and phalanges of the foot. Here, fluid-filled chambers 270, 272 provide resilient cushioning when the foot leaves the ground during running activities (e.g., long-distance running), while cushioning member 250a provides soft cushioning in the heel region 16 to absorb the initial ground reaction force before the foot rolls to engage and leave the ground upon heel impact. One of the fluid-filled chambers 270, 272 may be located adjacent to the outer side 18 of the footwear 10a, while the other may be located adjacent to the inner side 20 of the footwear 10a. Each fluid-filled chamber 270, 272 may include a corresponding segment attached to the outsole 210a.The forefoot region 12 near the toe tip of the cushioning member 250a and the heel region 16 of the cushioning member 250a may each include separate corresponding sections for attaching the outsole 210a. Small gaps may separate fluid-filled chambers 270, 272 along the internal region of the footwear 10a between the outer portion 18 and the inner portion 20.

[0198] and Figures 1 to 21 Like the shoe plate 300, the shoe plate 300a is disposed within the sole structure 200a to reduce energy loss at the MTP joint and enhance foot rolling during running as the shoe 10a rolls to engage the ground. Given the substantial structural and functional similarity of components related to the shoe plate 300 with respect to the shoe plate 300a, the same reference numerals are used hereinafter and in the accompanying drawings to identify the same components, while the same reference numerals including letter extensions are used to identify those components that have been modified. A sleeve / cavity 240a is defined within an internal portion between the top surface 254 and the bottom surface 252a, whereby the shoe plate 300a is received within the cavity 240a and held in place between the top surface 254 and the bottom surface 252a. In other configurations, the shoe plate 300 is disposed above the top surface 254 of the cushioning member 250 and below the padding 220. In these configurations, the liner 220 is optional, and the shoe plate 300a can be fixed to the upper 100a to define an internal space 102, which may or may not have an insole disposed on top of the shoe plate 300a. For example, the shoe plate 300a can be fixed to the upper 100a using adhesive. In some implementations, the shoe plate 300a is sandwiched between the top surface 254 of the cushioning member 250a and another cushioning member (not shown) below the liner 220. The shoe plate 300a can define a length that extends through at least a portion of the length of the sole structure 200a. In some examples, the length of the plate 300a extends through the forefoot portion 12, the midfoot portion 14, and the heel portion 16 of the sole structure 200. In other examples, the length of the plate 300a extends through the forefoot portion 12 and the midfoot portion 14, but is not present in the heel portion 16. In other configurations, plate 300a is disposed within the interior space 102 of upper 100 on footbed 224 of padding 220. Figure 23 Furthermore, additional cushioning components or insoles may be disposed within the internal space 102 to sandwich the plate 300a within the internal space 102 between the footbed 224 of the padding 220 and the bottom surface of the additional cushioning components or insoles.

[0199] As with the shoe plate 300, the shoe plate 300a may be formed of at least two layers of fibers 450 to impart anisotropic stiffness, wherein the stiffness in one direction on the plate 300a differs from the stiffness in another direction. Here, the at least two layers of fibers 450 are anisotropic to impart gradient stiffness and gradient load paths on the plate 300. In one configuration, the plate 300 provides a longitudinal stiffness (e.g., in the direction transverse to the longitudinal axis L) greater than the lateral stiffness (e.g., in the direction transverse to the longitudinal axis L). In one example, the lateral stiffness is at least ten percent (10%) lower than the longitudinal stiffness. In another example, the lateral stiffness is about ten percent (10%) to about twenty percent (20%) of the longitudinal stiffness. Fibers 450 may comprise one or more layers of fiber bundles 400a and / or layers having at least one of carbon fiber, boron fiber, glass fiber, and polymer fiber. In a particular configuration, fibers 450 comprise carbon fiber, or glass fiber, or a combination of carbon fiber and glass fiber. The fiber bundles 400a of fiber 450 can be attached to a substrate. The fiber bundles 400a of fiber 450 can be attached by sewing and / or using an adhesive. Additionally or alternatively, the fiber bundles 400a of fiber 450 and / or the layers of fiber 450 can be bonded with a resin formed from a thermosetting polymer material and / or a thermoplastic polymer material.

[0200] Therefore, plate 300a can have tensile or flexural strength in a transverse direction substantially perpendicular to the longitudinal axis L. The stiffness of plate 300a can be selected for a specific wearer based on that wearer's tendon flexibility, calf muscle strength, and / or MTP joint flexibility. Furthermore, the stiffness of plate 300a can also be customized based on the athlete's running motion. In other configurations, plate 300a is formed from one or more layers / sheets of unidirectional strips. In some examples, each layer of the stack includes an orientation different from the layer disposed below. Plate 300a can be formed from unidirectional strips comprising at least one of carbon fiber, boron fiber, glass fiber, and polymer fiber. In some examples, one or more materials forming plate 300a have a Young's modulus of at least 70 gigapascals (GPa). Plate 300a can be defined... Figures 1 to 21 Any geometry of the plate 300, including the geometry of the shoe plate disclosed in U.S. Provisional Application No. 62 / 474,030, filed March 20, 2017, U.S. Patent Application No. 15 / 248,051, filed August 26, 2016, and U.S. Patent Application No. 15 / 248,059, filed August 26, 2016, the entire contents of which are incorporated herein by reference.

[0201] The length of the shoe plate 300a may extend between a first end 301 located near the heel portion 16 of the sole structure 200a and a second end 302 located near the forefoot portion 12 of the sole structure 200a. The first end 301 may be located near the heel portion 16 of the sole structure 200, and the second end 302 may be located near the forefoot portion 12 of the sole structure 200. In some examples, the length of the shoe plate 300a is less than the length of the cushioning member 250a. The shoe plate 300a may also include a thickness extending substantially perpendicular to the longitudinal axis L of the sole structure 200a and a width extending between the outer portion 18 and the inner portion 20. Thus, the length, width, and thickness of the plate 300a may substantially occupy the cavity 240a defined by the cushioning member 250a. In some examples, the peripheral edge of the shoe plate 300a is visible on the outer portion 18 and / or the inner portion 20 of the shoe 10a.

[0202] Figure 23 An exploded view of footwear 10a is provided, showing various segments of the outsole 210a, a cushioning member 250a disposed on the inner surface of the outsole 210a at the heel region 16 and the toe end of the forefoot region 12, a generally rigid shoe plate 300a located within a cavity 240a defined by the cushioning member 250a, and fluid-filled chambers 270, 272 attached to the exposed portion of the shoe plate 300a near the MTP joint of the foot within a gap 242 defined by the contoured bottom surface 252a of the cushioning member 250a. Each fluid-filled chamber 270, 272 may include a corresponding segment 210a attached to the outsole 210a. The cushioning member 250a and plate 300a can substantially occupy the entire volume of the space between the liner 220 and the outsole 210a at the toe end of the heel region 16 and the forefoot region 12. Simultaneously, the cushioning member 250a, plate 300a, and fluid-filled chambers 270, 272 can substantially occupy the entire volume of the space near the MTP joint of the foot between the liner 220 and the outsole 210a at the intersection of the midfoot region 14 and the forefoot region 12 of the sole structure 200a. The cushioning member 250 can be compressed between the liner 220 and the outsole 210 to provide a soft cushioning level, while the fluid-filled chambers 270, 272 can be compressed between the plate 300a and the outsole 210a to provide elastic cushioning, thereby assisting in take-off during running. In some configurations, the cushioning member 250a corresponds to a preform of polymer foam having a surface profile configured to receive the plate 300a therein or on it. Fluid-filled chambers 270 and 272 may include pressurized fluid (e.g., air) and may be formed of thermoplastic materials such as thermoplastic polyurethane (TPU).

[0203] Figure 24 and Figure 25A top view is provided of the first strands / tows 400a, 410a of fiber 450 that can form layer 1100a of shoe plate 300a. The pattern of the first tow 410a of fiber 450 is shown relative to the peripheral edge P of the finished shoe plate 300a. In some examples, the first tow 410a is attached to / attached to a base layer including a corresponding substrate 500a. In other examples, the first tow 410a is attached to / attached on top of a base layer comprising layers 900a to 900b below, in a layered configuration, all of which are attached to / attached to individual substrates 500s. Figure 26 The layer 900a to 900b can be sheet material 600a to 600e. Figure 7 (e.g., unidirectional strip) or layer 700a to 700e ( Figure 9 (e.g., strands / tows). For example, one or more layers 1100a formed by the first filament bundle 410a of fiber 450 can replace Figure 7 One or more of the sheet material from 600a to 600e or Figure 9 One or more of layers 700a to 700e are used to form the finished shoe plate 300a. Therefore, from Figure 24 and Figure 25 In the example shown, any layers 700a to 700e / sheets 600a to 600e of fibers located below or above layer 1100a associated with the first bundle 410a of fiber 450 are omitted. Instead, the formation... Figure 11 and Figure 12 The first strand / tow 400 and 410 of the fiber 450 in the layer 1100 of the shoe plate 300 provide a greater density of fiber 450 in the midfoot region 14 than in the forefoot region 12, forming Figure 24 and Figure 25 The first strands / tows 400a and 410a of the fibers 450 in layer 1100a provide a greater density of fibers 450 in the foreleg region 12 than in the middle leg region 14 and the heel region 16. In some examples, the first strands / tows 400a and 410a of the fibers 450 forming layer 1100a provide greater stiffness in the foreleg region 12 than in the middle leg region 14 along the base line of plate 300a, i.e., from the first end 301 along the longitudinal axis (L) of plate 300a to the second end 302. Additionally, layer 1100a may provide greater stiffness in the foreleg region 12 than in the middle leg region 14 (and also the heel region 16) over the width of plate 300a from the outer side 18 to the inner side 20. Alternatively, layer 1100a may provide approximately the same stiffness across the width of plate 300a in both front leg region 12 and middle leg region 14, while still providing greater stiffness along the base line of plate 300a in front leg region 12 than in middle leg region 14.

[0204] In some examples, the first bundle 410a is formed from corresponding continuous strands of fiber 450. However, in other configurations, the first bundle 410a is formed from two or more strands of fiber 450. The size of the first bundle 410a can vary from about 1,000 fibers per bundle to about 48,000 fibers per bundle. In some examples, the first bundle 410a comprises 12,000 carbon fibers per bundle blended with nylon 6 or nylon 12 resin material. The first bundle 410a may include the same or different fiber types as the layers 900a to 900b, 700a to 700e / sheets 600a to 600e of the fibers formed in a layered configuration below or above the first bundle to form the finished shoe plate 300a. For example, the first bundle 410a may include at least one of carbon fiber, boron fiber, glass fiber, and polymer fiber. Fiber 450 may be mixed with thermosetting polymer materials and / or thermoplastic polymer materials to assist in attaching the first filament bundle 410a to the substrate 500a and / or attaching the first filament bundle 410a to any layer 700a to 700e / sheet 600a to 600e located below or above the first filament bundle 410a of the fiber, thereby forming a plate 300a.

[0205] Figure 24 A first filament bundle 410a of fiber 450, including an annular portion 415a, is shown. The annular portion 415a is disposed outside the peripheral edge P of the shoe plate 300a or base 500a for connecting adjacent segments / parts 412a, 414a, 418a of the first filament bundle 410a. The annular portion 415a can be consolidated when the first filament bundle 410a and other layers 700a to 700e / sheets 600a to 600e are subjected to heat and pressure, thereby consolidating the fiber 450 to form the shoe plate 300a. In some cases, when the layered configuration is subjected to pressure (e.g., molding) to consolidate the fiber 450 to form the shoe plate 300a, the annular portion 415a extending outside the peripheral edge P creates a compression point. Therefore, Figure 25 The following first filament bundle 410a of fiber 450a is shown: the first filament bundle 410a of fiber 450a is cut along the peripheral edge P of shoe plate 300a to remove the annular portion 415a, thereby removing the present extrusion point when pressure is applied to form the finished shoe plate 300a.

[0206] In some configurations, a first bundle 410a of fibers is attached to a substrate 500a via a stitch 416a. For example, the stitch 416a may zigzag across the first bundle 410a between first attachment sites located on or beneath the substrate 500a in a layer of fibers (e.g., strands or unidirectional tape). Here, the attachment sites may be spaced apart from the first bundle 410a along the peripheral edge P of the finished shoe plate 300a. The stitch 416a may be formed of the same material as the substrate 500a, or it may be formed of a different material than the material forming the substrate 500a, such that the stitch 416a is associated with a higher melting point than the substrate 500a. Providing the stitch 416a with a higher melting point than the substrate 500a allows the stitch 416a to melt after the substrate 500a when heat is applied, thus allowing the stitch 416a to melt after the substrate 500a has begun to melt. In some examples, suture 416, or at least a portion of suture 416, is formed of resin. In some configurations, fiber 902 ( Figure 26 Layers 900a to 900b, such as fiber 602, 702 sheets 600a to 600e ( Figure 7 (e.g., unidirectional strip) or layer 700a to 700e ( Figure 9 (e.g., strands / tows) are disposed between the substrate 500a and the first filament bundle 410a, and the stitch 416a may zigzag across the first filament bundle 410a between attachment sites located on the substrate 500a. In these configurations, the stitch 416a may penetrate the substrate 500a at the attachment site and / or may extend through the sheets 600a to 600e / layers 900a to 900b, 70a to 700e of fibers 602, 702, 902 disposed on the substrate 500a and below the first filament bundle 410a. For example, the suture 416a can be attached to the substrate 500a by passing over the first bundle 410a of fiber 450a at the attachment location, extending through the sheets 600a to 600e / layers 900a to 900b, 700a to 700e of fibers 602, 702, 902, and penetrating the substrate 500a. In some examples, the suture 416a and the substrate 500a are formed of thermoplastic nylon 6 / 6 material.

[0207] The first filament bundle 410 of fiber 450 includes a plurality of first portions / segments 412a, a plurality of second portions / segments 414a, and a plurality of third portions / segments 418a. In the example shown, the first portions 412a of the first filament bundle 410a are associated with a first shape, and the second portions 414a of the first filament bundle 410a are associated with a second shape different from the first shape. Similarly, the third portions 418a of the first filament bundle 410a are associated with a third shape different from the first and third shapes. Therefore, the different shapes provided by the first portions 412a, the second portions 414a, and the third portions 418a can impart anisotropic stiffness properties to the finished shoe plate 300a. Furthermore, the first portions 412a of the first filament bundle 410a can be associated with a first length that is shorter than the length of the second portions 414a and the third portions 418a of the first filament bundle 410a. Similarly, a second segment 414a of the first filament bundle 410a can be associated with a second length that is longer than the length of the first segment 412a of the first filament bundle 410a and shorter than the length of the third segment 414a of the first filament bundle 410a. Therefore, a third segment 418a of the first filament bundle 410a can be associated with a third length that is longer than the first length of the first segment 412a and the second length of the second segment 414a, respectively. The corresponding shapes and lengths of the various segments 412a, 414a, and 418a of the first filament bundle 410a can be designed to emphasize providing corresponding performance characteristics that differ from those provided by the other segments 412a, 414a, and 418a of the first filament bundle. Furthermore, the corresponding shapes and lengths of the various segments 412a, 414a, and 418a of the first filament bundle 410a can be matched to adjust the stiffness of the shoe plate 300a, such that adjacent segments 412a, 414a, and 418a are positioned closer to each other in the forefoot region 12 of the plate 300a than in the midfoot region 14 and heel region 16, across the width between the inner side 20 and the outer side 18 of the plate 300a. Therefore, the density / concentration of the fiber 450 is greater in the forefoot region 12 of the plate 300a than in the midfoot region 14 and heel region 16.

[0208] The first segments 412a can be arranged adjacent to each other and generally parallel. Each first segment 412a has a corresponding first length extending between a corresponding first end and a corresponding second end, wherein the corresponding first end is near the peripheral edge P of the second end 302 of the plate 300a, and the corresponding second end is near the peripheral edge P of the inner portion 20 of the plate 300a in the forefoot region 12. Furthermore, each first segment 412a of the first filament bundle 410a traverses the shoe plate 300a in an inverted "C" shape, such that a portion along the length of each first segment 412a extends from the second end 302 of the plate 300a in a direction generally parallel to the longitudinal axis L of the plate 300a to the inner region of the forefoot region 14, and then bends and extends toward the inner portion of the plate 300a in the forefoot region 12 in a direction generally perpendicular to the longitudinal axis L of the plate 300a. Figure 24 and Figure 25 The spacing between each adjacent first segment 412a is shown, which is longer than the spacing near the peripheral edge P of the plate 300a at the following bend: the bend extends through the interior region of the plate 300a in a direction converging with the longitudinal axis (L). In other words, the distance separating adjacent first segments 412a decreases in the front foot region 12 as the segments 412a move away from the bend and traverse toward the peripheral edge P of the plate 300a located at the second end 302 of the plate 300a and at the inner side 20 of the plate 300a.

[0209] The second segment 414a can converge to the first segment 412a, and the second segments 414a are arranged adjacent to each other and substantially parallel. Each second segment 414a has a corresponding second length extending between a corresponding first end and a corresponding second end, wherein the corresponding first end is near the peripheral edge P of the outer portion 18 in the front foot region 12 of the plate 300a, and the corresponding second end is near the peripheral edge P of the inner portion 20 in the middle foot region 14 of the plate 300a. Furthermore, each second segment 414a of the first filament bundle 410a traverses the shoe plate 300a in an inverted "S" shape, such that a portion along the second length of each second segment 414a extends from the outer portion 18 of the plate 300a in the forefoot region 12 in a direction generally parallel to the longitudinal axis L, then bends to extend from the outer portion 18 of the plate in a direction generally perpendicular to the longitudinal axis L of the plate 300a to the inner portion 20, and then bends a second time to extend along the inner portion 20 in the midfoot region 14 in a direction generally parallel to the longitudinal axis L of the plate 300a. As with the first segment 412a, the interval between each adjacent second segment 412 is longer near the first bend of the outer portion 18 of the plate 300a and near the second bend of the inner portion 20 of the plate 300a than the interval between each adjacent segment traversing away from the first and second bends. In other words, the spacing between adjacent second segments 414a decreases as segments 414a extend in both directions parallel to and perpendicular to the longitudinal axis (L). Figure 24 and Figure 25 The first curved portion of the second segment 414a is shown below: the first curved portion of the second segment 414a is aligned with the curved portion of the first segment 412a to form a continuous curved portion in the front foot region 12, which extends from the inner portion 20 in a direction converging with the longitudinal axis (L) to the outer portion 18.

[0210] The third segment 418a may converge to the first segment 412a and the second segment 414a, and the third segments 418a are arranged adjacent to each other and substantially parallel. Each third segment 418a has a corresponding third length extending between a corresponding first end and a corresponding second end, wherein the corresponding first end is near the peripheral edge P of the outer side 18 of the plate 300a in the midfoot region 14, and the corresponding second end is near the first end 301 of the plate 300a in the heel region 16. Furthermore, each third segment 418a of the first bundle 410a traverses the shoe plate 300a in a “C” shape, such that a portion of the first length of each third segment 418a extends from the outer side 18 of the plate 300a toward the inner region in a direction substantially perpendicular to the longitudinal axis L of the plate 300a, and then bends and extends toward the first end 301 of the plate 300a in the heel region 16 in a direction substantially parallel to the longitudinal axis L of the plate 300a. The curved portion of the third segment 418a is substantially aligned with the second curved portion of the second segment 414a to form a continuous curved portion that extends through the middle foot region 14 of the plate 300a in a direction converging with the longitudinal axis (L) and is parallel to the first curved portion that extends through the front foot region 12. Figure 24 and Figure 25 The spacing between each adjacent third segment 418a is shown, which is smaller in the middle leg region 14 than in the heel region 16. In other words, the distance separating adjacent third segments 418a increases as the segment 418a moves away from the middle leg region 14 of the plate 300a and traverses towards the heel region 16 of the plate 300a.

[0211] Compared to the spacing in the midfoot region 14 and the heel region 16, the spacing between adjacent segments 412a, 414a, and 418a of the first filament bundle 410a of fiber 450 is smaller in the forefoot region 12. Therefore, segments 412a, 414a, and 418a collectively provide a greater concentration / density of fiber 450 in the forefoot region 12 compared to the fiber concentration / density in the midfoot region 14 and the heel region 16, respectively. Consequently, the first filament bundle 410a of fiber 450 provides the shoe plate 300a with a stiffness in the forefoot region 12 that is greater than the stiffness of the shoe plate 300a in either the midfoot region 14 or the heel region 16. In some examples, the stiffness of the shoe plate 300a is greater in the forefoot region 12 than in the midfoot region 14 along the base line of the plate 300a, i.e., from the first end 301 along the longitudinal axis (L) of the plate 300a to the second end 302. The stiffness of the shoe plate 300a across the width from the outer side 18 to the inner side 20 may be greater in the forefoot region 12 than in the midfoot region 14, or the stiffness across the width of the shoe plate 300a may be approximately the same in the forefoot region 12 and in the midfoot region 14.

[0212] Reference Figure 26 In some implementations, one or more layers of layers 1100a formed by the corresponding first bundle 410a of fiber 450 may be incorporated into a series of stacked layers 900a to 900b of fiber 902 to adjust the stiffness properties imparted by the finished shoe plate 300a. In some examples, the stacked layers 900a to 900b include Figure 7 The layers 900a to 900b may be unidirectional tape pre-impregnated fiber sheets 600a to 600e, or multiaxial fabric comprising resin-impregnated fibers 902. Alternatively, some layers 900a to 900b may be unidirectional tape, while others may be multiaxial fabric. Here, one layer of layers 900a to 900b may be unidirectional tape, while another layer may be multiaxial fabric. In other examples, the stacked layers 900a to 900b include Figure 9 Layers 700a to 700e are formed by individual strands 902 of fibers. In these examples, each strand 902 refers to a bundle of multiple fibers, a bundle of monofilaments, a bundle of yarn, or a bundle pre-impregnated with a polymer. For example, a strand 902 may comprise multiple carbon fibers and multiple resin fibers that are cured upon activation to hold the carbon fibers in a desired shape and to position the multiple carbon fibers and the multiple resin fibers relative to each other. As used herein, the term “bundle” refers to a bundle (i.e., multiple) of filaments (e.g., fiber 450) that may be twisted or untwisted, and each bundle may be specified with a size associated with the multiple fibers contained in the corresponding bundle. For example, the size of a single strand 902 can vary from about 1,000 fibers per bundle to about 48,000 fibers per bundle. Each strand 902 may be attached to a corresponding substrate 500a, or all strands 902 may be attached to the same substrate 500 representing a base layer for preforming the shoe plate 300a. Whether the layer 900 corresponds to a sheet of unidirectional tape, a multiaxial fabric with fibers 902, or a layer formed by corresponding strands 902 of fibers, the fibers 902 include at least one of carbon fibers, boron fibers, glass fibers, and polymer fibers. Fibers such as carbon fibers, aramid fibers, and boron fibers can provide high Young's modulus, while glass fibers (e.g., glass filaments) and polymer fibers (e.g., synthetic fibers) provide medium modulus. Glass filament fibers may include E6 318 fibers manufactured by Jushi™. Carbon fibers may include Teryf1TC35 fibers, Hyosun H2550 fibers, or Tenax-E HTS 40 fibers.

[0213] In some implementations, layers 900a to 900b include fibers 902 formed at different angles relative to each other, such that the longitudinal axis of the fibers 902 (unidirectional tape, multiaxial fabric, strands) is positioned at an angle (Φ) relative to the longitudinal axis (L) of each layer 900a to 900b. In one configuration, the fibers 902 of layer 900a are positioned at an angle (Φ) equal to 60 degrees (60°) relative to the longitudinal axis (L), and the fibers 902 of layer 900b are positioned at an angle (Φ) equal to -60 degrees (-60°) relative to the longitudinal axis (L). Therefore, when layers 900a to 900b are stacked on each other, the longitudinal axis of the fibers 902 is positioned at different angles relative to the longitudinal axis (L) of plate 300a. Furthermore, the spacing between each adjacent bundle / strand of fibers 902 is at MTP point 320 of plate 300. Figure 23 The density of fiber 902 is smaller near the junction of the foreleg region 12 and the middle leg region 14, and increases in the direction toward the first end 301 (e.g., the heel end) and the second end 302 (e.g., the toe end) of the plate 300a. Therefore, the region near the MTP point 320 of each layer 900a to 900b has a higher density / concentration of fiber 902 compared to the density / concentration of fiber 902 further away from the MTP point 320.

[0214] Figure 26A stacked configuration comprising a total of seven (7) layers is shown, the stacked configuration having: a bottom layer 900a comprising fibers 902 positioned at 60° relative to the longitudinal axis (L), a next layer 900b comprising fibers 902 positioned at -60° relative to the longitudinal axis (L), three (3) layers 1100a formed by a first bundle 410a of fibers 450, a next layer 900b comprising fibers 902 positioned at -60° relative to the longitudinal axis (L), and a top and last layer 900a comprising fibers 902 positioned at 60° relative to the longitudinal axis (L). Three (3) layers 1100a formed by the first bundle 410a of fiber 450 increase the stiffness of the shoe plate 300 in the forefoot region 12 along the base line of the plate 300 (e.g., from the first end 301 along the longitudinal axis (L) to the second end 302) and in the forefoot region 12 along the width of the plate 300 (e.g., perpendicular to the longitudinal axis (L)), while generally maintaining the stiffness in the midfoot region 14 (and the heel region 16). Variations in the spacing and pattern of the segments 412a, 414a, 418a of the first bundle 410a can be provided along the base line of the plate 300a: the concentration / density of fiber 450 in the forefoot region 12 of the plate 300a is greater than the concentration / density of fiber 450 in the midfoot region 14 and the heel region 16. In some configurations, the bottom layer 900a comprises fibers 902 applied in 16 layers of unidirectional tape.

[0215] In one configuration, the stiffness of the front foot region 12 along the width from the outer side 18 to the inner side 20 of the plate 300a is greater than 150 N / mm. In another configuration, the stiffness of the front foot region 12 along the width from the outer side 18 to the inner side 20 of the plate 300a is approximately 200 N / mm. In yet another configuration, the stiffness of the front foot region 12 along the width from the outer side 18 to the inner side 20 of the plate 300a is approximately 225 N / mm.

[0216] In one configuration, the stiffness of the base line of the plate 300a in the front foot region 12, from the first end 301 to the second end 302, is greater than 350 N / mm. In another configuration, the stiffness of the base line of the plate 300a in the front foot region 12, from the first end 301 to the second end 302, is approximately 375 N / mm. In yet another configuration, the stiffness of the base line of the plate 300a in the front foot region 12, from the first end 301 to the second end 302, is approximately 400 N / mm.

[0217] In one configuration, the stiffness of the middle leg region 14 over the width from the outer side 18 to the inner side 20 of the plate 300a is greater than 150 N / mm. In another configuration, the stiffness of the middle leg region 14 over the width from the outer side 18 to the inner side 20 of the plate 300a is approximately 175 N / mm. In yet another configuration, the stiffness of the middle leg region 14 over the width from the outer side 18 to the inner side 20 of the plate 300a is approximately 200 N / mm.

[0218] Figure 27 and Figure 28 A top view is provided of the second strands / tows 400a, 420a of fiber 450 that can form layer 1300a of shoe plate 300a. The pattern of the second tows 420a of fiber 450 is shown relative to the peripheral edge P of the finished shoe plate 300a. In some examples, the second tows 420a are attached to / attached to a base layer including a corresponding substrate 500a. In other examples, the second tows 420a are attached to / attached on top of a base layer comprising layers 1000a to 1000b of fibers in a layered configuration, all of which are attached to / attached to a single substrate 500s. Figure 29 The layer 1000a to 1000b can be sheet material 600a to 600e. Figure 7 (e.g., unidirectional strip) or layer 700a to 700e ( Figure 9 (e.g., strands / tows). For example, one or more layers 1300a formed from the second filament bundle 420a of fiber 450 can replace... Figure 7 One or more of the sheet material from 600a to 600e or Figure 9 One or more of layers 700a to 700e are used to form the finished shoe plate 300a. Therefore, from Figure 27 and Figure 28 The example shown omits any layers 700a to 700e / sheets 600a to 600e of fibers located below or above layer 1300a associated with the second bundle 420a of fiber 450. As formed... Figure 24 and Figure 25 Like the first strand / tow of fiber 450 in layer 1100a, forming layer 400a, 410a. Figure 27 and Figure 28The second strands / tows 400a, 420 of the fibers 450 of layer 1300a can provide greater stiffness in the front foot region 12 than in the middle foot region 14 along the base line of plate 300a, i.e., from the first end 301 along the longitudinal axis (L) of plate 300a to the second end 302. Additionally, layer 1300a can provide greater stiffness in the front foot region 12 than in the middle foot region 14 (and also the heel region 16) over the width of plate 300a from the outer side 18 to the inner side 20. Alternatively, layer 1300a can provide approximately the same stiffness across the width of plate 300a in both the front foot region 12 and the middle foot region 14, while still providing greater stiffness in the front foot region 12 than in the middle foot region 14 along the base line of plate 300a.

[0219] As Figure 24 and Figure 25 Similar to the first strand / tow 410a, the second strand / tow 420a can be formed from corresponding continuous strands of fiber 450 or from two or more strands of fiber 450, and the size of the second strand / tow 420a varies from about 1,000 fibers per bundle to about 48,000 fibers per bundle. The second strand 420a may include the same or different fiber types as the layers 1000a to 1000b, 700a to 700e / sheets 600a to 600e of the fibers formed in a layered configuration below or above the first strand to form the finished shoe plate 300a. For example, the second strand 420a may include at least one of carbon fiber, boron fiber, glass fiber, and polymer fiber. Fiber 450 may be mixed with thermosetting polymer materials and / or thermoplastic polymer materials to assist in attaching the second filament bundle 420a to the substrate 500a and / or attaching the second filament bundle 420a to any layer 700a to 700e / sheet 600a to 600e located below or above the first filament bundle 410a of fiber 450, thereby forming plate 300a.

[0220] Figure 27 A second filament bundle 420a of fiber 450, including an annular portion 425a, is shown. The annular portion 425a is disposed outside the peripheral edge P of the shoe plate 300a or base 500a for connecting adjacent segments / parts 422a, 424a of the second filament bundle 420. The annular portion 425a can be consolidated when the second filament bundle 420a and other layers / sheets 1000a to 1000b, 600a to 600e, 700a to 700e are subjected to heat and pressure, thereby consolidating the fiber 450 to form the shoe plate 300a. In some cases, when the layered configuration is subjected to pressure (e.g., molding) to consolidate the fiber 450 to form the shoe plate 300a, the annular portion 425a extending outside the peripheral edge P creates a compression point. Therefore, Figure 28 The following second filament bundle 420a of fiber 450 is shown: the second filament bundle 420a of fiber 450 is cut along the peripheral edge P of shoe plate 300a to remove the annular portion 415a, thereby removing the present extrusion point when pressure is applied to form the finished shoe plate 300a.

[0221] In some configurations, the second bundle 420a of fiber 450 is attached to the substrate 500a via a stitch 426a. For example, the stitch 426a may zigzag across the second bundle 420a of fiber 450 between first attachment sites located on or beneath the substrate 500a in a layer of fibers (e.g., bundles or unidirectional tapes). Here, the attachment sites may be spaced apart from the second bundle 420a of fiber 450 along the peripheral edge P of the finished shoe plate 300a. The stitch 426a may be formed of the same material as the substrate 500a, or it may be formed of a different material than the material forming the substrate 500a, such that the stitch 426a is associated with a higher melting point than the substrate 500a. Providing the stitch 426a with a higher melting point than the substrate 500a allows the stitch 426a to melt after the substrate 500a when heat is applied, thus allowing the stitch 426a to melt after the substrate 500a has begun to melt. In some examples, the suture 426a, or at least a portion thereof, is formed of resin. In some configurations, layers 1000a to 1000b of fiber 1002 ( Figure 29 For example, sheets of fiber 602 and 702, ranging from 600a to 600e. Figure 7 (e.g., unidirectional strip) or layer 700a to 700e ( Figure 9 (e.g., strands / tows) are disposed between the substrate 500a and the second filament bundle 420a, and the stitch 416a may zigzag across the second filament bundle 410a between attachment sites located on the substrate 500a. In these configurations, the stitch 426a may penetrate the substrate 500a at the attachment site and / or may extend through the sheets / layers 1000a to 1000b, 600a to 600e, 700a to 700e of fibers 602, 702, 1002 disposed on the substrate 500a and below the second filament bundle 420a. For example, the stitch 426a can attach the second filament bundle 420a of the fiber 450 to the substrate 500a by passing over the second filament bundle 420a of the fiber 450a at the attachment location, extending through the sheets / layers 1000a to 1000b, 600a to 600e, 700a to 700e of the fibers 602, 702, 1002, and penetrating the substrate 500a.

[0222] The second filament bundle 420a of fiber 450 includes a plurality of first portions / segments 422a and a plurality of second portions / segments 424a. In the example shown, the first portions 422a of the second filament bundle 420a are associated with a first shape, and the second portions 424a of the second filament bundle 420a are associated with a second shape different from the first shape. The different shapes given by the first portions 422a and the second portions 422a can impart anisotropic stiffness properties to the finished shoe plate 300a. Furthermore, the corresponding shapes of each segment 422a, 424a of the second filament bundle 420a can be matched to adjust the stiffness on the shoe plate 300a, so that adjacent segments 422a, 424a are positioned closer to each other in the forefoot region 12 of the plate 300a than in the midfoot region 14 and heel region 16 in the width between the inner side 20 and the outer side 18 of the plate 300a, and therefore, the density / concentration of the fiber 450 is greater in the forefoot region 12 of the plate 300a than in the midfoot region 14 and heel region 16 of the plate 300a.

[0223] The first segments 422a are arranged adjacent to each other and substantially parallel within the forefoot region 12. Each first segment 422a has a corresponding length extending between a corresponding first end and a corresponding second end, wherein the corresponding first end is near the peripheral edge P of the outer portion 18 of the plate 300a in the forefoot region 12, and the corresponding second end is near the peripheral edge P of the inner portion 20 of the plate 300a in the forefoot region 12. More specifically, each first segment 422a of the second filament bundle 420a traverses the shoe plate 300a in a U-shaped configuration, such that a portion along the length of each first segment 422a extends from the peripheral edge P of the outer portion 18 of the plate 300a in a direction substantially parallel to the longitudinal axis L toward the first end 301 of the plate 300a, then bends and extends into the inner region of the plate 300a, and then bends again in a direction substantially parallel to the longitudinal axis L toward the peripheral edge P of the inner portion 20 of the plate 300a and toward the second end 302a of the plate 300a. Figure 27 and Figure 28 The spacing between each adjacent first segment 422a is shown, which is smaller within the MTP region 427 of the plate 300a than at the peripheral edge P of the plate 300a. For example, the distance separating adjacent first segments 422a increases as adjacent segments 422a become closer to the second end (e.g., the toe end) of the shoe plate 300a and as segments 422a traverse toward the peripheral edge P of the plate 300a.

[0224] The second segment 424a may converge to the first segment 422a, and the second segments 424a are arranged adjacent to each other and substantially parallel in the middle leg region 14 and / or the heel region 16. Each second segment 424a has a corresponding length extending between a corresponding first end and a corresponding second end, wherein the corresponding first end is near the peripheral edge P of the outer side 18 of the corresponding one of the middle leg region 14 and the heel region 16 of the plate 300a, and the corresponding second end is near the peripheral edge P of the inner side 20 of the corresponding one of the middle leg region 14 and the heel region 16 of the plate 300a. More specifically, each second segment 424a of the second filament bundle 420a traverses the shoe plate 300a in an inverted U-shape, such that a portion along the length of each second segment 424a extends from the peripheral edge P at the outer portion 18 of the plate 300a in a direction generally parallel to the longitudinal axis L toward the second end 301 of the plate 300a, then bends and extends into the inner region of the plate 300a, and then bends again to extend in a direction generally parallel to the longitudinal axis L toward the peripheral edge P at the inner portion 20 of the plate 300a and toward the first end 302 of the plate 300a. Thus, the second segment 424a is inverted relative to the first segment 422a. Figure 27 and Figure 28 The spacing between each adjacent second segment 424a is shown, which is smaller in the inner region of the plate 300a than on the peripheral edge P of the plate 300a. A portion of the second segment 424a mates with a portion of the first segment 422a to provide an MTP region 427, which has a spacing between adjacent segments 422a, 422a that is smaller than the spacing between adjacent segments 422a, 424a and the spacing on the peripheral edge P of the plate 300a. For example, the distance separating adjacent first segments 422a increases as adjacent segments 422a move closer to the second end 302 (e.g., the toe end) of the shoe plate 300a and as segments 422a traverse toward the peripheral edge P of the plate 300a. Furthermore, the distance separating adjacent second segments 424a increases as segments 424a move away from the midfoot region 14 of the plate 300a and traverse toward the heel region 16 of the plate 300a.

[0225] Compared to the spacing in the midfoot region 14 and the heel region 16, respectively, the spacing between adjacent segments 412a, 414a, and 418a of the first filament bundle 410a of fiber 450 is smaller in the forefoot region 12. Therefore, segments 412a, 414a, and 418a collectively provide a greater concentration / density of fiber 450 in the forefoot region 12 compared to the concentration / density of fiber 450 in the midfoot region 14 and the heel region 16, respectively. Thus, the first filament bundle 410a of fiber 450 provides the shoe plate 300a with a stiffness in the forefoot region 12 that is greater than the stiffness of the shoe plate 300a in either the midfoot region 14 or the heel region 16. In some examples, the stiffness of the shoe plate 300a is greater in the forefoot region 12 than in the midfoot region 14 along the base line of the plate 300a, i.e., from the first end 301 along the longitudinal axis (L) of the plate 300a to the second end 302. The stiffness of the shoe plate 300a across the width from the outer side 18 to the inner side 20 may be greater in the forefoot region 12 than in the midfoot region 14, or the stiffness of the shoe plate 300a across the width may be approximately the same in the forefoot region 12 and in the midfoot region 14.

[0226] Compared to the spacing in the midfoot region 14 and the heel region 16, and the spacing near the peripheral edge P, the spacing between adjacent segments 422a and 424a of the second filament bundle 420a of fiber 450 is smallest in the MTP region 427 of the forefoot region 12 (and a portion of the midfoot region 14). Therefore, segments 422a and 424a together provide a greater concentration / density of fiber 450 in the MTP region 427 compared to the fiber concentration / density outside the MTP region 427. Thus, the first filament bundle 410a of fiber 450 provides the shoe plate 300a with a stiffness greater than that in the midfoot region 14 and the heel region 16 than in each of them. In some examples, the stiffness of the shoe plate 300a along the base line of the plate 300a, i.e., along the longitudinal axis (L) of the plate 300a from the first end 301 to the second end 302, is greater in the forefoot region 12 than in the midfoot region 14. The stiffness of the shoe plate 300a across the width from the outer side 18 to the inner side 20 may be greater in the forefoot region 12 than in the midfoot region 14, or the stiffness across the width of the shoe plate 300a may be approximately the same in the forefoot region 12 and the midfoot region 14.

[0227] Reference Figure 29In some implementations, one or more layers of layers 1300a formed by the corresponding second bundle 420a of fiber 450 may be incorporated into a series of stacked layers 1000a to 1000b of fiber 1002 to adjust the stiffness properties imparted by the finished shoe plate 300a. In some examples, the stacked layers 1000a to 1000b include Figure 7 The layers may be unidirectional tape pre-impregnated fiber sheets 600a to 600e, or multiaxial fabric comprising resin-impregnated fibers 902. Alternatively, some layers of layers 1000a to 1000b may be unidirectional tape, while others may be multiaxial fabric. Here, one layer of layers 1000a to 1000b may be unidirectional tape, while another layer may be multiaxial fabric. In other examples, the stacked layers 1000a to 1000b include Figure 9 Layers 700a to 700e are formed by individual strands 1002 of fibers. In these examples, each strand 1002 refers to a bundle of multiple fibers, a bundle of monofilaments, a bundle of yarn, or a bundle pre-impregnated with a polymer. For example, strand 1002 may include multiple carbon fibers and multiple resin fibers that are cured upon activation to hold the carbon fibers in a desired shape and to position the multiple carbon fibers and multiple resin fibers relative to each other. As used herein, the term “bundle” refers to a bundle (i.e., multiple) of filaments (e.g., fiber 450) that may be twisted or untwisted, and each bundle may be specified with a size associated with the multiple fibers contained in the corresponding bundle. For example, the size of a single strand 1002 can vary from about 1,000 fibers per bundle to about 48,000 fibers per bundle. Each strand 1002 may be attached to a corresponding substrate 500a, or all strands 1002 may be attached to the same substrate 500 representing a base layer for preforming the shoe plate 300a. Whether the layer 1000 corresponds to a sheet of unidirectional tape, a multiaxial fabric with fibers 1002, or a layer formed from corresponding strands 1002 of fibers, the fibers 1002 include at least one of carbon fibers, boron fibers, glass fibers, and polymer fibers. Fibers such as carbon fibers, aramid fibers, and boron fibers can provide higher Young's modulus, while glass fibers (e.g., glass filaments) and polymer fibers (e.g., synthetic fibers) provide medium modulus.

[0228] In some implementations, layers 1000a to 1000b include fibers 1002 formed at different angles relative to each other, such that the longitudinal axis of the fibers 1002 (unidirectional tape, multiaxial fabric, strands) is positioned at an angle (Φ) relative to the longitudinal axis (L) of each layer 1000a to 1000b. In one configuration, the fibers 1002 of layer 1000a are positioned at an angle (Φ) equal to 60 degrees (60°) relative to the longitudinal axis (L), and the fibers 1002 of layer 1000b are positioned at an angle (Φ) equal to -60 degrees (-60°) relative to the longitudinal axis (L). Therefore, when layers 1000a to 1000b are stacked on top of each other, the longitudinal axis of the fibers 1002 is positioned at different angles relative to the longitudinal axis (L) of the plate 300a. Furthermore, the spacing between each adjacent bundle / strand of fibers 1002 is at MTP point 320 of the plate 300. Figure 23 The density / concentration of fibers 1002 is smaller near the junction of the foreleg region 12 and the middle leg region 14, and increases in the direction toward the first end 301 (e.g., the heel end) and the second end 302 (e.g., the toe end) of the plate 300a. Therefore, the region near the MTP point 320 of each layer 1000a to 1000b has a higher density / concentration of fibers 1002 compared to the region further away from the MTP point 320.

[0229] Figure 29 A stacked configuration comprising a total of five (5) layers is shown, the stacked configuration having: a bottom layer 1000a, the bottom layer 1000a including fibers 1002 positioned at 60° relative to the longitudinal axis (L), a next layer 1000b, the next layer 1000b including fibers 1002 positioned at -60° relative to the longitudinal axis (L), a layer 1300a formed by a second bundle 410a of fibers 450, a next layer 1000b, the next layer 1000b including fibers 1002 positioned at -60° relative to the longitudinal axis (L), and a top and last layer 1000a, the layer 1000a including fibers 1002 positioned at 60° relative to the longitudinal axis (L). The individual layers 1300a of the second filament bundle 420a of fiber 450 increase the stiffness of the shoe plate 300 in the forefoot region 12 along the base line of the plate 300 (e.g., from the first end 301 along the longitudinal axis (L) to the second end 302) and near the MTP point 320 of the plate 300a in the forefoot region 12. Figure 23The stiffness of the shoe plate 300 is increased along the width of the plate 300 (e.g., perpendicular to the longitudinal axis (L)) while substantially maintaining the stiffness in the midfoot region 14 (and the heel region 16). Variations in the spacing and pattern of the segments 422a, 424a of the second filament bundle 420a can provide that, along the base line of the plate 300a, the concentration / density of fiber 450 in the forefoot region 12 of the plate 300a is greater than the concentration / density of fiber 450 in the midfoot region 14 and the heel region 16.

[0230] In one configuration, the stiffness of the front foot region 12 along the width from the outer side 18 to the inner side 20 of the plate 300a is greater than 175 N / mm. In another configuration, the stiffness of the front foot region 12 along the width from the outer side 18 to the inner side 20 of the plate 300a is approximately 225 N / mm. In yet another configuration, the stiffness of the front foot region 12 along the width from the outer side 18 to the inner side 20 of the plate 300a is approximately 250 N / mm. Figure 24 and Figure 25 Compared to the stiffness provided by the first bundle 410a of the first fiber 450a of the first layer 1100a, the second bundle 420a of the fiber 450 of the second layer 1300a forming the shoe plate 300a can provide greater stiffness in the forefoot region 12 over the width of the plate 300a from the outer side 18 to the inner side 20.

[0231] In one configuration, the stiffness of the front foot region 12 along the base line of the plate 300a from the first end 301 to the second end 302 is greater than 400 N / mm. In another configuration, the stiffness of the front foot region 12 along the base line of the plate 300a from the first end 301 to the second end 302 is approximately 425 N / mm. In yet another configuration, the stiffness of the front foot region 12 along the base line of the plate 300a from the first end 301 to the second end is approximately 450 N / mm. Figure 24 and Figure 25 Compared to the stiffness provided by the first bundle 410a of the first fiber 450a of the first layer 1100a, the second bundle 420a of the fiber 450 of the second layer 1300a forming the shoe plate 300a can provide greater stiffness in the forefoot region 12 along the base line of the plate 300a.

[0232] In one configuration, the stiffness of the middle leg region 14 over the width from the outer side 18 to the inner side 20 of the plate 300a is greater than 125 N / mm. In another configuration, the stiffness of the middle leg region 14 over the width from the outer side 18 to the inner side 20 of the plate 300a is approximately 150 N / mm. In yet another configuration, the stiffness of the middle leg region 14 over the width from the outer side 18 to the inner side 20 of the plate 300a is approximately 175 N / mm. Figure 24 and Figure 25Compared to the stiffness provided by the first bundle 410a of the first fiber 450a of the first layer 1100a, the second bundle 420a of the fiber 450 of the second layer 1300a forming the shoe plate 300a can provide less stiffness in the midfoot region 12 over the width of the plate 300a from the outer side 18 to the inner side 20.

[0233] The stiffness data for the 300a shoe plate can be obtained using an Instron 5965 impact testing machine, which has a quarter-inch (0.25-inch) diameter upper diameter section and a pair of half-inch (0.5-inch) diameter lower support members. Testing may involve operating the Aonix plate by increasing the span of the lower support rods to 70 mm with a preload of 25 N to prevent slippage, and applying a load at a rate of 300 mm / min to achieve a compressive tensile strength of 5 mm. To reduce the risk of plate failure, only a single cycle is applied.

[0234] Special reference Figure 30 and Figure 31 The formation of the shoe plate 300a is described in conjunction with mold 800a. Given the... Figure 20 and Figure 21 The components associated with mold 800 are substantially similar in structure and function to those of mold 800a. The same reference numerals are used to identify the same components in the following text and the accompanying drawings, while the same reference numerals including letter extensions are used to identify those components that have been modified.

[0235] Mold 800a includes a first half mold 802a and a second half mold 804a. The first half mold 802a and the second half mold 804a have cavities 806a that include the shape of the shoe plate 300a, allowing mold 800a to impart the desired shape of a specific plate 300. Figure 26 Stacked layers 900a to 900b, or given Figure 29 The stacked layers 1000a to 1000b, wherein, Figure 26 The stacked layers 900a to 900b comprise corresponding first bundles 410a of fibers 450. Figure 24 and Figure 25 One or more layers in layer 1100a, Figure 29 The stacked layers 1000a to 1000b comprise corresponding second bundles 420a of fibers 450. Figure 27 and Figure 28 One or more layers of layer 1300a.

[0236] After forming the stacked layers 900a to 900b / 1000a to 1000b, the layers 900a to 900b / 1000a to 1000b are inserted into the mold cavity 806a between the half molds 802a and 804a. At this time, the mold 800a closes by moving the half molds 802a and 804a toward each other or by moving one of the half molds 802a and 804a toward the other. Once closed, the mold 800a applies heat and pressure to the stacked layers 900a to 900b / 1000a to 1000b disposed in the mold cavity 806 to activate the resin associated with the stacked layers 900a to 900b / 1000a to 1000b. The heat and pressure applied to the stacked layers 900a to 900b / 1000a to 1000b cause a specific shape of the mold cavity 806a to be applied to the stacked layers 900a to 900b / 1000a to 1000b, and once cured, the resin associated with the stacked layers 900a to 900b / 1000a to 1000b causes the stacked layers 900a to 900b / 1000a to 1000b to harden and maintain the desired shape. Furthermore, the bonding layers 1100a, 1300a formed from the corresponding bundles 410a, 420a of the fibers 450 may include thermoplastic yarns and / or stitching 416a, 426a formed from thermoplastic or thermosetting materials to assist in attaching the stacked layers 900a to 900b / 1000a to 1000b to maintain the desired shape. In some examples, at least the second half of the mold 804 is heated to approximately 160°F to approximately 165°F, and the resin is poured onto the stack to impregnate layers 900a to 900b / 1000a to 1000b, and the mold 800a is closed to apply pressure for a period of time within the resin gel profile range, i.e., between approximately 7.5 minutes and approximately 8.5 minutes, ranging from 75 psi to approximately 100 psi. After the plate 300 has fully cured for approximately 30 minutes, the formed plate 300 can be removed from the mold 800a.

[0237] It should be noted that although layers 900a to 900b / 1000a to 1000b are described as comprising resin material, layers 900a to 900b / 1000a to 1000b may additionally be provided with resin injected into mold 800. The injected resin may supplement the impregnated resin of layers 900a to 900b / 1000a to 1000b, or alternatively, may be used in place of the impregnated resin. The injected resin may comprise thermoplastic or thermosetting materials.

[0238] The aforementioned process can be used to form shoe plates and cushioning elements suitable for manufacturing custom shoes. For example, various foot dimensions can be recorded to determine the appropriate dimensions of the shoe plates and cushioning components incorporated into the footwear. Additionally, data associated with foot behavior (gate) can be obtained to determine whether the foot indicates toe impact or heel impact. Foot measurements and the obtained data can be used to determine the optimal angles and radii of curvature of the shoe plate, as well as the thickness of one or more cushioning components positioned above, below, or enclosing the shoe plate. Furthermore, the length and width of the shoe plate can be determined based on the collected data and foot measurements. In some examples, foot measurements and collected data are used to select a shoe plate and / or cushioning component that closely conforms to the wearer's foot from multiple prefabricated shoe plates and / or cushioning components of various sizes and dimensions.

[0239] Custom-designed shoe plates also allow for the plate stiffness to be tailored to the specific wearer of the shoe. For example, an athlete's tendon stiffness and calf muscle strength can be measured to determine the appropriate plate stiffness for the athlete. Here, the plate stiffness can vary depending on the athlete's strength or the size / condition of their tendons. Additionally or alternatively, the plate stiffness can be customized based on a particular athlete's biomechanics and running mechanisms, such as how the angles of the athlete's joints change during running. In some examples, the athlete's force and motion measurements are obtained before a custom plate is manufactured for them. In other examples, the plate is manufactured in specific stiffness ranges or increments to provide semi-custom shoes, allowing individual athletes to choose the appropriate stiffness.

[0240] The following clauses provide exemplary configurations for methods of forming the plates of the aforementioned footwear articles.

[0241] Clause 1: A method of forming a plate for footwear, the method comprising applying a first strand portion to a base layer, the first strand portion being applied to the base layer comprising positioning first segments of the first strand portion adjacent to each other on the base layer to form a first layer on the base layer, the method further comprising removing portions of the first segments to define an outer edge of the plate and applying at least one of heat and pressure to the first strand portion and the base layer to conform the first strand portion and the base layer to a predetermined shape.

[0242] Clause 2: The method according to Clause 1, wherein removing the portion of the first segment comprises cutting off the first strand portion at a first end of each first segment and cutting off the first strand portion at a second end of each first segment located at the end opposite to the first end of the respective first strand portion.

[0243] Clause 3: The method according to Clause 1, wherein removing the portion of the first segment includes removing the annular portion connecting the adjacent first segments of the first strand portion.

[0244] Clause 4: The method according to Clause 1, wherein applying the first strand portion to the base layer includes applying the first strand portion to a second layer having multiple fibers and / or to a second layer formed of unidirectional tape.

[0245] Clause 5: The method according to Clause 1, wherein applying the first strand portion to the base layer includes applying the first strand portion to the substrate.

[0246] Clause 6: The method according to any of the preceding clauses, wherein applying the first strand portion to the base layer includes attaching the first strand portion to the base layer via a suture.

[0247] Clause 7: The method according to any of the preceding clauses, wherein applying the first strand portion to the base layer includes applying a continuous strand.

[0248] Clause 8: The method according to Clause 7, wherein the continuous strands applied to the first strand portion include an annular portion forming the first strand portion.

[0249] Clause 9: The method according to Clause 8, wherein removing the portion of the first segment includes removing the annular portion between adjacent first segments of the first strand portion.

[0250] Clause 10: The method according to any of the preceding clauses further includes forming the first strand portion from a first bundle of fibers.

[0251] Clause 11: The method according to Clause 10, wherein the formation of the first strand portion from the first bundle of fibers comprises forming the first strand portion from at least one of carbon fiber, boron fiber, glass fiber and polymer fiber.

[0252] Clause 12: The method according to any of the preceding clauses, wherein applying the first strand portion to the base layer comprises positioning adjacent first segments on the width of the plate between the inner and outer portions such that they are closer to each other at the middle foot region of the plate than at the front foot region of the plate.

[0253] Clause 13: The method according to any of the preceding clauses, wherein applying the first strand portion to the base layer comprises positioning adjacent first segments on the width of the plate between the inner and outer portions such that they are closer to each other at the middle foot region of the plate than at the heel region of the plate.

[0254] Clause 14: also includes incorporating the plate into footwear.

[0255] Clause 15: A method of forming a plate for footwear, the method comprising applying a first strand portion to a base layer, the first strand portion being applied to the base layer comprising positioning adjacent first segments of the first strand portion on the width of the plate between an inner and outer portion such that they are closer to each other at a midfoot region of the plate than at a heel region of the plate, to form a first layer on the base layer, and applying at least one of heat and pressure to the first strand portion and the base layer to conform the first strand portion and the base layer to a predetermined shape.

[0256] Clause 16: The method according to Clause 15 further includes removing a portion of the first segment to define the outer edge of the plate.

[0257] Clause 17: The method according to Clause 16, wherein removing the portion of the first segment comprises cutting off the first strand portion at a first end of each first segment and cutting off the first strand portion at a second end of each first segment located at the end opposite to the first end of the respective first strand portion.

[0258] Clause 18: The method according to Clause 16, wherein removing the portion of the first segment includes removing the annular portion connecting the adjacent first segments of the first strand portion.

[0259] Clause 19: The method according to Clause 15, wherein applying the first strand portion to the base layer includes applying the first strand portion to a second layer having multiple fibers and / or to a second layer formed of unidirectional tape.

[0260] Clause 20: The method according to Clause 15, wherein applying the first strand portion to the base layer includes applying the first strand portion to the substrate.

[0261] Clause 21: The method according to any of the preceding clauses, wherein applying the first strand portion to the base layer includes attaching the first strand portion to the base layer via a suture.

[0262] Clause 22: The method according to any of the preceding clauses, wherein applying the first strand portion to the base layer includes applying a continuous strand.

[0263] Clause 23: The method according to Clause 22, wherein the continuous strand applied to the first strand portion includes an annular portion forming the first strand portion.

[0264] Clause 24: The method according to Clause 23 further includes removing the annular portion between adjacent first segments of the first strand portion to define the outer edge of the plate.

[0265] Clause 25: The method according to any of the preceding clauses further includes forming the first strand portion from a first bundle of fibers.

[0266] Clause 26: The method according to Clause 25, wherein the formation of the first strand portion from the first bundle of fibers comprises forming the first strand portion from at least one of carbon fiber, boron fiber, glass fiber and polymer fiber.

[0267] Clause 27: The method according to any of the preceding clauses, wherein applying the first strand portion to the base layer comprises positioning adjacent first segments on the width of the plate between the inner and outer portions such that they are closer to each other at the middle foot region of the plate than at the front foot region of the plate.

[0268] Clause 28: also includes incorporating the plate into footwear.

[0269] Clause 29: A method of forming a plate for footwear, the method comprising applying a first strand portion to a base layer, the first strand portion being applied to the base layer comprising positioning adjacent first segments of the first strand portion on the width of the plate between an inner and outer portion such that they are closer to each other at a midfoot region of the plate than at a forefoot region of the plate, to form a first layer on the base layer, and applying at least one of heat and pressure to the first strand portion and the base layer to conform the first strand portion and the base layer to a predetermined shape.

[0270] Clause 30: The method according to Clause 29 further includes removing a portion of the first segment to define the outer edge of the plate.

[0271] Clause 31: The method according to Clause 30, wherein removing the portion of the first segment comprises cutting off the first strand portion at a first end of each first segment and cutting off the first strand portion at a second end of each first segment located at the end opposite to the first end of the respective first strand portion.

[0272] Clause 32: The method according to Clause 30, wherein removing the portion of the first segment includes removing the annular portion connecting the adjacent first segments of the first strand portion.

[0273] Clause 33: The method according to Clause 29, wherein applying the first strand portion to the base layer includes applying the first strand portion to a second layer having multiple fibers and / or to a second layer formed of unidirectional tape.

[0274] Clause 34: The method according to Clause 29, wherein applying the first strand portion to the base layer includes applying the first strand portion to the substrate.

[0275] Clause 35: The method according to any of the preceding clauses, wherein applying the first strand portion to the base layer includes attaching the first strand portion to the base layer via a suture.

[0276] Clause 36: The method according to any of the preceding clauses, wherein applying the first strand portion to the base layer includes applying a continuous strand.

[0277] Clause 37: The method according to Clause 36, wherein the continuous strand applied to the first strand portion includes an annular portion forming the first strand portion.

[0278] Clause 38: The method according to Clause 37 further includes removing the annular portion between adjacent first segments of the first strand portion to define the outer edge of the plate.

[0279] Clause 39: The method according to any of the preceding clauses further includes forming the first strand portion from a first bundle of fibers.

[0280] Clause 40: The method according to Clause 39, wherein the formation of the first strand portion from the first bundle of fibers comprises forming the first strand portion from at least one of carbon fiber, boron fiber, glass fiber and polymer fiber.

[0281] Clause 41: The method according to any of the preceding clauses, wherein applying the first strand portion to the base layer comprises positioning adjacent first segments on the width of the plate between the inner and outer portions such that they are closer to each other at the middle foot region of the plate than at the heel region of the plate.

[0282] Clause 42: also includes incorporating the plate into footwear.

[0283] Clause 43: The method according to any one of Clauses 1 to 42 further comprises consolidating the fiber of the first strand portion with a polymer resin.

[0284] Clause 44: The method according to Clause 43, wherein the fibers are consolidated with the polymer resin during the application of heat and / or pressure.

[0285] Clause 45: A plate for footwear, the plate comprising a first layer, a second layer, a third layer, and a polymer resin, the first layer comprising a first high tensile strength fiber, the second layer comprising a second high tensile strength fiber, and the third layer comprising a third high tensile strength fiber, the polymer resin binding the first high tensile strength fiber, the second high tensile strength fiber, and the third high tensile strength fiber together, wherein the plate comprises a forefoot region, a heel region, and a midfoot region disposed between the forefoot region and the heel region, the forefoot region having a stiffness of about 80 N / mm to about 90 N / mm.

[0286] Clause 46: The plate according to Clause 45, wherein the stiffness of the heel region is from about 20 N / mm to about 30 N / mm.

[0287] Clause 47: The plate according to Clause 45, wherein the stiffness of the middle leg region is from about 75 N / mm to about 120 N / mm.

[0288] Clause 48: The plate as described in Clause 45, wherein the stiffness of the heel region is from about 50 N / mm to about 60 N / mm.

[0289] Clause 49: The plate according to Clause 45, wherein the stiffness of the middle leg region is from about 20 N / mm to about 55 N / mm.

[0290] Clause 50: The board according to any of the preceding clauses, wherein at least one of the first high tensile strength fiber, the second high tensile strength fiber and the third high tensile strength fiber comprises at least one of carbon fiber, boron fiber, glass fiber and polymer fiber.

[0291] Clause 51: The board according to any of the preceding clauses, wherein the polymer resin is a thermosetting resin or a thermoplastic resin.

[0292] Clause 52: A board according to any of the preceding clauses, wherein at least one of the first high tensile strength fiber, the second high tensile strength fiber and the third high tensile strength fiber is applied in a unidirectional band.

[0293] Clause 53: A board according to any of the preceding clauses, wherein at least one of the first high tensile strength fiber, the second high tensile strength fiber and the third high tensile strength fiber is applied as a strand of fiber sewn downward into the base layer.

[0294] Clause 54: The plate according to Clause 45, wherein at least two of the first high tensile strength fiber, the second high tensile strength fiber and the third high tensile strength fiber are applied as a unidirectional strip, and the other of the first high tensile strength fiber, the second high tensile strength fiber and the third high tensile strength fiber are applied as a strand of fiber sewn downward into the base layer.

[0295] Clause 55: The board according to Clause 45, wherein the first high tensile strength fiber, the second high tensile strength fiber and the third high tensile strength fiber are applied as strands of fibers sewn downward into the base layer and each comprising a different pattern.

[0296] Clause 56: The board according to Clause 45, wherein at least one of the first high tensile strength fiber, the second high tensile strength fiber and the third high tensile strength fiber is applied as a strand of fiber sewn downward into the base layer.

[0297] Clause 57: The board according to Clause 56, wherein adjacent segments of the strands of the fibers are positioned on the width of the board between the inner and outer portions as closer to each other at the middle foot region of the board than at the heel region of the board, to form the first layer.

[0298] Clause 58: The board according to Clause 56, wherein adjacent segments of the strands of the fibers are positioned on the width of the board between the inner and outer portions such that they are closer to each other at the middle foot region of the board than at the front foot region of the board, to form the first layer.

[0299] Clause 59: A plate for footwear, the plate comprising a first layer, a second layer, a third layer, and a polymer resin, the first layer comprising a first high tensile strength fiber, the second layer comprising a second high tensile strength fiber, the third layer comprising a third high tensile strength fiber, the polymer resin binding the first high tensile strength fiber, the second high tensile strength fiber, and the third high tensile strength fiber together, wherein the plate comprises a forefoot region, a heel region, and a midfoot region disposed between the forefoot region and the heel region, the midfoot region having a stiffness of about 60 N / mm to about 70 N / mm.

[0300] Clause 60: The plate as described in Clause 59, wherein the stiffness of the heel region is from about 20 N / mm to about 30 N / mm.

[0301] Clause 61: The plate as described in Clause 59, wherein the stiffness of the front foot region is from about 95 N / mm to about 105 N / mm.

[0302] Clause 62: The plate as described in Clause 59, wherein the stiffness of the heel region is about 50 N / mm to about 60 N / mm.

[0303] Clause 63: The plate as described in Clause 59, wherein the stiffness of the front foot region is from about 75 N / mm to about 120 N / mm.

[0304] Clause 64: The board according to any of the preceding clauses, wherein at least one of the first high tensile strength fiber, the second high tensile strength fiber and the third high tensile strength fiber comprises at least one of carbon fiber, boron fiber, glass fiber and polymer fiber.

[0305] Clause 65: The board according to any of the preceding clauses, wherein the polymer resin is a thermosetting resin or a thermoplastic resin.

[0306] Clause 66: A board according to any of the preceding clauses, wherein at least one of the first high tensile strength fiber, the second high tensile strength fiber and the third high tensile strength fiber is applied in a unidirectional band.

[0307] Clause 67: A board according to any of the preceding clauses, wherein at least one of the first high tensile strength fiber, the second high tensile strength fiber and the third high tensile strength fiber is applied as a strand of fiber sewn downward into the base layer.

[0308] Clause 68: The plate according to Clause 59, wherein at least two of the first high tensile strength fiber, the second high tensile strength fiber and the third high tensile strength fiber are applied as a unidirectional strip, and the other of the first high tensile strength fiber, the second high tensile strength fiber and the third high tensile strength fiber are applied as a strand of fiber sewn downward into the base layer.

[0309] Clause 69: The board according to Clause 59, wherein the first high tensile strength fiber, the second high tensile strength fiber and the third high tensile strength fiber are applied as strands of fibers sewn downward into the base layer and each comprising a different pattern.

[0310] Clause 70: The board according to Clause 59, wherein at least one of the first high tensile strength fiber, the second high tensile strength fiber and the third high tensile strength fiber is applied as a strand of fiber sewn downward into the base layer.

[0311] Clause 71: The board according to Clause 70, wherein adjacent segments of the strands of the fibers are positioned on the width of the board between the inner and outer portions such that they are closer to each other at the middle foot region of the board than at the heel region of the board, to form the first layer.

[0312] Clause 72: The board according to Clause 70, wherein adjacent segments of the strands of the fibers are positioned on the width of the board between the inner and outer portions such that they are closer to each other at the middle foot region of the board than at the front foot region of the board, to form the first layer.

[0313] Clause 73: A plate for footwear, the plate comprising a first layer, a second layer, a third layer, and a polymer resin, the first layer comprising a first high tensile strength fiber, the second layer comprising a second high tensile strength fiber, the third layer comprising a third high tensile strength fiber, the polymer resin binding the first high tensile strength fiber, the second high tensile strength fiber, and the third high tensile strength fiber together, wherein the plate comprises a forefoot region, a heel region, and a midfoot region disposed between the forefoot region and the heel region, the heel region having a stiffness of about 35 N / mm to about 45 N / mm.

[0314] Clause 74: The plate according to Clause 73, wherein the stiffness of the middle leg region is from about 20 N / mm to about 55 N / mm.

[0315] Clause 75: The plate as described in Clause 73, wherein the stiffness of the front foot region is from about 95 N / mm to about 105 N / mm.

[0316] Clause 76: The plate according to Clause 73, wherein the stiffness of the middle leg region is from about 75 N / mm to about 120 N / mm.

[0317] Clause 77: The plate according to Clause 73, wherein the stiffness of the front foot region is from about 75 N / mm to about 120 N / mm.

[0318] Clause 78: The board according to any of the preceding clauses, wherein at least one of the first high tensile strength fiber, the second high tensile strength fiber and the third high tensile strength fiber comprises at least one of carbon fiber, boron fiber, glass fiber and polymer fiber.

[0319] Clause 79: The board according to any of the preceding clauses, wherein the polymer resin is a thermosetting resin or a thermoplastic resin.

[0320] Clause 80: A plate according to any of the preceding clauses, wherein at least one of the first high tensile strength fiber, the second high tensile strength fiber and the third high tensile strength fiber is applied in a unidirectional band.

[0321] Clause 81: A board according to any of the preceding clauses, wherein at least one of the first high tensile strength fiber, the second high tensile strength fiber and the third high tensile strength fiber is applied as a strand of fiber sewn downward into the base layer.

[0322] Clause 82: The plate according to Clause 73, wherein at least two of the first high tensile strength fiber, the second high tensile strength fiber and the third high tensile strength fiber are applied as a unidirectional strip, and the other of the first high tensile strength fiber, the second high tensile strength fiber and the third high tensile strength fiber are applied as a strand of fiber sewn downward into the base layer.

[0323] Clause 83: The board according to Clause 73, wherein the first high tensile strength fiber, the second high tensile strength fiber and the third high tensile strength fiber are applied as strands of fibers sewn downward into the base layer and each comprising a different pattern.

[0324] Clause 84: The board according to Clause 73, wherein at least one of the first high tensile strength fiber, the second high tensile strength fiber and the third high tensile strength fiber is applied as a strand of fiber sewn downward into the base layer.

[0325] Clause 85: The board according to Clause 84, wherein adjacent segments of the strands of the fibers are positioned on the width of the board between the inner and outer portions such that they are closer to each other at the middle foot region of the board than at the heel region of the board, to form the first layer.

[0326] Clause 86: The board according to Clause 84, wherein adjacent segments of the strands of the fibers are positioned on the width of the board between the inner and outer portions such that they are closer to each other at the middle foot region of the board than at the front foot region of the board, to form the first layer.

[0327] Clause 87: A method of forming a plate for footwear, the method comprising applying a first strand portion to a base layer, the application of the first strand portion to the base layer comprising positioning adjacent segments of the first strand portion to form a first layer on the base layer, the adjacent segments of the first strand portion having a greater density in the width of the plate between an inner and outer portion at a midfoot region of the plate than at a forefoot region and at a heel region of the plate, and applying at least one of heat and pressure to the first strand portion and the base layer to conform the first strand portion and the base layer to a predetermined shape.

[0328] Clause 88: The method according to Clause 87 further includes removing the annular portion connecting the adjacent segments of the first strand to define the outer edge of the plate.

[0329] Clause 89: The method according to any of the preceding clauses, wherein applying the first strand portion to the base layer comprises applying the first strand portion to a substrate and at least one of a second layer having multiple fibers and / or a second layer formed of unidirectional tape.

[0330] Clause 90: The method according to any of the preceding clauses further includes positioning a second strand portion on the first layer to form a second layer on the first layer.

[0331] Clause 91: The method according to Clause 90, wherein applying the first strand portion to the base layer includes applying a first stitch that crosses the first strand portion at a first attachment location spaced apart from the first strand portion and penetrates the base layer, and positioning the second strand portion on the first layer includes applying a second stitch that crosses the second strand portion at a second attachment location, extends through the first strand portion, and penetrates the base layer.

[0332] Clause 92: The method according to any of the preceding clauses, wherein applying the first strand portion to the base layer comprises positioning adjacent segments on the width of the plate between the inner and outer portions such that they are closer to each other at the middle foot region of the plate than at the front foot region and the heel region of the plate.

[0333] Clause 93: The method according to any of the preceding clauses, wherein applying the first strand portion to the base layer includes positioning first segments of the first strand portion on the base layer, wherein each first segment has a corresponding length extending between a corresponding first end portion at the front foot region of the plate near one of the inner and outer portions and a corresponding second end portion at the heel region of the plate near one of the inner and outer portions, the first segments being arranged adjacent to each other and substantially parallel.

[0334] Clause 94: The method according to Clause 93, wherein applying the first strand portion to the base layer further comprises positioning a second segment of the first strand portion on the base layer, wherein each second segment has a corresponding length extending between a corresponding first end portion at the front foot region of the plate near the other of the inner and outer portions and a corresponding second end portion at the heel region of the plate near the other of the inner and outer portions, the second segments converging with the first segments and the second segments being arranged adjacent to each other and substantially parallel.

[0335] Clause 95: The method according to Clause 94, wherein positioning the second segment of the first strand portion on the base layer includes causing the second segment to intersect the first segment in an inner region of the plate located at the middle foot region.

[0336] Clause 96: The method according to Clause 94, wherein positioning the first segment includes positioning each adjacent first segment to have a substantially consistent interval over the corresponding length of the first segment, and positioning the second segment includes positioning each adjacent second segment to have a substantially consistent interval over the corresponding length of the second segment.

[0337] Clause 97: The method according to any of the preceding clauses further comprises forming the first strand portion from a first bundle of fibers having at least one of carbon fiber, boron fiber, glass fiber and polymer fiber.

[0338] Clause 98: The method according to any of the preceding clauses further comprises consolidating the fibers of the first strand portion with a polymer resin, said polymer resin being a thermosetting resin or a thermoplastic resin, during the application of heat and / or pressure.

[0339] Clause 99: The method according to Clause 87, wherein forming the plate includes forming a plate having a front leg region having a stiffness of about 80 N / mm to about 90 N / mm, a middle leg region having a stiffness of about 75 N / mm to about 120 N / mm or about 20 N / mm to about 55 N / mm, and a heel region having a stiffness of about 20 N / mm to about 30 N / mm or about 50 N / mm to about 60 N / mm.

[0340] Clause 100: The method described in Clause 87, forming the plate includes forming a plate having a middle leg region with a stiffness of about 60 N / mm to about 70 N / mm, a front leg region with a stiffness of about 95 N / mm to about 105 N / mm or about 75 N / mm to about 120 N / mm, and a heel region with a stiffness of about 20 N / mm to about 30 N / mm or about 50 N / mm to about 60 N / mm.

[0341] Clause 101: The method according to Clause 87, wherein forming the plate includes forming a plate having a heel region having a stiffness of about 35 N / mm to about 45 N / mm, a midfoot region having a stiffness of about 20 N / mm to about 55 N / mm or about 75 N / mm to about 120 N / mm, and a forefoot region having a stiffness of about 95 N / mm to about 105 N / mm or about 75 N / mm to about 120 N / mm.

[0342] Clause 102: A method of forming a plate for footwear, the method comprising applying a first strand portion to a base layer, the application of the first strand portion to the base layer comprising positioning adjacent segments of the first strand portion to form a first layer on the base layer, the adjacent segments of the first strand portion having a greater density in the width of the plate between an inner and outer portion at a midfoot region of the plate than at a forefoot region of the plate and at a heel region of the plate, and applying at least one of heat and pressure to the first strand portion and the base layer to conform the first strand portion and the base layer to a predetermined shape.

[0343] Clause 103: The method according to Clause 102 further includes removing a portion of the segment to define the outer edge of the plate.

[0344] Clause 104: The method according to Clause 103, wherein removing the portion of the segment comprises cutting off the first strand portion at a first end of each segment and cutting off the first strand portion at a second end of each first segment located at the end opposite to the first end of the corresponding first strand portion.

[0345] Clause 105: The method according to Clause 103, wherein removing the portion of the segment includes removing the annular portion connecting the adjacent segments of the first strand portion.

[0346] Clause 106: The method according to Clause 102, wherein applying the first strand portion to the base layer includes applying the first strand portion to a second layer having multiple fibers and / or to a second layer formed of unidirectional tape.

[0347] Clause 107: The method according to Clause 102, wherein applying the first strand portion to the base layer includes applying the first strand portion to the substrate.

[0348] Clause 108: The method according to any of the preceding clauses, wherein applying the first strand portion to the base layer includes applying a suture to attach the first strand portion to the base layer.

[0349] Clause 109: The method according to Clause 108, wherein applying the suture includes zigzagging the suture across the first strand portion between the first attachment positions.

[0350] Clause 110: The method according to Clause 102 further includes positioning a second strand portion on the first layer to form a second layer on the first layer.

[0351] Clause 111: The method according to Clause 110, wherein applying the first strand portion to the base layer includes applying a first stitch that crosses the first strand portion at a first attachment location spaced apart from the first strand portion and penetrates the base layer, and positioning the second strand portion on the first layer includes applying a second stitch that crosses the second strand portion at a second attachment location, extends through the first strand portion, and penetrates the base layer.

[0352] Clause 112: The method according to any of the preceding clauses, wherein applying the first strand portion to the base layer includes positioning the adjacent segments on the width of the plate between the inner and outer portions such that they are closer to each other at the middle foot region of the plate than at the front foot region of the plate.

[0353] Clause 113: The method according to any of the preceding clauses, wherein applying the first strand portion to the base layer comprises positioning the adjacent segments on the width of the plate between the inner and outer portions such that they are closer to each other at the middle foot region of the plate than at the heel region of the plate.

[0354] Clause 114: The method according to any of the preceding clauses, wherein applying the first strand portion to the base layer includes positioning adjacent first segments of the first strand portion on the base layer, wherein each first segment has a corresponding length extending between a corresponding first end portion at the front foot region of the plate near one of the inner and outer portions and a corresponding second end portion at the heel region of the plate near one of the inner and outer portions.

[0355] Clause 115: The method according to Clause 114, wherein applying the first strand portion to the base layer includes positioning adjacent second segments of the first strand portion on the base layer, wherein each second segment has a corresponding length extending between a corresponding first end portion at the front foot region of the plate near the other of the inner and outer portions and a corresponding second end portion at the heel region of the plate near the other of the inner and outer portions.

[0356] Clause 116: The method according to Clause 115, wherein positioning adjacent first segments and positioning adjacent second segments comprises such that the first segments and the second segments overlap each other in the inner region of the plate located at the center foot region.

[0357] Clause 117: The method according to Clause 115, wherein positioning adjacent first segments and positioning adjacent second segments comprises: extending the first segments and the second segments substantially parallel to the longitudinal axis of the plate at the middle foot region, and separating the first segments and the second segments from each other as they extend from the middle foot region toward their corresponding first ends at the front foot region.

[0358] Clause 118: The method according to Clause 115, wherein positioning adjacent first segments includes positioning adjacent first segments such that they have substantially equal intervals over their respective lengths, and positioning adjacent second segments includes positioning adjacent second segments such that they have substantially equal intervals over their respective lengths.

[0359] Clause 119: The method according to Clause 115, wherein positioning an adjacent second segment includes positioning the adjacent second segment to have a corresponding length that is longer than the corresponding length of the adjacent first segment.

[0360] Clause 120: The method according to Clause 115, wherein applying the first strand portion to the base layer comprises positioning adjacent third segments of the first strand portion on the base layer between the first segment and the second segment, wherein each third segment has a corresponding length extending between a corresponding first end located at the front foot region of the plate and a corresponding second end located at the heel region of the plate.

[0361] Clause 121: The method according to Clause 120, wherein positioning the adjacent third segment of the first strand portion includes positioning the adjacent third segment to have a corresponding length different from the corresponding length of the first segment and the corresponding length of the third segment.

[0362] Clause 122: The method according to any of the preceding clauses, wherein applying the first strand portion to the base layer includes applying a continuous strand.

[0363] Clause 123, the method according to Clause 122, wherein the continuous strand applied to the first strand portion includes an annular portion forming the first strand portion.

[0364] Clause 124: The method according to Clause 123 further includes removing the annular portion between adjacent segments of the first strand portion to define the outer edge of the plate.

[0365] Clause 125: The method according to any of the preceding clauses further includes forming the first strand portion from a first bundle of fibers.

[0366] Clause 126: The method according to Clause 124, wherein the formation of the first strand portion from the first bundle of fibers comprises forming the first strand portion from at least one of carbon fiber, boron fiber, glass fiber and polymer fiber.

[0367] Clause 127: also includes incorporating the plate into footwear.

[0368] Clause 128: The method according to any of the preceding clauses further includes consolidating the fibers of the first strand portion with a polymer resin.

[0369] Clause 129: The method according to Clause 128, wherein the fiber is consolidated with the polymer resin during the application of heat and / or pressure.

[0370] Clause 130: A board for footwear, the board comprising: a first layer comprising a first prepreg fiber sheet having fibers positioned at -15° or -30° relative to the longitudinal axis of the board; a second layer disposed on the first layer and comprising a second prepreg fiber sheet having fibers positioned at 15° relative to the longitudinal axis of the board; a third layer disposed on the second layer and comprising first strand portions having adjacent first segments positioned on the width of the board between an inner and outer portion such that they are closer to each other at the midfoot region of the board than at the forefoot region of the board; and a fourth layer disposed on the third layer and comprising... The plate comprises a second strand portion having adjacent second segments positioned on the width of the plate between the inner and outer portions such that the segments are closer to each other at the middle foot region of the plate than at the front foot region of the plate; a fifth layer disposed on the fourth layer and comprising a third prepreg sheet having fibers positioned at -15° or -30° relative to the longitudinal axis of the plate; and a sixth layer disposed on the fifth layer and comprising a fourth prepreg sheet having fibers positioned at 15° relative to the longitudinal axis of the plate, wherein the stiffness of the plate is greater at the middle foot region of the plate than at the front foot region and the heel region of the plate.

[0371] Clause 131: The plate according to Clause 130 further includes a polymer resin for bonding the first prepreg fiber sheet, the second prepreg fiber sheet, the first strand portion, the second strand portion, the third prepreg fiber sheet, and the fourth prepreg fiber sheet.

[0372] Clause 132: The board according to any of the preceding clauses, wherein the first prepreg fiber sheet, the second prepreg fiber sheet, the first strand portion, the second strand portion, the third prepreg fiber sheet and the fourth prepreg fiber sheet comprise at least one of carbon fiber, boron fiber, glass fiber and polymer fiber.

[0373] Clause 133: The board according to Clause 132, wherein the first prepreg fiber sheet, the second prepreg fiber sheet, the third prepreg fiber sheet and the fourth prepreg fiber sheet comprise glass fiber.

[0374] Clause 134: The plate according to Clause 132, wherein the first prepreg fiber sheet, the second prepreg fiber sheet, the third prepreg fiber sheet and the fourth prepreg fiber sheet comprise carbon fibers.

[0375] Clause 135: A board according to any of the preceding clauses, wherein the first prepreg fiber sheet, the second prepreg fiber sheet, the third prepreg fiber sheet and the fourth prepreg fiber sheet are applied in a unidirectional band.

[0376] Clause 136: The board according to any of the preceding clauses, wherein the polymer resin is a thermosetting resin or a thermoplastic resin.

[0377] Clause 137: The board according to any of the preceding clauses, wherein the stiffness of the heel region is from about 15 percent (15%) to about 35 percent (35%) or from about 20 percent (20%) to about 30 percent (30%) of the stiffness of the midfoot region.

[0378] Clause 138: The board according to any of the preceding clauses, wherein the stiffness of the forefoot region is about 40 percent (40%) to about 60 percent (60%) or about 45 percent (45%) to about 55 percent (55%) of the stiffness of the middle foot region.

[0379] The foregoing description has been provided for purposes of illustration and description. The foregoing description is not intended to be exhaustive or limiting of this disclosure. Elements or features of a particular configuration are generally not limited to that particular configuration, but are interchangeable where applicable and can be used in the chosen configuration, even if not specifically shown or described. Elements or features of a particular configuration may also vary in many ways. These variations should not be considered as departing from this disclosure, and all such modifications are intended to be included within the scope of this disclosure.

Claims

1. A board for footwear, the board comprising: A base having a peripheral edge that defines an inner and outer portion extending between a heel region and a forefoot region; A bundle of fibers, the bundle of fibers being attached to the substrate and extending between a first end of the plate disposed in the heel region and a second end disposed in the forefoot region; The fiber bundle has multiple segments, and the annular portion corresponding to a first segment in the multiple segments and in the front foot region is positioned closer to the second end of the plate than the annular portion corresponding to a second segment in the multiple segments and in the front foot region. The fiber bundle comprises a first segment group and a second segment group, wherein the second segment group comprises the same or a different number of segments as the first segment group; and The interval between adjacent segments in at least one of the first segment group and the second segment group increases as the segment crosses from the middle foot region into the front foot region, and then the interval gradually decreases until the segment terminates at the corresponding annular portion in the front foot region.

2. The plate according to claim 1, wherein, The first segment of the fiber bundle extends from the heel region to a first position in the forefoot region, the second segment of the fiber bundle extends from the heel region to a second position in the forefoot region, and the first position is closer to the second end of the plate than the second position.

3. The plate according to claim 1, wherein, The multiple segments of the fiber bundle are portions of the same integral strand.

4. The plate according to claim 1, wherein, The fiber bundle includes multiple annular portions for connecting the multiple segments.

5. The plate according to any one of claims 1-4, further comprising a polymeric resin for binding the fiber bundles.

6. The plate according to any one of claims 1-4, wherein, The fiber bundles include at least one of carbon fiber, boron fiber, glass fiber, and polymer fiber.

7. A footwear article comprising a plate according to any one of claims 1-6.

8. A board for footwear, said board comprising: A base having a peripheral edge that defines an inner and outer portion extending between a heel region and a forefoot region; A bundle of fibers, the bundle of fibers being attached to the substrate and extending between a first end of the plate disposed in the heel region and a second end disposed in the forefoot region; The fiber bundle has multiple segments, a first segment extending between a first annular portion located at a first position in the forefoot region and a second annular portion located at a second position in the heel region, a second segment extending between a third annular portion located at the first position in the forefoot region and a fourth annular portion located at the second position in the heel region, the third annular portion extending at the first position along a longitudinal axis perpendicular to the base and aligned with a first transverse axis between the inner and outer portions of the first annular portion; The fiber bundle comprises a first segment group and a second segment group, wherein the second segment group comprises the same or a different number of segments as the first segment group; and The interval between adjacent segments in at least one of the first segment group and the second segment group increases as the segment crosses from the middle foot region into the front foot region, and then the interval gradually decreases until the segment terminates at the corresponding annular portion in the front foot region.

9. The plate according to claim 8, wherein, The fourth annular portion extends at the second position along the longitudinal axis perpendicular to the base and is aligned with the second annular portion along the second transverse axis between the inner and outer portions.

10. The plate according to claim 8, wherein, The multiple segments of the fiber bundle are portions of the same integral strand.

11. The plate according to claim 8, wherein, The fiber bundle is formed by one continuous strand of fiber or two or more strands of fiber.

12. The plate according to claim 8, wherein, The plurality of segments have the same length and extend between the first position and the second position.

13. The plate according to claim 8, wherein, The fiber bundle also includes annular portions disposed at the first and second positions for connecting adjacent segments of the fiber bundle.

14. The plate according to claim 8, wherein, The segments of the fiber bundles near the outer side of the plate and located inside the plate extend parallel to each other and parallel to the longitudinal axis between the first position and the second position.

15. The plate according to claim 8, wherein, The segments of the fiber bundles near the inner side of the plate converge toward the interior of the plate as they extend from the second position toward the center foot region, and then separate and fan out in a manner away from the interior of the plate as they extend from the center foot region to the first position.

16. The plate according to claim 15, wherein, The convergence of the segments near the inner side toward the interior of the plate reduces the spacing between adjacent segments in the middle foot region of the plate.

17. The plate according to claim 8, wherein, The section near the inner side generally follows the curvature of the peripheral edge of the plate at the inner side.

18. The plate according to any one of claims 8-17, further comprising a polymeric resin for consolidating the fiber bundles.

19. The plate according to any one of claims 8-17, wherein, The fiber bundles include at least one of carbon fiber, boron fiber, glass fiber, and polymer fiber.

20. A footwear article comprising a plate according to any one of claims 8-19.

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