shoe plate

Abstract

The present application relates to a shoe plate. A plate for an article of footwear, the plate comprising a base, a first strand portion and a second strand portion, the first strand portion being attached to the base via a first stitch, the second strand portion being disposed on the first layer. The first strand portion comprises first sections each extending between two different locations along the base to form a first layer on the base. The second strand portion comprises second sections each extending between two different locations along the base to form a second layer on the first layer.

Description

[0001] This application is a divisional application of the application filed on July 20, 2017, with application number 202110533408.5 and invention title "Shoe Board".

[0002] The application with the application date of July 20, 2017, application number 202110533408.5, and invention title "Shoe Board" is a divisional application of the application with the application date of July 20, 2017, application number 201780044383.4, and invention title "Shoe Board".

[0003] Cross-application of related applications

[0004] This application claims priority to U.S. Provisional Application Serial No. 62 / 364,594, filed July 20, 2016; U.S. Provisional Application Serial No. 62 / 364,585, filed July 20, 2016; U.S. Provisional Application Serial No. 15 / 248,051, filed August 26, 2016; U.S. Provisional Application Serial No. 15 / 248,059, filed August 26, 2016; and U.S. Provisional Application Serial 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 articles including a sole structure having a footplate and foam for improving the performance efficiency of the shoe during running motions. Background Technology

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

[0007] Footwear typically comprises an upper and a sole structure. The upper can be formed from 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 of the upper around the shoe. 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 formed, at least in part, of a polymer foam material that elastically compresses under applied loads to protect the foot by attenuating ground reaction forces. The midsole may define a sole surface on one side opposite the outsole and a footbed on the opposite side, the footbed being profiled to conform to the contours of the sole surface of the foot. 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] The metatarsophalangeal (MTP) joint of the foot is known to absorb energy during dorsiflexion as it flexes during running. Since the foot does not move through plantarflexion until it pushes off the ground, the MTP joint returns a small portion of the energy absorbed to the running motion, and thus, the MTP joint is known to be a source of energy loss during running. It is known to embed a flat, rigid plate with longitudinal stiffness within the sole structure to increase the overall stiffness of the sole structure. While the use of a 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 ankle plantarflexion, thereby reducing the foot's efficiency during running, particularly during long-distance running. Summary of the Invention

[0010] This application relates to the following aspects:

[0011] 1. A board for footwear, the board comprising:

[0012] Base;

[0013] The first strand portion is attached to the substrate via a first stitch and includes first segments, each of which extends between two different locations along the substrate to form a first layer on the substrate;

[0014] The second strand portion is disposed on the first layer and includes second segments, each of which extends between two different locations along the substrate to form a second layer on the first layer;

[0015] Located at the foremost point in the forefoot area of ​​the footwear;

[0016] The last point is located closer to the heel area of ​​the footwear than the foremost point;

[0017] A concave portion extending between the foremost point and the rearmost point, and the concave portion including a constant radius of curvature from the foremost point to the metatarsophalangeal (MTP) point of the footwear, the MTP point being opposite the MTP joint of the foot during use; and

[0018] A polymer resin that, when heat and pressure are applied, binds the first strand portion, the second strand portion, and the substrate to form a composite material.

[0019] 2. The plate according to aspect 1, wherein the first seam crosses the first strand portion and penetrates the substrate at a first attachment position spaced apart from the first strand portion.

[0020] 3. The plate according to any of the foregoing aspects, wherein the second strand portion is attached to the substrate via a second seam, the second seam crossing the second strand portion, extending through the first strand portion and penetrating the substrate at a second attachment location.

[0021] 4. The plate according to aspect 3, wherein at least one of the first seam and the second seam has a higher melting point than the substrate.

[0022] 5. The plate according to any of the foregoing aspects, wherein the first strand portion and the second strand portion are portions of the same continuous strand.

[0023] 6. The plate according to any of the foregoing aspects, wherein the first strand portion is formed from a first bundle of fibers including at least one of carbon fiber, boron fiber, glass fiber and polymer fiber.

[0024] 7. The plate according to any of the foregoing aspects, wherein the second strand portion is formed of a second bundle of fibers including at least one of carbon fiber, boron fiber, glass fiber and polymer fiber.

[0025] 8. The plate according to aspect 7, wherein the second bundle of the fibers comprises approximately the same number of fibers as the first bundle of the fibers.

[0026] 9. The plate according to aspect 7, wherein the second bundle of the fibers comprises a different number of fibers than the first bundle of the fibers.

[0027] 10. The plate according to any of the foregoing aspects, wherein the first strand portion and the second strand portion include a surrounding portion disposed near the periphery of the substrate, the surrounding portion connecting an adjacent first segment and an adjacent second segment.

[0028] 11. The plate according to any of the foregoing aspects, wherein at least two adjacent first segments and / or at least two adjacent second segments are disconnected at the periphery of the substrate.

[0029] 12. The plate according to any of the foregoing aspects, wherein the first layer has a first segment having a first density applied to the substrate, and the second layer has a second segment having a second density applied to the first layer, which is different from that of the first layer.

[0030] 13. The plate according to any of the foregoing aspects, wherein the first segment is applied to the substrate at a first angle relative to the longitudinal axis of the substrate, and the second segment is applied to the first layer at a second angle different from the first angle relative to the longitudinal axis of the substrate.

[0031] 14. The plate according to aspect 13 further includes a third strand portion disposed on the second layer and including third segments, each of the third segments extending between two different locations along the substrate to form a third layer on the second layer, the third segments converging with the first segments and the second segments, and the third segments being adjacent to each other and disposed substantially parallel to each other.

[0032] 15. The plate according to any of the foregoing aspects, wherein the first strand portion forms a first cavity in the first layer.

[0033] 16. The plate according to aspect 15, wherein the second strand portion forms a second cavity in the second layer, the second cavity being aligned with or spaced apart from the first cavity.

[0034] 17. The plate according to aspect 15, wherein the substrate is exposed within the first cavity or is not present within the first cavity.

[0035] 18. The plate according to aspect 1, wherein the plate includes a generally flat portion disposed in the heel region of the footwear, the last point being located within the generally flat portion.

[0036] 19. The plate according to aspect 1, wherein the MTP point is positioned at approximately 30 percent, or 30 percent, of the total length of the plate from the foremost point.

[0037] 20. The plate according to aspect 1 further includes a buffer layer disposed at least partially within the concave portion.

[0038] 21. The plate according to aspect 20, wherein the buffer layer has a maximum thickness defined near the MTP point. Attached Figure Description

[0039] The accompanying drawings described herein are for illustrative purposes only and are not intended to limit the scope of this disclosure.

[0040] Figure 1 It is a top perspective view of a footwear product based on the principles of this disclosure;

[0041] Figure 2 yes Figure 1 An exploded view of a footwear product showing a shoe plate arranged on a cushioning member within a cavity located between the inner surface of the outsole and the bottom surface of the midsole;

[0042] Figure 3 It is along Figure 1 The cross-sectional view taken by line 3-3 shows the shoe plate arranged on the cushioning member in the cavity between the inner surface of the outsole and the bottom surface of the midsole;

[0043] Figure 4 It is a top perspective view of a footwear product based on the principles of this disclosure;

[0044] Figure 5 yes Figure 4 An exploded view of a footwear product showing a shoe plate arranged between a first cushioning member and a second cushioning member within a cavity located between the inner surface of the outsole and the bottom surface of the midsole.

[0045] Figure 6 It is along Figure 4 The cross-sectional view taken by line 6-6 shows the shoe plate between the first cushioning member and the second cushioning member arranged in a cavity located between the inner surface of the outsole and the bottom surface of the midsole.

[0046] Figure 7 It is a top perspective view of a footwear product based on the principles of this disclosure;

[0047] Figure 8 yes Figure 7 An exploded view of a footwear product showing a cushioning member housed in a cavity between the inner surface of the outsole and the bottom surface of the midsole, and a shoe plate arranged on the inner surface in the forefoot area and embedded in the cushioning member in the heel area of ​​the shoe.

[0048] Figure 9 It is along Figure 7 The cross-sectional view taken by line 9-9 shows the cushioning member housed in a cavity between the inner surface of the outsole and the bottom surface of the midsole, and the shoe plate arranged on the inner surface in the forefoot area of ​​the shoe and embedded in the cushioning member in the heel area of ​​the shoe.

[0049] Figure 10 It is a top perspective view of a footwear product based on the principles of this disclosure;

[0050] Figure 11 yes Figure 10 An exploded view of a footwear product showing a cushioning member housed in a cavity between the inner surface of the outsole and the bottom surface of the midsole, and a shoe plate embedded in the cushioning member in the forefoot area and arranged between the cushioning member and the bottom surface of the midsole in the heel area of ​​the shoe.

[0051] Figure 12 It is along Figure 10 The cross-sectional view taken by line 12-12 shows a cushioning member housed in a cavity between the inner surface of the outsole and the bottom surface of the midsole, and a shoe plate embedded in the cushioning member in the forefoot area of ​​the shoe and arranged between the cushioning member and the bottom surface of the midsole in the heel area of ​​the shoe.

[0052] Figure 13 It is a top perspective view of a footwear product based on the principles of this disclosure;

[0053] Figure 14 yes Figure 13 An exploded view of a footwear product showing a cushioning member housed in a cavity between the inner surface of the outsole and the bottom surface of the midsole, and a shoe plate embedded in the cushioning member in the forefoot area and arranged between the cushioning member and the inner surface of the outsole in the heel area of ​​the shoe.

[0054] Figure 15 It is along Figure 13 The cross-sectional view taken by line 15-15 shows a cushioning member housed in a cavity between the inner surface of the outsole and the bottom surface of the midsole, and a shoe plate embedded in the cushioning member in the forefoot area of ​​the shoe and arranged between the cushioning member and the inner surface of the outsole in the heel area of ​​the shoe.

[0055] Figure 16 It is a top perspective view of a shoe plate for footwear products based on the principles of this disclosure;

[0056] Figure 17 yes Figure 16 Side view of the shoe plate;

[0057] Figure 18 yes Figure 16 A top view of the shoe sole;

[0058] Figure 19 It is a top perspective view of a shoe plate for footwear products based on the principles of this disclosure;

[0059] Figure 20 yes Figure 19 Side view of the shoe plate;

[0060] Figure 21 yes Figure 19 A top view of the shoe sole;

[0061] Figure 22 It is a top perspective view of a shoe plate for footwear products based on the principles of this disclosure;

[0062] Figure 23 yes Figure 22 Side view of the shoe plate;

[0063] Figure 24 yes Figure 22 A top view of the shoe sole;

[0064] Figure 25 It is a top view of a shoe plate for footwear products based on the principles of this disclosure;

[0065] Figure 26 It is a top view of a shoe plate for the forefoot area of ​​a footwear product, based on the principles of this disclosure;

[0066] Figure 27 It is a top view of a shoe plate for footwear products based on the principles of this disclosure;

[0067] Figure 28 It is a top view of a shoe plate for footwear products based on the principles of this disclosure;

[0068] Figure 29 This is a top view of a shoe plate for footwear products based on the principles of this disclosure;

[0069] Figure 30 This is a top view of a shoe plate for footwear products based on the principles of this disclosure;

[0070] Figure 31 A top perspective view of a footwear product based on the principles of this disclosure is provided;

[0071] Figure 32 It is along Figure 31 The cross-sectional view taken by line 32-32 shows the shoe plate arranged between the outsole and the midsole in the forefoot area of ​​the shoe and between the cushioning member and the midsole in the heel area of ​​the shoe;

[0072] Figure 33 A top perspective view of a footwear product based on the principles of this disclosure is provided;

[0073] Figure 34 It is along Figure 33 The cross-sectional view taken by line 34-34 shows the shoe plate arranged between the outsole and the cushioning member;

[0074] Figure 35 A top perspective view of a footwear product based on the principles of this disclosure is provided;

[0075] Figure 36 It is along Figure 35 The cross-sectional view taken by line 36-36 shows multiple openings formed through the outsole and cushioning member to expose the shoe plate arranged between the cushioning member and the midsole;

[0076] Figure 37 It is a top perspective view of a footwear product based on the principles of this disclosure;

[0077] Figure 38 yes Figure 37 An exploded view of a footwear product showing a fluid-filled bladder-like element arranged on a cushioning member within a cavity located between the inner surface of the outsole and the bottom surface of the midsole;

[0078] Figure 39 It is along Figure 37 The cross-sectional view taken by line 39-39 shows a fluid-filled bladder on a cushioning member arranged in a cavity between the inner surface of the outsole and the bottom surface of the midsole.

[0079] Figures 40A to 40E Various prepreg fiber sheets for forming shoe plates are shown according to the principles of this disclosure;

[0080] Figure 41 An exploded view of a stack of prepreg sheets for forming a shoe plate, according to the principles of this disclosure, is shown.

[0081] Figures 42A to 42E The various layers of fiber strands used to form a shoe plate are shown according to the principles of this disclosure;

[0082] Figure 43 An exploded view of the layers of fiber strands used to form a shoe plate, according to the principles of this disclosure, is shown.

[0083] Figure 44 This is a perspective view of a mold for forming a shoe plate according to the principles of this disclosure, shown together with a stack of fibers prior to being formed into the shoe plate;

[0084] Figure 45 This is a perspective view of a mold for forming a shoe plate according to the principles of this disclosure, shown together with the formed shoe plate;

[0085] Figure 46 A top view of a base for forming a shoe plate, according to the principles of this disclosure, is shown;

[0086] Figure 47 It shows the attachment to Figure 46 A top view of the top surface of the substrate to show the first bundle of fibers forming the first layer on the substrate;

[0087] Figure 48The diagram shows a top view of an embroidery prefab comprising a first bundle of fibers, a second bundle of fibers, and a third bundle of fibers, which are attached to... Figure 46 The top surface of the substrate is used to form corresponding first, second and third layers on the substrate;

[0088] Figure 49 yes Figure 48 An exploded view of the embroidery preform, showing the first bundle of fibers, the second bundle of fibers, the third bundle of fibers, and the substrate;

[0089] Figure 50 It shows Figure 47 A close-up view of the first bundle of fibers attached to the substrate via the first suture;

[0090] Figure 51 It is along Figure 50 The cross-sectional view taken by line 51-51 shows the first stitch attaching the first bundle of fibers to the top surface of the substrate, and the fibers include non-polymer fibers and polymer fibers.

[0091] Figure 52 A top view is provided of a fiber bundle attached to a substrate and forming a first layer on the substrate in accordance with the principles of this disclosure;

[0092] Figure 53 Provided Figure 52 A detailed view of a portion of the filament bundle, showing a filament bundle including a surrounding portion arranged near the periphery of the base for connecting adjacent segments of the first filament bundle;

[0093] Figure 54 An exploded view of an embroidery preform comprising a substrate and a first bundle of fibers, a second bundle of fibers, and a third bundle of fibers, according to the principles of this disclosure, wherein the first bundle of fibers, the second bundle of fibers, and the third bundle of fibers are attached to the substrate to form corresponding first, second, and third layers on the substrate.

[0094] Figure 55 Provided Figure 54 A top view of the substrate and the first bundle of fibers, the second bundle of fibers, and the third bundle of fibers attached to the substrate, side by side;

[0095] Figure 56 A preform plate comprising a first bundle of fibers and a second bundle of fibers disposed on the top surface of a substrate, in accordance with the principles of this disclosure, is provided.

[0096] Figure 57 Provided along Figure 56The cross-sectional view taken by line 57-57 shows that the second bundle of fibers is arranged along the periphery of the substrate to provide an external reinforcing region for the first bundle of fibers.

[0097] Figure 58 Provided along Figure 56 The alternative cross-sectional view taken by line 57-57 shows the second bundle of polymer material replacing the fiber to provide an external reinforcing region for the first bundle of fiber;

[0098] Figure 59 Provided along Figure 56 An alternative cross-sectional view taken from line 57-57 shows the periphery of the substrate including folds to provide an external reinforcing region for the first bundle of fibers;

[0099] Figure 60 This is a schematic diagram of a mold, showing an embroidery preform positioned between the upper mold portion and the lower mold portion of the mold when the mold is opened according to the principles of the invention. The embroidery preform includes fiber bundles attached to a substrate.

[0100] Figure 61 yes Figure 60 A schematic diagram of the mold, showing the embroidery preform located between the upper and lower mold portions when the mold is closed; and

[0101] Figure 62 yes Figure 60 A schematic diagram of the mold shows the mold opening and the embroidered preform being molded and cured to form a substantially rigid shoe plate with curved and generally flat portions provided by the upper and lower mold portions.

[0102] Throughout the accompanying drawings, the corresponding reference numerals indicate the corresponding components. Detailed Implementation

[0103] The exemplary configurations will now be described more fully with reference to the accompanying drawings. Exemplary configurations are provided so that this disclosure will be thorough and will fully convey the scope of this disclosure to those skilled in the art. Specific details, such as those of particular components, apparatus, and methods, are set forth to provide a thorough understanding of the configurations of this disclosure. It will be apparent to those skilled in the art that specific details are not required, the exemplary configurations may be implemented in many different forms, and the specific details and exemplary configurations should not be construed as limiting the scope of this disclosure.

[0104] The terminology used herein is for the purpose of describing particular exemplary configurations only and is not restrictive. As used herein, the singular articles “a,” “an,” and “the” may also be intended to include the plural forms unless the context clearly indicates otherwise. The terms “comprising,” “including,” “containing,” and “having” are inclusive and thus specify the presence of features, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and / or combinations thereof. Unless specifically specified in order of execution, the method steps, processes, and operations described herein should not be construed as requiring them to be performed in the particular order discussed or described. Additional or alternative steps may be employed.

[0105] When an element or layer is referred to as “on,” “joined to,” “connected to,” “attached to,” or “linked to” another element or layer, the element or layer may be directly on, joined to, connected to, 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,” “directly joined to,” “directly connected to,” “directly attached to,” 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 should be interpreted in a similar manner (e.g., “between” vs. “directly between,” “adjacent” vs. “directly adjacent,” etc.). As used herein, the term “and / or” includes any and all combinations of one or more of the associated listed items.

[0106] The terms first, second, third, etc., may be used herein to describe various elements, components, regions, layers, and / or parts. These elements, components, regions, layers, and / or parts should not be limited by these terms. These terms may be used only to distinguish one element, component, region, layer, or part from another. Unless the context clearly indicates otherwise, terms such as “first,” “second,” and other numerical terms do not imply sequence or order. Therefore, without departing from the teachings of the example configuration, the first element, component, region, layer, or part discussed below may be referred to as the second element, component, region, layer, and / or part.

[0107] One aspect of this disclosure provides a sole structure for footwear articles having an upper portion. The sole structure includes: an outsole; a plate disposed between the outsole and the upper; and a first cushioning layer disposed between a concave portion and the upper. The plate includes a foremost portion disposed in the forefoot region of the sole structure and a rearmost portion disposed closer to the heel region of the sole structure than the foremost point. The plate also includes a concave portion extending between the foremost and rearmost points, and the concave portion includes a constant radius of curvature from the foremost point to the metatarsophalangeal (MTP) point of the sole structure. The MTP point is opposite the MTP joint of the foot during use.

[0108] Implementations of this disclosure may include one or more of the optional features described below. In some implementations, the foremost and rearmost points are coplanar. The plate may also include a generally flat portion disposed within the heel region of the sole structure. The rearmost point may be located within the generally flat portion.

[0109] In some examples, the sole structure includes a blended section disposed between and connecting the concave and generally flat portions. The blended section may include a substantially constant curvature. The foremost and rearmost points may be coplanar at the junction of the blended and generally flat portions.

[0110] The sole structure may include a second cushioning layer disposed between a generally flat portion and the upper. A third cushioning layer may be disposed between the outsole and the plate. In some examples, the third cushioning layer is disposed in the heel area. The third cushioning layer may extend from the heel area to the forefoot area.

[0111] The sole structure may also include at least one fluid-filled chamber disposed between the plate and the upper and / or between the outsole and the plate. This at least one fluid-filled chamber may be disposed within at least one of the second and third cushioning layers.

[0112] In some examples, the MTP point is located at approximately thirty percent (30%) of the total length of the plate from the foremost point. The center of the radius of curvature can be located at the MTP point. A constant radius of curvature can extend from the foremost point through the MTP point. A constant radius of curvature can extend from the foremost point through the MTP point to at least forty percent (40%) of the total length of the plate from the foremost point.

[0113] In some examples, the outsole includes a ground contact surface and an inner surface formed on the side of the outsole opposite to the ground contact surface. The inner surface can be directly attached to the plate. The inner surface can be attached to the plate near the concave portion.

[0114] Another aspect of this disclosure provides a sole structure for footwear articles having an upper. The sole structure includes: an outsole; a plate disposed between the outsole and the upper; and a first cushioning layer disposed between a flexure portion and the upper. The plate includes a foremost point disposed in the forefoot region of the sole structure and a rearmost point disposed closer to the heel region of the sole structure than the foremost point. The plate also includes a flexure portion extending between and connecting the foremost and rearmost points, and the flexure portion includes a constant radius of curvature from the foremost point to the metatarsophalangeal (MTP) point of the sole structure. The MTP point is opposite the MTP joint of the foot during use.

[0115] This aspect may include one or more of the following optional features. In some implementations, the foremost and rearmost points are coplanar. The plate may include a generally flat portion disposed within the heel area of ​​the sole structure, with the rearmost point located within the generally flat portion.

[0116] In some examples, the sole structure includes a hybrid section arranged between and connecting the curved and generally flat sections. The hybrid section may include a substantially constant curvature. The foremost and rearmost points may be coplanar at the junction of the hybrid section and the generally flat section.

[0117] The sole structure may include a second cushioning layer disposed between a generally flat portion and the upper. A third cushioning layer may be disposed between the outsole and the plate. The third cushioning layer may be disposed in the heel area. The third cushioning layer may extend from the heel area to the forefoot area.

[0118] In some examples, the sole structure includes at least one fluid-filled chamber disposed between the plate and the upper and / or between the outsole and the plate. This at least one fluid-filled chamber may be disposed within at least one of a second cushioning layer and a third cushioning layer.

[0119] In some examples, the MTP point is located at approximately thirty percent (30%) of the total length of the plate from the foremost point. The center of the radius of curvature can be located at the MTP point. A constant radius of curvature can extend from the foremost point through the MTP point. A constant radius of curvature can extend from the foremost point through the MTP point to at least forty percent (40%) of the total length of the plate from the foremost point.

[0120] The outsole may include a ground contact surface and an inner surface formed on the side of the outsole opposite to the ground contact surface. The inner surface may be directly attached to the plate. The inner surface may be attached to the plate near the bend.

[0121] Another aspect of this disclosure provides a sole structure for footwear articles having an upper. The sole structure includes: an outsole; a plate disposed between the outsole and the upper; and a first cushioning layer disposed between a flexure portion and the upper. The plate includes a foremost point disposed in the forefoot region of the sole structure and a rearmost point disposed closer to the heel region of the sole structure than the foremost point. The plate also includes a flexure portion extending between and connecting the foremost and rearmost points, and the flexure portion includes a circular curvature from the foremost point to the metatarsophalangeal (MTP) point of the sole structure. The MTP point is opposite the MTP joint of the foot during use.

[0122] This aspect may include one or more of the following optional features. In some implementations, the foremost and rearmost points are coplanar. The plate may include a generally flat portion disposed within the heel region of the sole structure. The rearmost point may be located within the generally flat portion. The plate may also include a generally flat portion disposed within the heel region of the sole structure. The rearmost point may be located within the generally flat portion.

[0123] In some examples, the sole structure includes a hybrid section arranged between and connecting the curved and generally flat sections. The hybrid section has a substantially constant curvature. The foremost and rearmost points may be coplanar at the junction of the hybrid section and the generally flat section.

[0124] The sole structure may include a second cushioning layer disposed between a generally flat portion and the upper. A third cushioning layer may be disposed between the outsole and the plate. The third cushioning layer may be disposed in the heel area. In some examples, the third cushioning layer extends from the heel area to the forefoot area.

[0125] The sole structure may include at least one fluid-filled chamber disposed between the plate and the upper and / or between the outsole and the plate. The at least one fluid-filled chamber may be disposed within at least one of a second cushioning layer and a third cushioning layer.

[0126] In some examples, the MTP point is located at approximately thirty percent (30%) of the total length of the plate from the foremost point. The center of the circular curvature can be located at the MTP point. The circular curvature can extend from the foremost point through the MTP point. The circular curvature can extend from the foremost point through the MTP point to at least forty percent (40%) of the total length of the plate from the foremost point.

[0127] In some implementations, the outsole includes a ground contact surface and an inner surface formed on the side of the outsole opposite to the ground contact surface. The inner surface may be directly attached to the plate. Additionally or alternatively, the inner surface may be attached to the plate near a flexural portion. In some examples, the sole structure also includes a second cushioning layer disposed on the side of the plate opposite to the first cushioning layer to form at least a portion of the outsole.

[0128] Another aspect of this disclosure provides a sole structure for footwear articles having an upper portion. The sole structure includes: an outsole; a plate disposed between the outsole and the upper; and a first cushioning layer disposed between a concave portion and the upper. The plate includes a foremost portion disposed in the forefoot region of the sole structure and a rearmost portion disposed closer to the heel region of the sole structure than the foremost point. The plate also includes a concave portion extending between the foremost and rearmost points, and the concave portion includes a constant radius of curvature from the foremost point to the metatarsophalangeal (MTP) point of the sole structure. The MTP point is opposite the MTP joint of the foot during use.

[0129] Implementations of this disclosure may include one or more of the optional features described below. In some implementations, the foremost and rearmost points are coplanar. The plate may also include a generally flat portion disposed within the heel region of the sole structure. The rearmost point may be located within the generally flat portion.

[0130] In some examples, the sole structure includes a blended section disposed between and connecting the concave and generally flat portions. The blended section may include a substantially constant curvature. The foremost and rearmost points may be coplanar at the junction of the blended and generally flat portions.

[0131] The sole structure may include a second cushioning layer disposed between a generally flat portion and the upper. A third cushioning layer may be disposed between the outsole and the plate. In some examples, the third cushioning layer is disposed in the heel area. The third cushioning layer may extend from the heel area to the forefoot area.

[0132] The sole structure may also include at least one fluid-filled chamber disposed between the plate and the upper and / or between the outsole and the plate. This at least one fluid-filled chamber may be disposed within at least one of the second and third cushioning layers.

[0133] In some examples, the MTP point is located at approximately thirty percent (30%) of the total length of the plate from the foremost point. The center of the radius of curvature can be located at the MTP point. A constant radius of curvature can extend from the foremost point through the MTP point. A constant radius of curvature can extend from the foremost point through the MTP point to at least forty percent (40%) of the total length of the plate from the foremost point.

[0134] In some examples, the outsole includes a ground contact surface and an inner surface formed on the side of the outsole opposite to the ground contact surface. The inner surface can be directly attached to the plate. The inner surface can be attached to the plate near the concave portion.

[0135] Another aspect of this disclosure provides a sole structure for footwear articles having an upper. The sole structure includes: an outsole; a plate disposed between the outsole and the upper; and a first cushioning layer disposed between a flexure portion and the upper. The plate includes a foremost point disposed in the forefoot region of the sole structure and a rearmost point disposed closer to the heel region of the sole structure than the foremost point. The plate also includes a flexure portion extending between and connecting the foremost and rearmost points, and the flexure portion includes a constant radius of curvature from the foremost point to the metatarsophalangeal (MTP) point of the sole structure. The MTP point is opposite the MTP joint of the foot during use.

[0136] This aspect may include one or more of the following optional features. In some implementations, the foremost and rearmost points are coplanar. The plate may include a generally flat portion disposed within the heel area of ​​the sole structure, with the rearmost point located within the generally flat portion.

[0137] In some examples, the sole structure includes a hybrid section arranged between and connecting the curved and generally flat sections. The hybrid section may include a substantially constant curvature. The foremost and rearmost points may be coplanar at the junction of the hybrid section and the generally flat section.

[0138] The sole structure may include a second cushioning layer disposed between a generally flat portion and the upper. A third cushioning layer may be disposed between the outsole and the plate. The third cushioning layer may be disposed in the heel area. The third cushioning layer may extend from the heel area to the forefoot area.

[0139] In some examples, the sole structure includes at least one fluid-filled chamber disposed between the plate and the upper and / or between the outsole and the plate. This at least one fluid-filled chamber may be disposed within at least one of a second cushioning layer and a third cushioning layer.

[0140] In some examples, the MTP point is located at approximately thirty percent (30%) of the total length of the plate from the foremost point. The center of the radius of curvature can be located at the MTP point. A constant radius of curvature can extend from the foremost point through the MTP point. A constant radius of curvature can extend from the foremost point through the MTP point to at least forty percent (40%) of the total length of the plate from the foremost point.

[0141] The outsole may include a ground contact surface and an inner surface formed on the side of the outsole opposite to the ground contact surface. The inner surface may be directly attached to the plate. The inner surface may be attached to the plate near the bend.

[0142] Another aspect of this disclosure provides a sole structure for footwear articles having an upper. The sole structure includes: an outsole; a plate disposed between the outsole and the upper; and a first cushioning layer disposed between a flexure portion and the upper. The plate includes a foremost point disposed in the forefoot region of the sole structure and a rearmost point disposed closer to the heel region of the sole structure than the foremost point. The plate also includes a flexure portion extending between and connecting the foremost and rearmost points, and the flexure portion includes a circular curvature from the foremost point to the metatarsophalangeal (MTP) point of the sole structure. The MTP point is opposite the MTP joint of the foot during use.

[0143] This aspect may include one or more of the following optional features. In some implementations, the foremost and rearmost points are coplanar. The plate may include a generally flat portion disposed within the heel region of the sole structure. The rearmost point may be located within the generally flat portion. The plate may also include a generally flat portion disposed within the heel region of the sole structure. The rearmost point may be located within the generally flat portion.

[0144] In some examples, the sole structure includes a hybrid section arranged between and connecting the curved and generally flat sections. The hybrid section has a substantially constant curvature. The foremost and rearmost points may be coplanar at the junction of the hybrid section and the generally flat section.

[0145] The sole structure may include a second cushioning layer disposed between a generally flat portion and the upper. A third cushioning layer may be disposed between the outsole and the plate. The third cushioning layer may be disposed in the heel area. In some examples, the third cushioning layer extends from the heel area to the forefoot area.

[0146] The sole structure may include at least one fluid-filled chamber disposed between the plate and the upper and / or between the outsole and the plate. The at least one fluid-filled chamber may be disposed within at least one of a second cushioning layer and a third cushioning layer.

[0147] In some examples, the MTP point is located at approximately thirty percent (30%) of the total length of the plate from the foremost point. The center of the circular curvature can be located at the MTP point. The circular curvature can extend from the foremost point through the MTP point. The circular curvature can extend from the foremost point through the MTP point to at least forty percent (40%) of the total length of the plate from the foremost point.

[0148] In some implementations, the outsole includes a ground contact surface and an inner surface formed on the side of the outsole opposite to the ground contact surface. The inner surface may be directly attached to the plate. Additionally or alternatively, the inner surface may be attached to the plate near a flexural portion. In some examples, the sole structure also includes a second cushioning layer disposed on the side of the plate opposite to the first cushioning layer to form at least a portion of the outsole.

[0149] Another aspect of this disclosure includes a board for footwear, the board having: a base; a first thread portion attached to the base and forming a first layer on the base; and a second thread portion disposed on the first layer and forming a second layer. The first thread portion is attached to the base via a first seam, the first seam crossing the first thread portion and penetrating the base at a first attachment location spaced apart from the first thread portion. The second thread portion is attached to the base via a second seam, the second seam crossing the second thread portion, extending through the first thread portion, and penetrating the base at a second attachment location.

[0150] In some configurations, the first strand portion is positioned between the second attachment position and the second strand portion. The first and second strand portions can be portions of the same continuous strand. The first and second strand portions can be formed of the same material or different materials.

[0151] In some examples, the first strand is formed from a first bundle of fibers. The first bundle of fibers may include at least one of carbon fibers, boron fibers, glass fibers, and polymer fibers. In some examples, the second strand is formed from a second bundle of fibers. The second bundle of fibers may include at least one of carbon fibers, boron fibers, glass fibers, and polymer fibers.

[0152] In some implementations, the second bundle of fibers comprises approximately the same number of fibers as the first bundle. In other implementations, the second bundle of fibers comprises a different number of fibers than the first bundle. The first and second strand portions may have different lengths or may have approximately the same length.

[0153] In some configurations, the first strand portion forms a first cavity in the first layer. The substrate may be exposed within the first cavity. Furthermore, the second strand portion may form a second cavity in the second layer. Here, the second cavity may be aligned with the first cavity to expose the substrate in the second layer, or the second cavity may be spaced apart from the first cavity.

[0154] The first strand portion can be applied to the substrate in a first shape, and the second strand portion can be applied to the first layer in a second shape. In one configuration, the first shape and the second shape are substantially the same. In another configuration, the first shape and the second shape are different.

[0155] The first and second sutures can be formed of resin. The first and second sutures can be formed of the same material as the substrate. In some examples, at least one of the first and second sutures has a higher melting point than the substrate. Additionally or alternatively, the first suture may zigzag across a first strand portion between first attachment locations. Similarly, the second suture may zigzag across a second strand portion between second attachment locations.

[0156] Another aspect of this disclosure includes a board for footwear, the board having a base defining a periphery, a first thread portion attached to the base, and a second thread portion disposed on a first layer. The first thread portion includes first segments, each extending between two different locations along the periphery of the base to form a first layer on the base. The first segments are arranged adjacent to each other and generally parallel. The second thread portion includes second segments, each extending between two different locations along the periphery of the base to form a second layer on the first layer. The second segments converge with the first segments and are arranged adjacent to each other and generally parallel.

[0157] At least one of the first and second strand portions can be a continuous strand, or the first and second strand portions can be portions of the same continuous strand. In some examples, the first and second strand portions are formed of the same material, while in other examples, the first and second strand portions are formed of different materials.

[0158] In some configurations, the first strand portion is formed from a first bundle of fibers. In some configurations, the first bundle of fibers may include at least one of carbon fibers, boron fibers, glass fibers, and polymer fibers.

[0159] In some configurations, the second strand is formed from a second bundle of fibers. In these configurations, the second bundle of fibers may include at least one of carbon fibers, boron fibers, glass fibers, and polymer fibers. The second bundle of fibers may include substantially the same number of fibers as the first bundle of fibers, or the second bundle of fibers may include a different number of fibers than the first bundle of fibers.

[0160] In some implementations, the first strand portion includes a first surrounding portion arranged near the periphery of the substrate, the first surrounding portion connecting to adjacent first segments. Furthermore, the second strand portion may include a second surrounding portion arranged near the periphery of the substrate, the second surrounding portion connecting to adjacent second segments.

[0161] The first strand portion may form a first cavity in the first layer. Here, the substrate may be exposed within the first cavity. Additionally or alternatively, the second strand portion may form a second cavity in the second layer. The second cavity may be aligned with the first cavity to expose the substrate in the second layer, or the second cavity may be spaced apart from the first cavity.

[0162] In some configurations, a first segment is applied to the substrate at a first angle relative to the longitudinal axis of the substrate, and a second segment is applied to the first layer at a second angle relative to the longitudinal axis of the substrate, different from the first angle. In these configurations, a third segment may be arranged on the second layer and includes a third segment, each extending between two different locations along the periphery of the substrate to form a third layer on the second layer. The third segments may converge with the first and second segments, and the third segments are arranged adjacent to each other and substantially parallel. In some examples, the third segment is applied to the second layer at a third angle relative to the longitudinal axis of the substrate, different from the first and second angles.

[0163] In some implementations, a first thread portion is attached to the substrate via a first seam, and a second thread portion is attached to the substrate via a second seam. At least one of the first and second seams can be formed of the same material as the substrate. In some examples, at least one of the first and second seams has a higher melting point than the substrate. At least one of the first and second seams can be formed of resin. Furthermore, the first seam can zigzag across the first thread portion and penetrate the substrate at a first attachment location, and the second seam can additionally or alternatively zigzag across the second thread portion and penetrate the substrate at a second attachment location. The first attachment location can be spaced apart from the first thread portion. The first thread portion can be disposed between the second layer and the second attachment location. The second seam can extend through the first thread portion. In some configurations, the first and second layers are anisotropic.

[0164] Another aspect of this disclosure provides a board for footwear. The board includes a base and a first strand portion attached to the base and forming a first layer on the base. The first strand portion forms a first cavity in the first layer, thereby exposing the base within the first cavity.

[0165] In some implementations, the board includes a second strand portion disposed on the first layer and forming the second layer. The first and second strand portions can be portions of the same continuous strand. The first and second strand portions can be formed of the same material. In some examples, the first and second strand portions are formed of different materials. The first and second strand portions can have different lengths. In some examples, the first and second strand portions have approximately the same length.

[0166] In some configurations, the second strand portion forms a second cavity in the second layer. The second cavity may be aligned with the first cavity to expose the substrate at the second layer. The second cavity may be spaced apart from the first cavity. In some implementations, the first strand is applied to the substrate in a first shape, and the second strand portion is applied to the first layer in a second shape. The first shape may be substantially the same as the second shape. The first shape may differ from the second shape.

[0167] In some examples, the first strand is attached to the substrate via a suture. The suture can be formed of resin. Alternatively, the suture can be formed of the same material as the substrate. The suture can have a higher melting point than the substrate. In some configurations, the suture zigzags across the first strand between attachment points on the substrate.

[0168] The first strand portion may be formed from a first bundle of fibers. The first bundle of fibers may include at least one of carbon fibers, boron fibers, glass fibers, and polymer fibers. The second strand portion may be disposed on the first layer and form a second layer, and the second strand portion may be formed from a second bundle of fibers. The second bundle of fibers may include at least one of carbon fibers, boron fibers, glass fibers, and polymer fibers. The second bundle of fibers may include approximately the same number of fibers as the first bundle of fibers. The second bundle of fibers may include a different number of fibers than the first bundle of fibers.

[0169] Another aspect of this disclosure provides a plate for footwear. The plate includes a base defining a first region and a second region, a first thread portion, and a second thread portion. The first thread portion is attached to and opposite the base in one of the first and second regions, and includes a first pattern to provide a first performance characteristic for said one of the first and second regions. The second thread portion is attached to and opposite the base in the other of the first and second regions, and includes a second pattern different from the first pattern. The second thread portion also provides a second performance characteristic different from the first performance characteristic for said other of the first and second regions.

[0170] A first strand portion may form a first edge to define the shape of one of the first and second regions. A second strand portion may form a second edge to define the shape of the other of the first and second regions. The first edge may be spaced apart from and separated from the second edge. The first edge may be adjacent to the second edge. In some configurations, the first and second strand portions may be portions of the same continuous strand. The first and second strand portions may be formed of the same material. The first and second strand portions may be formed of different materials.

[0171] The first strand portion may be formed from a first bundle of fibers. The first bundle of fibers may include at least one of carbon fibers, boron fibers, glass fibers, and polymer fibers. The second strand portion may be formed from a second bundle of fibers. The second bundle of fibers may include at least one of carbon fibers, boron fibers, glass fibers, and polymer fibers. The second bundle of fibers may include approximately the same number of fibers as the first bundle of fibers. The second bundle of fibers may also include a different number of fibers than the first bundle of fibers.

[0172] In some examples, the first and second strand portions have different lengths. The first and second strand portions may have substantially the same length. At least one of the first and second strand portions may form a cavity in at least one of the first and second regions. The substrate may be exposed within this cavity. The first and second strand portions may have different thicknesses. In some configurations, the first and second strand portions have substantially the same thickness. The first and second regions may have different thicknesses. The first and second regions may have substantially the same thickness.

[0173] In some implementations, one of the first and second regions is located in one of the forefoot, midfoot, and heel portions of the footwear. The other of the first and second regions may be located in the other of the forefoot, midfoot, and heel portions of the footwear. A first thread portion may be attached to the substrate via a first seam, and a second thread portion may be attached to the substrate via a second seam. At least one of the first and second seams may be formed of resin. At least one of the first and second seams may be formed of the same material as the substrate. In some examples, at least one of the first and second seams has a higher melting point than the substrate. The first seam may zigzag across the first thread portion and penetrate the substrate at a first attachment location spaced apart from the first thread portion. The second seam may zigzag across the second thread portion and penetrate the substrate at a second attachment location spaced apart from the second thread portion.

[0174] Another aspect of this disclosure provides a plate for footwear. The plate includes a base and a first thread portion. The base has a forefoot region and a heel region. The first thread portion is attached to the base and includes a plurality of segments extending between a first end disposed in the forefoot region and a second end disposed in the heel region. A plurality of segments intersecting each other in the midfoot region are disposed between the forefoot region and the heel region.

[0175] In some implementations, the first strand portion is formed of continuous strands. The first strand portion may include a first surrounding portion joining corresponding first ends of multiple segments and a second surrounding portion joining corresponding second ends of the multiple segments. The multiple segments, the first surrounding portion, and the second surrounding portion cooperate to provide a continuous structure for the first strand portion. The first strand portion may extend to the upper of the footwear.

[0176] In some configurations, the plate includes a tension strand extending between a first strand portion and the upper of the footwear, and connecting the first strand portion to the upper of the footwear. The tension strand may be attached to the first strand portion along at least one of the plurality of segments between a first end and a second end. The plate may also include a lace operable to move the upper between a tightened state and a relaxed state. The tension strand may extend between the lace and at least one of the plurality of segments and engage the lace and at least one of the plurality of segments.

[0177] The base may include a spike member extending from the surface of the base. In some examples, a first strand portion is attached to the surface of the base and extends around a portion of the spike member. The first strand portion may be attached to the surface of the base and surround at least one spike member. The first strand portion may also be attached to the surface of the base, and at least one of a plurality of segments may surround at least one spike member.

[0178] In some examples, multiple segments are woven together at the midfoot region. A first strand portion may be formed from a first bundle of fibers. The first bundle of fibers may include at least one of carbon fiber, boron fiber, glass fiber, and polymer fiber. The first strand portion may form at least one cavity between at least two segments. A substrate may be exposed within said at least one cavity. In some configurations, a first bundle of multiple segments and a second bundle of said multiple segments cooperate to define at least one cavity. The at least one cavity may be arranged between the first bundle and the second bundle.

[0179] Another aspect of this disclosure provides a method for forming a plate for footwear. The method includes: sewing a first thread portion to a substrate to form a first layer on the substrate; and sewing a second thread portion to the first layer to form a second layer. The first thread portion includes applying a first seam that crosses the first thread portion and penetrates the substrate at a first attachment location spaced apart from the first thread portion. The second thread portion includes applying a second seam that crosses the second thread portion, extends through the first thread portion, and penetrates the substrate at a second attachment location.

[0180] In some examples, sewing the second thread portion onto the first layer includes positioning the first thread portion between the second attachment location and the second thread portion. The method also includes forming the first and second thread portions from the same continuous thread. The method may further include forming the first and second thread portions from the same material. In some implementations, the method includes forming the first and second thread portions from different materials.

[0181] The first strand portion may be formed 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 second strand portion may be formed from a second bundle of fibers. Forming the second strand portion from the second bundle of fibers may include forming the second strand portion from at least one of carbon fibers, boron fibers, glass fibers, and polymer fibers. Forming the second strand from the second bundle of fibers may include providing approximately the same number of fibers as the first bundle of fibers. Forming the second strand from the second bundle of fibers may include providing a different number of fibers than the first bundle of fibers.

[0182] In some examples, the method includes forming a first thread portion and a second thread portion with different lengths. The first thread portion and the second thread portion may have substantially the same length. Sewing the first thread portion to the substrate may include forming a first cavity in a first layer. The method may include exposing the substrate within the first cavity. Sewing the second thread portion to the first layer may include forming a second cavity in a second layer. The second cavity may include aligning the second cavity with the first cavity to expose the substrate in the second layer. Forming the second cavity may include spaced the second cavity from the first cavity.

[0183] In some configurations, sewing a first thread portion to a substrate includes applying the first thread portion to the substrate in a first shape. Sewing a second thread portion onto a first layer may include applying the second thread portion to the first layer in a second shape. Applying the first thread portion in the first shape and the second thread portion in the second shape may include applying the first thread portion and the second thread portion in substantially the same shape. In some examples, applying the first thread portion in the first shape and the second thread portion in the second shape includes applying the first thread portion and the second thread portion in different shapes. The method may include applying at least one of the first suture and the second suture, which may include applying a suture formed of resin. The method may also include applying at least one of the first suture and the second suture, which may include applying a suture formed of the same material as the substrate.

[0184] In some implementations, the method includes at least one of applying a first suture and applying a second suture, which may include applying a suture having a melting point higher than that of the substrate. Applying the first suture may include zigzagging across a first strand portion between first attachment locations. Applying the second suture may include zigzagging across a second strand portion between second attachment locations. In some examples, the method includes applying at least one of heat and pressure to the first strand portion and the second strand portion to bond the first strand portion to both the substrate and the second strand portion. Applying at least one of heat and pressure may include shaping the substrate, the first strand portion, and the second strand portion into a desired shape.

[0185] Another aspect of this disclosure includes a method of forming a plate for footwear. The method includes attaching a first strand of thread to a substrate and positioning a second strand of thread on a first layer. Attaching the first strand of thread includes positioning first segments of the first strand of thread on the substrate such that each first segment extends between two different locations along the periphery of the substrate to form a first layer on the substrate. The first segments are arranged adjacent to each other and generally parallel. Positioning the second strand of thread includes positioning second segments of the second strand of thread on the first layer such that each second segment extends between two different locations along the periphery of the substrate to form a second layer on the first layer. The second segments converge with the first segments and are arranged adjacent to each other and generally parallel.

[0186] The method may include at least one of attaching a first strand portion to a substrate and positioning a second strand portion on a first layer, which may include positioning a continuous strand. At least one of attaching the first strand portion to a substrate and positioning the second strand portion on a first layer may include positioning a single continuous strand. The method may include forming the first and second strand portions from the same material. In some examples, the method may include forming the first and second strand portions from different materials.

[0187] 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 forming a second strand portion from a second bundle of fibers. Forming the second strand portion from the second bundle of fibers may include forming the second strand portion from at least one of carbon fibers, boron fibers, glass fibers, and polymer fibers. Forming the second strand from the second bundle of fibers may include providing approximately the same number of fibers as the first bundle of fibers. Forming the second strand from the second bundle of fibers may include providing a different number of fibers than the first bundle of fibers.

[0188] In some examples, the method includes providing a first surrounding portion arranged near the periphery of a first strand portion, the first surrounding portion connecting adjacent first segments. The method may also include providing a second surrounding portion arranged near the periphery of a second strand portion, the second surrounding portion connecting adjacent second segments. Attaching the first strand portion to the substrate may include forming a first cavity in a first layer. The method may also include exposing the substrate within the first cavity.

[0189] In some examples, the method includes positioning a second strand portion on a first layer and including forming a second cavity in the second layer. Forming the second cavity may include aligning the second cavity with the first cavity to expose the substrate at the second layer. Forming the second cavity may include spaced the second cavity from the first cavity. Positioning a first segment of the first strand portion on the substrate may include applying the first segment at a first angle relative to the longitudinal axis of the substrate. Positioning a second segment of the second strand portion on the first layer may include applying the second segment at a second angle relative to the longitudinal axis of the substrate, different from the first angle. In some examples, positioning a third strand portion on the second layer includes positioning a third segment of the third strand portion on the second layer such that each third segment extends between two different locations along the periphery of the substrate to form a third layer on the second layer. The third segments may converge with the first and second segments, and the third segments may be arranged adjacent to each other and generally parallel. Positioning the third segments on the second layer may include applying the third segment at a third angle relative to the longitudinal axis of the substrate, different from the first and second angles.

[0190] Attaching a first thread portion to a substrate may include applying a first suture, and positioning a second thread portion on a first layer may include applying a second suture. Applying at least one of the first and second sutures may include applying a suture formed of the same material as the substrate. Applying at least one of the first and second sutures may include applying a suture having a higher melting point than the substrate. In some examples, applying the first suture includes zigzag-crossing the first thread portion between first attachment locations. Applying the second suture may include zigzag-crossing the second thread portion between second attachment locations. Applying the second suture may include extending the second suture through the first thread portion. The method may include applying at least one of heat and pressure to the first and second thread portions to bond the first thread portion to both the substrate and the second thread portion. Applying at least one of heat and pressure may include shaping the substrate, the first thread portion, and the second thread portion into a desired shape.

[0191] Another aspect of this disclosure includes a method of forming a plate for footwear. The method includes attaching a first strand portion to a substrate to form a first layer on the substrate. The first strand portion may form a first cavity in the first layer, thereby exposing the substrate within the first cavity.

[0192] The method may include positioning a second strand portion on a first layer to form a second layer. The method may also include forming the first and second strand portions from the same continuous strand. In some examples, the method includes forming the first and second strand portions from the same material. The method may also include forming the first and second strand portions from different materials. The method may further include providing first and second strand portions with different lengths. The first and second strand portions may be formed to have approximately the same length.

[0193] In some configurations, positioning the second strand portion includes forming a second cavity in the second layer. The method may also include aligning the second cavity with the first cavity to expose the substrate at the second layer. The method may further include spaced the second cavity from the first cavity.

[0194] Attaching the first thread portion may include applying the first thread portion to a substrate in a first shape, and positioning the second thread portion may include applying the second thread portion to a first layer in a second shape. Applying the first thread portion in the first shape and the second thread portion in the second shape may include applying the first and second thread portions in substantially the same shape. Applying the first thread portion in the first shape and the second thread portion in the second shape may include applying the first and second thread portions in different shapes. Attaching the first thread portion to the substrate may include applying a suture. Applying a suture may also include applying a suture formed of resin. Applying a suture may also include applying a suture formed of the same material as the substrate. In some examples, applying a suture includes applying a suture having a higher melting point than the substrate. Applying a suture may also include zigzagging the suture across the first thread portion between first attachment locations on the substrate.

[0195] 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 further 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 positioning a second strand portion on the first layer to form a second layer, the second strand portion being formed from a second bundle of fibers. Forming the second strand portion from the second bundle of fibers may include forming the second strand portion from at least one of carbon fibers, boron fibers, glass fibers, and polymer fibers. Forming the second strand portion from the second bundle of fibers may include providing approximately the same number of fibers as the first bundle of fibers. Forming the second strand portion from the second bundle of fibers may further include providing a different number of fibers than the first bundle of fibers.

[0196] Another aspect of this disclosure provides a method of forming a footwear article. The method includes: defining a first region and a second region on a substrate; attaching a first strand of thread to the substrate in one of the first and second regions; and attaching a second strand of thread to the substrate in the other of the first and second regions. Attaching the first strand of thread to the substrate includes shaping the first strand of thread into a first pattern, the first strand of thread being opposite to the substrate and providing a first performance characteristic in one of the first and second regions. Attaching the second strand of thread to the substrate includes shaping the second strand of thread into a second pattern different from the first pattern, the second strand of thread being opposite to the substrate and providing a second performance characteristic different from the first performance characteristic in the other of the first and second regions.

[0197] Forming the first strand portion may include forming a first edge to define the shape of one of the first and second regions. Forming the second strand portion may include forming a second edge to define the shape of the other of the first and second regions. In some examples, the method includes spaced the first edge and the second edge apart. The method may also include making the first edge adjacent to the second edge.

[0198] In some examples, the method includes forming a first strand portion and a second strand portion from the same continuous strand. The method may also include forming the first strand portion and the second strand portion from the same material. The first strand portion and the second strand portion may be made of different materials. 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. In some examples, the method includes forming a second strand portion from a second bundle of fibers. Forming the second strand portion from a second bundle of fibers may include forming the second strand portion from at least one of carbon fibers, boron fibers, glass fibers, and polymer fibers.

[0199] Forming a second strand from a second bundle of fibers may include providing approximately the same number of fibers as the first bundle of fibers. Forming a second strand from a second bundle of fibers may include providing a different number of fibers than the first bundle of fibers. In some examples, the method includes providing first strand portions and second strand portions of different lengths. The method may include providing first strand portions and second strand portions of approximately the same length. The method may further include at least one of attaching the first strand portion to a substrate and attaching the second strand portion to a substrate, which may include forming a cavity in at least one of a first region and a second region. In some implementations, the method includes exposing the substrate within the cavity. The first strand portion and the second strand portion may be provided with different thicknesses. The method may further include providing first strand portions and second strand portions of approximately the same thickness. Additionally or alternatively, the first region and the second region may be provided with different thicknesses. In some examples, the method includes providing a first region and a second region of approximately the same thickness.

[0200] In some configurations, the method includes positioning one of the first and second regions in one of the forefoot, midfoot, and heel portions of the footwear. The method may also include positioning the other of the first and second regions in another of the forefoot, midfoot, and heel portions of the footwear. In some examples, the method includes attaching a first thread portion to a substrate via a first seam and attaching a second thread portion to a substrate via a second seam. Attaching the first thread portion to the substrate via the first seam and the second thread portion to the substrate via the second seam may include using a thread formed of resin. Attaching the first thread portion to the substrate via the first seam and the second thread portion to the substrate via the second seam may include using a thread formed of the same material as the substrate. Attaching the first thread portion to the substrate via the first seam and the second thread portion to the substrate via the second seam may include using a thread having a higher melting point than the substrate.

[0201] In some examples, the method includes zigzagging a first suture across a first strand portion and penetrating the substrate at a first attachment location spaced apart from the first strand portion. The method may also include zigzagging a second suture across a second strand portion and penetrating the substrate at a second attachment location spaced apart from the second strand portion.

[0202] Another aspect of this disclosure provides a method for forming a footwear article. The method includes: attaching a first strand portion to a flexible substrate to form a first layer on the substrate; positioning the substrate on a first mold surface to change the shape of the substrate; applying at least one of heat and pressure to the first strand portion and the substrate to conform the shape of the substrate to the first mold surface; and bonding the substrate to the footwear article.

[0203] In some examples, the method includes attaching a second strand portion to a substrate to form a second layer on the substrate. Attaching the second strand portion to the substrate may include attaching the second strand portion adjacent to a first strand portion. Attaching the second strand portion to the substrate may also include overlapping at least a portion of the second strand portion onto the first strand portion.

[0204] In some implementations, the method includes forming a first strand portion and a second strand portion from the same continuous strand. The first strand portion and the second strand portion may be made of the same material. Alternatively or additionally, the first strand portion and the second strand portion may be made of different materials.

[0205] The method may further include 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 further include forming a second strand portion from a second bundle of fibers. Forming the second strand portion from the second bundle of fibers may include forming the second strand portion from at least one of carbon fibers, boron fibers, glass fibers, and polymer fibers. Forming the second strand from the second bundle of fibers may further include providing approximately the same number of fibers as the first bundle of fibers. In some examples, forming the second strand from the second bundle of fibers includes providing a different number of fibers than the first bundle of fibers.

[0206] In some configurations, the method includes providing a first wire portion and a second wire portion of different lengths. The method may also include providing a first wire portion and a second wire portion of substantially the same length. Attaching at least one of the first wire portion to a substrate and attaching the second wire portion to a substrate may include forming a cavity in at least one of the first and second layers. In some examples, the method includes exposing the substrate within the cavity. The first wire portion and the second wire portion may be provided with different thicknesses. Additionally or alternatively, the first wire portion and the second wire portion may be provided with substantially the same thickness. The method may also include providing a first layer and a second layer with different thicknesses. In some examples, the method includes providing a first layer and a second layer with substantially the same thickness.

[0207] Conforming the shape of the substrate to the surface of the first mold can include providing the substrate with a front foot portion, a middle foot portion, and a heel portion. The method can include attaching a first strand of thread to the substrate via a first stitch and attaching a second strand of thread to the substrate via a second stitch. Attaching the first strand of thread to the substrate via the first stitch and attaching the second strand of thread to the substrate via the second stitch can include using a suture formed of resin. Attaching the first strand of thread to the substrate via the first stitch and attaching the second strand of thread to the substrate via the second stitch can also include using a suture formed of the same material as the substrate. In some examples, attaching the first strand of thread to the substrate via the first stitch and attaching the second strand of thread to the substrate via the second stitch includes using a suture having a higher melting point than the substrate. Applying at least one of heat and pressure can include activating the resin material bonded to the first strand of thread.

[0208] In some configurations, the method includes injecting a liquid material into a first strand portion. Applying heat and pressure may include subjecting the substrate and the first strand portion to at least one of vacuum molding and compression molding to cure the liquid material. Curing the liquid material may include curing a thermosetting material. Curing a thermosetting material may include curing at least one of epoxy resin, polyurethane, polymerizable composition, and prepolymer. In some examples, injecting the liquid material into the first strand portion includes adding a polymer to the liquid material to increase the ductility of the liquid material upon curing. Adding a polymer to the liquid material may include adding at least one of rubber and block copolymer.

[0209] In some examples, the method includes forming a substrate from a thermoplastic film. The method may include attaching a first thread portion to the thermoplastic film via a suture. Attaching the first thread portion to the thermoplastic film via a suture may include using a suture formed of a thermoplastic material. Applying at least one of heat and pressure to the first thread portion and the substrate may include thermoforming the thermoplastic film and the thermoplastic suture to bond the first thread portion to the substrate. Applying at least one of heat and pressure may include subjecting the substrate and the first thread portion to at least one of vacuum molding and compression molding.

[0210] Another aspect of this disclosure provides a method for forming a footwear article. The method includes: attaching a first strand of thread to a first substrate to form a first layer on the first substrate; and attaching a second strand of thread to a second substrate to form a second layer on the second substrate. The method further includes: positioning the second substrate on the first substrate to form a substrate stack; positioning the substrate stack on a first mold surface; applying at least one of heat and pressure to the substrate stack to conform the substrate stack to the shape of the first mold surface; and incorporating the substrate stack into the footwear article.

[0211] In some examples, applying at least one of heat and pressure includes activating the resin material bonded to the first and second strand portions. The method may include injecting liquid material into the first and second strand portions. Applying at least one of heat and pressure may include subjecting the substrate stack to at least one of vacuum molding and compression molding to cure the liquid material. Curing the liquid material may include curing a thermosetting material. Curing a thermosetting material may include curing at least one of epoxy resin, polyurethane, polymerizable compositions, and prepolymers. In some examples, injecting liquid material into the first and second strand portions includes adding a polymer to the liquid material to increase the ductility of the liquid material upon curing. Adding a polymer to the liquid material may include adding at least one of rubber and block copolymers.

[0212] In some configurations, the method includes forming at least one of a first substrate and a second substrate from a thermoplastic film. The method may include attaching a first strand portion of thread to the first substrate via a first suture and attaching a second strand portion of thread to the second substrate via a second suture. Attaching the first strand portion of thread to the first substrate via the first suture and attaching the second strand portion of thread to the second substrate via the second suture may include using sutures formed of a thermoplastic material. Applying at least one of heat and pressure to the substrate stack may include: thermoforming the thermoplastic film of the first substrate and the first suture to bond the first strand portion to the first substrate, and thermoforming the thermoplastic film of the second substrate and the second suture to bond the second strand portion to the second substrate. In some examples, the method includes attaching a first strand portion of thread to the first substrate via a first suture and attaching a second strand portion of thread to the second substrate via a second suture. Attaching the first strand portion of thread to the substrate via the first suture and attaching the second strand portion of thread to the substrate via the second suture may include using sutures formed of a resin. Attaching a first strand of thread to the substrate via a first suture and attaching a second strand of thread to the substrate via a second suture may also include using sutures made of the same material as the substrate.

[0213] In some examples, attaching a first strand portion of thread to the substrate via a first suture and attaching a second strand portion of thread to the substrate via a second suture includes using a suture having a higher melting point than the substrate. Applying heat and pressure at least one of these can include activating the resin material bonded to at least one of the first and second strand portions. Applying heat and pressure at least one of these can include subjecting the substrate stack to at least one of vacuum molding and compression molding. The method can include forming the first and second strand portions from the same material. Additionally or alternatively, the method can include forming the first and second strand portions from different materials.

[0214] In some examples, 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 can include forming the first strand portion from at least one of carbon fibers, boron fibers, glass fibers, and polymer fibers. The method can also include forming a second strand portion from a second bundle of fibers. Forming the second strand portion from the second bundle of fibers can include forming the second strand portion from at least one of carbon fibers, boron fibers, glass fibers, and polymer fibers. In some examples, forming the second strand from the second bundle of fibers includes providing approximately the same number of fibers as the first bundle of fibers. Forming the second strand from the second bundle of fibers can include providing a different number of fibers than the first bundle of fibers.

[0215] In some configurations, the method includes providing first and second strand portions of different lengths. Additionally or alternatively, the method may include providing first and second strand portions of substantially the same length. Attaching at least one of the first strand portion to a first substrate and attaching the second strand portion to a second substrate may include forming a cavity in at least one of the first and second layers. The method may include exposing the substrate within the cavity. The method may also include providing first and second strand portions of different thicknesses. Additionally or alternatively, the method may include providing first and second strand portions of substantially the same thickness. In some examples, the first and second layers are provided with different thicknesses. The method may also include providing first and second layers of substantially the same thickness. Conforming the substrate stack to the shape of a first mold surface may include providing a front foot portion, a middle foot portion, and a heel portion for the substrate stack.

[0216] Another aspect of this disclosure provides a method for forming a plate for footwear. The method includes: providing a base having a forefoot region and a heel region; attaching a first thread portion to the base, the first thread portion having a plurality of segments extending between a first end disposed in the forefoot region and a second end disposed in the heel region; and causing the plurality of segments to cross in a midfoot region disposed between the forefoot region and the heel region.

[0217] In some implementations, attaching the first strand portion to the substrate includes attaching a continuous strand. Attaching the first strand portion to the substrate may include engaging respective first ends of the plurality of segments via a first surrounding portion and engaging respective second ends of the plurality of segments via a second surrounding portion to provide a continuous structure for the first strand portion. The method may also include extending the first strand portion to the upper of the footwear.

[0218] In some examples, the method includes extending a stretch strand between a first strand portion and the upper of the footwear. Extending the stretch strand between the first strand portion and the upper can include connecting the first strand portion and the upper via the stretch strand. The method can include attaching the stretch strand along at least one of the plurality of segments to the first strand portion between a first end and a second end. The method can also include extending the stretch strand between a shoelace and at least one of the plurality of segments, the shoelace being operable to move the upper between a tightened state and a relaxed state. Extending the stretch strand between the shoelace and at least one of the plurality of segments can include connecting the stretch strand to the shoelace and at least one of the plurality of segments.

[0219] In some configurations, the method includes providing a base with a spike member extending from a surface of the base. The method may include attaching a first strand portion to the surface of the base and extending the first strand portion around a portion of the spike member. The method may also include attaching the first strand portion to the surface of the base and surrounding at least one spike member of the spike members with the first strand portion. The method may further include attaching the first strand portion to the surface of the base and surrounding at least one spike member of the spike members with at least one of the plurality of segments. In some examples, the method includes weaving the plurality of segments together in a midfoot region.

[0220] The method may include forming a 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. Attaching the first strand portion to a substrate may include forming at least one cavity between at least two of the segments. The method may further include exposing the substrate within the at least one cavity. In some examples, the method includes defining the at least one space between a first bundle and a second bundle of the plurality of segments. The method may further include exposing the substrate within the at least one space.

[0221] 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 description, the drawings, and the aspects.

[0222] 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 length of the lever arm around the ankle. The mechanical demand 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 demand 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 length of the lever arm from the ankle joint by providing a rigid shoe plate including a curved portion opposite the MTP joint, thereby reducing the push-off torque at the ankle.

[0223] Reference Figures 1 to 3 The footwear 10 includes an upper 100 and a sole structure 200 attached to the upper 100. The footwear 10 can be divided into one or more parts. Each part may include a forefoot part 12, a midfoot part 14, and a heel part 16. During use of the shoe 10, the forefoot part 12 may correspond to the toes and the joints connecting the metatarsals and phalanges of the foot. The forefoot part 12 may correspond to the MTP joints of the foot. During use of the footwear 10, the midfoot part 14 may correspond to the arch region of the foot, and the heel part 16 may correspond to the posterior portion of the foot, including the calcaneus. The shoe 10 may include lateral portions 18 and medial portions 20, respectively corresponding to opposite sides of the shoe 10 and extending through each of the parts 12, 14, and 16.

[0224] The upper 100 includes an inner surface defining an internal cavity 102 that receives and secures the foot during use of the footwear 10 for supporting the foot on the sole structure 200. An ankle opening 104 located in the heel portion 16 provides an entrance to the internal cavity 102. For example, the ankle opening 104 may receive the foot to secure it within the cavity 102 and facilitate entry and exit of the foot from the internal cavity 102. In some examples, one or more fasteners 106 extend along the upper 100 to adjust the fit of the internal cavity 102 around the foot, while coordinating foot entry into and exit from the internal cavity. The upper 100 may include openings such as eyelets and / or other engagement features such as fabric 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.

[0225] The upper 100 may include a tongue portion 110 extending between the internal cavity 102 and the fastener 106. The upper 100 may be formed of one or more materials stitched or bonded together to form the internal cavity 102. Suitable materials for the upper may include, but are not limited to, fabrics, foams, leather, and synthetic leather. These materials may be selected and positioned to impart durability, breathability, abrasion resistance, flexibility, and comfort.

[0226] 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 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 arranged between the outsole 210 and the midsole 220 to separate the midsole 220 from the outsole 210. The midsole 220 may correspond to a conventional strobel. Therefore, unless otherwise stated, the terms "strobel" and "midsole" are used interchangeably when referring to element 220. 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 can be profiled to conform to the profile of the bottom surface of the foot (e.g., the sole) within the internal cavity 102. In some examples, the sole structure 200 may also include additional layers, such as the insole 260. Figure 2 and Figure 3 An additional layer, such as an insole, may be located within the internal cavity 102 of the upper 100 to receive the sole surface of the foot, thereby enhancing the comfort of the shoe 10. In some examples, a sidewall 230 surrounds at least a portion of the periphery of the cushioning member 250 and spaces the cushioning member 250 from the midsole / pad 220 to define a cavity 240 between the cushioning member 250 and the midsole / pad 220. For example, when the internal cavity 102 accommodates the foot, the sidewall 230 and the top surface 254 of the cushioning member 250 may cooperate to hold and support the foot on the cushioning member 250. For example, the sidewall 230 may define an edge around at least a portion of the periphery of the contoured top surface 254 of the cushioning member 250 to support the foot during walking or running activities during use of the shoe 10. When the cushioning member 250 is attached to the midsole 220, the edge may extend around the periphery of the midsole 220.

[0227] In some configurations, the plate 300 is arranged on the top surface 254 of the cushioning member 250 and beneath the midsole 220 to reduce energy loss at the MTP joint during running motion, while enhancing the foot's rolling motion as the shoe 10 rolls for ground engagement. The plate 300 may 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.

[0228] In some examples, the plate 300 includes a uniform local stiffness (e.g., tensile strength or flexural strength) over its entire surface area. The stiffness of the plate can be anisotropic, meaning that the stiffness in one direction across the plate differs from the stiffness in another direction. For example, the plate 300 can be formed from at least two fiber layers that are anisotropic to each other to apply gradient stiffness and gradient load paths across 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. In some configurations, the plate 300 is formed from one or more fiber bundle layers and / or fiber layers, the fibers including at least one of carbon fibers, boron fibers, glass fibers, and polymer fibers. In certain configurations, the fibers include carbon fiber or glass fiber, or a combination of carbon fiber and glass fiber. Fiber bundles can be attached to a substrate. The fiber bundles can be attached by sewing or using adhesives. Additionally or alternatively, the fiber bundles and / or fiber layers can be bonded with thermosetting polymers and / or thermoplastic polymers. Therefore, the plate 300 can have tensile or flexural strength in a transverse direction substantially perpendicular to the longitudinal axis L. The stiffness of the plate 300 can be selected for a specific wearer based on their tendon flexibility, calf muscle strength, and / or MTP joint flexibility. Furthermore, the stiffness of the plate 300 can also be customized based on an athlete's running motion. In other configurations, the plate 300 is formed from one or more layers / sheets of unidirectional bands. In some examples, each layer in the stack includes an orientation different from the layers arranged below. The plate can be formed from unidirectional bands, which include at least one of carbon fiber, boron fiber, glass fiber, and polymer fiber. In some examples, one or more materials forming plate 300 include a Young's modulus of at least 70 gigapascals (GPa).

[0229] In some implementations, plate 300 comprises a generally uniform thickness. In some examples, the thickness of plate 300 ranges from about 0.6 mm to about 3.0 mm. In one example, the thickness of the plate is substantially equal to 1.0 mm. In other implementations, the thickness of plate 300 is non-uniform, such that plate 300 can be defined in the midfoot portion 14 of sole structure 200 with a greater thickness than in the forefoot portion 12 and the heel portion 16.

[0230] In some examples, the outsole 210 may include a ground-contact 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, and the sidewall 230 extends from the periphery of the cushioning member 250 and is attached to the midsole 220 or the upper 100. Figure 1 The example shows an outsole 210 attached to the upper 100 near the tip of the forefoot portion 12. The outsole 210 typically provides abrasion resistance and 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 and enhance traction with the ground. For example, rubber can form at least a portion of the outsole 210.

[0231] The midsole / pad 220 may include a bottom surface 222 and a footbed 224 disposed on the side of the midsole 220 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 opposed to the inner surface 214 of the outsole 210 to define a space between the bottom surface 222 and the inner surface 214 of the outsole 210 for receiving a cushioning member 250.

[0232] Figure 2An 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 substantially 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. Here, a cavity 240 between the cushioning member 250 and the bottom surface 222 of the midsole 220 defines the remaining portion of the empty space accommodating the shoe plate 300. Thus, the cushioning member 250 and the plate 300 may substantially occupy the entire volume of space between the bottom surface 222 of the midsole 220 and the inner surface 214 of the outsole 210. The cushioning member 250 may be elastically compressible between the midsole 220 and the outsole 210. In some configurations, the cushioning member 250 corresponds to a sheet of polymer foam having a surface profile configured to receive the shoe plate 300 thereon. The cushioning member 250 can be formed from any suitable material that compresses elastically 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 cushioning member 250 can comprise approximately 0.05 grams per cubic centimeter (g / cm³). 3 (approximately 0.20 g / cm³) 3 The density is within a certain range. In some examples, the density of the buffer member 250 is approximately 0.1 g / cm³. 3 Furthermore, the buffer member 250 may include a hardness in the range of about eleven (11) Shore A to about fifty (50) Shore A. One or more materials forming the buffer member 250 may be adapted to provide at least sixty percent (60%) of the energy return.

[0233] In some examples, a fluid-filled bladder 400 is arranged in at least one portion 12, 14, 16 of the sole structure 200 between the plate 300 and the cushioning member 250 to enhance the cushioning properties of the shoe 10 in response to ground reaction forces. For example, the fluid-filled bladder 400 may define an internal cavity that contains pressurized fluid and provides a durable sealing barrier for retaining the pressurized fluid therein. The pressurized fluid may be air, nitrogen, helium, or a dense gas such as sulfur hexafluoride. The fluid-filled bladder may additionally or alternatively contain a liquid or gel. In other examples, the fluid-filled bladder 400 is arranged between the cushioning member 250 and the outsole 210, or between the plate 300 and the midsole 220. Figure 2 and Figure 3A fluid-filled bladder 400 is shown located in the heel portion 16 of the sole structure 200 to help dampen the initial impact with the ground occurring in the heel portion 16. In other configurations, one or more fluid-filled bladders 400 may additionally or alternatively extend through the midfoot portion 14 and / or forefoot portion 12 of the sole structure 200. When the sole structure 200 is under load, the cushioning member 250 and the fluid-filled bladders 400 can cooperate to enhance functionality and cushioning properties.

[0234] 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 arranged near the heel portion 16 of the sole structure 200, and the second end 302 may be arranged near the forefoot portion 12 of the sole structure 200. The first end 301 may also be referred to as the “rear 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 side portion 18 and the inner side portion 20. Thus, the length, width, and thickness of the plate 300 may substantially occupy the cavity 240 defined by the top surface 254 of the cushioning member 250 and the bottom surface 222 of the midsole, and may extend through the forefoot portion 12, midfoot portion 14, and heel portion 16 of the sole structure 200, respectively. In some examples (e.g., Figure 35 The periphery of the shoe plate 300 can be seen along the outer side 18 and / or the inner side 20 of the shoe 10.

[0235] Reference Figure 3 ,along Figure 1 The partial cross-sectional view taken by line 3-3 shows the shoe plate 300 arranged between the cushioning member 250 and the midsole 220, and the cushioning member 250 arranged between the outsole 210 and the shoe plate 300. The insole 260 can be arranged on the footbed 224 within the internal cavity 102 and is located under the foot. Figure 3A cushioning member 250 is shown, which defines a reduced thickness to house a fluid-filled bladder 40 within the heel region 16. In some examples, the cushioning member 250 encloses the bladder 400, while in other examples, the cushioning member 250 only defines a cutout for receiving the bladder 400. In some configurations, a portion of the plate 300 is in direct contact with the fluid-filled bladder 400. The cushioning member 250 may define 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 includes a surface profile contoured to match the surface profile of the plate 300 such that the plate 300 and the cushioning member 250 fit flush with each other. The cushioning member 250 may be defined in the forefoot portion 12 of the sole structure with a thickness ranging 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.

[0236] In some configurations, for example, in Figure 33 and Figure 34 In the shoe plate 10f, the shoe with spikes for track and field events—that is, the "track and field shoe"—includes a cushioning member 250f with a reduced thickness of about eight (8) mm located between the plate 300 and the outsole 210 within the forefoot portion 12. Figure 34 In these configurations, the cushioning member 250 may not be present between the plate 300 and the outsole 210 within the forefoot portion 12. Furthermore, cushioning material associated with the same cushioning member 250 or different cushioning members may be arranged between the plate 300 and the midsole 220 and extend through the forefoot portion 12, the midfoot portion 14, and the heel portion 16, respectively.

[0237] 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 rear point 301. The curved region 310 is associated with a radius of curvature about 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 and the foremost point (AMP) 302 (e.g., the second end 302) of the plate 300, while the rear curved portion 324 extends between the MTP point 320 and a rear point 326 disposed 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 mirror-image of the 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 include 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 includes 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. Additionally or alternatively, 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 herein, the term “generally flat” refers to a flat area within five (5) degrees horizontally, that is, within five (5) degrees parallel to the ground 312.

[0238] MTP point 320 is the closest point between the plate 300 and the inner surface 214 of the outsole 210, while the rear points 326 and AMP 302 of the plate 300 are positioned further away from the outsole 210 than MTP point 320. In some configurations, the rear points 301 and AMP 302 are coplanar. In some examples, when the foot is housed within the internal cavity 102 of the upper 100, the MTP point 320 of the plate 300 is positioned directly below the MTP joint of the foot. In other examples, the MTP point 320 is positioned 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 provide longitudinal stiffness to the plate 300, which reduces energy loss near the MTP joint of the foot during running motion and enhances foot roll, thereby reducing lever arm distance and relieving stress on the ankle joint.

[0239] In some implementations, AMP 302 and rear point 326 are located approximately equal to the position height H above MTP point 320. Here, position height H extends from MTP 320 along a direction approximately perpendicular to the longitudinal axis L of sole structure 200. Height H ranges from about three (3) millimeters (mm) to about twenty-eight (28) millimeters. In other examples, height H ranges from about three (3) millimeters to about seventeen (17) millimeters. In one example, height H is equal to about seventeen (17) millimeters. Therefore, since the fore-bend portion 322 extends from MTP point 320 toward AMP 302 away from outsole 210, the toes of the foot located above the fore-bend portion 322 can be biased upward. Additionally or alternatively, 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 line extends along a length L, approximately parallel to the longitudinal axis, between MTP point 320 and the corresponding point AMP 302 and AMP 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% (25%) to approximately 35% (35%) of the total length of the board 300, 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 L P The length of the flat region 312 is approximately equal to that of the curved region 310. The radius of curvature of the curved region 310 is changed so that the length L... A and L P And / or the height (H) of the foremost point 302 and the rearmost point 306 changes relative to the MTP point 320. For example, decreasing the radius of curvature increases the angle between the MTP point 320 and AMP 302, and also increases the height H of AMP 302 above the MTP point 320. In configurations where the curved portions 322 and 324 each include different radii of curvature, the corresponding length L A and L P And / or the height 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.

[0240] In some implementations, the MTP point 320 is positioned 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 (i.e., the concave portion) is associated with a constant radius of curvature extending from AMP 302 through the MTP point 320. In some examples, the constant radius of curvature may extend from AMP 302 through the MTP point 320 to at least forty percent (40%) of the total length of the plate relative to AMP 302.

[0241] Figures 4 to 6 Footwear 10a is provided, comprising an upper 100 and a sole structure 200a attached to the upper 100. Given the substantial structural and functional similarity of the components associated with footwear 10a with respect to footwear 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.

[0242] The sole structure 200a may include an outsole 210, a first cushioning member 250a, a shoe plate 300, a second cushioning member 270, and a midsole / pad 220a arranged in a layered configuration. Figure 5An exploded view of footwear 10a is provided, showing a sole structure 200a (e.g., outsole 210, cushioning member 250a, cushioning member 270, plate 300, and midsole 220a) defining a longitudinal axis L. The outsole 210 includes an inner surface 214 disposed on the side of the outsole 210 opposite to the ground contact surface 212. The midsole 220a includes a bottom surface 222a disposed on the side of the midsole 220a opposite to the footbed 224 and opposite the inner surface 214 of the outsole 210.

[0243] A cushioning member 250a, a shoe plate 300, and a second cushioning member 270 are arranged between an inner surface 214 and a bottom surface 222a to separate the midsole 220a from the outsole 210. For example, the first cushioning member 250a includes a bottom surface 252 received by the inner surface 214 of the outsole 210 and a top surface 254a arranged on the side of the cushioning member 250a opposite to the bottom surface 252 and opposite the midsole 220a to support the shoe plate 300 thereon. The second cushioning member 270 is arranged on the side of the shoe plate 300 opposite to the first cushioning member. For example, the second cushioning member 270 includes a bottom surface 272 opposite to the shoe plate 300 and a top surface 274 arranged on the side of the second cushioning member 270 opposite to the bottom surface 272 and opposite to the bottom surface 222a of the midsole 220a. The top surface 274 may be profiled to conform to the profile of the bottom surface (e.g., sole) of the foot within the internal cavity 102. Figures 1 to 3 Like the cushioning member 250, the second cushioning member 270 may define a sidewall 230a that surrounds at least a portion of the periphery of the second cushioning member 270. The sidewall 230a may define an edge that extends around the periphery of the midsole 220a when the second cushioning member 270 is attached to the midsole 220a.

[0244] In some configurations, the total thickness of the first buffer member 250a and the second buffer member 270 is respectively equal to Figures 1 to 3 The thickness of the cushioning member 250 of the footwear 10. The thickness of the first cushioning member 250 may be the same as or different from the thickness of the second cushioning member 270. The first cushioning member 250a and the second cushioning member 270 are operable to embed or sandwich the shoe plate 300 between the first cushioning member 250a and the second cushioning member 270, such that the shoe plate 300 is separated from the inner surface 214 of the outsole 210 and the bottom surface 222a of the midsole 220a. Therefore, the cushioning members 250a, 270 and the plate 300 can substantially occupy the entire space volume between the bottom surface 222a of the midsole / pad 220 and the inner surface 214 of the outsole 210.

[0245] The cushioning members 250a and 270 can be elastically compressed between the insole 220 and the outsole 210. The cushioning members 250a and 270 can each be formed from a sheet of polymer foam, which can be formed from... Figures 1 to 3 The cushioning members 250 are formed of the same or more materials. For example, cushioning members 250a and 270 may be formed of one or more of EVA copolymers, polyurethanes, polyethers, olefin block copolymers, PEBA copolymers, and / or TPU. In some implementations, cushioning members 250a and 270 provide different cushioning properties. For example, the first cushioning member 250a may elastically compress under applied load to prevent the plate 300 from translating into contact with the ground, while the second cushioning member 270 may provide a degree of soft cushioning for the foot to reduce ground reaction forces and enhance the comfort of the wearer's foot. The sole structure 200a may also include a fluid-filled bladder 400 located in at least one portion 12, 14, 16 of the sole structure between the plate 300 and the first cushioning member 250a to enhance the cushioning properties of the shoe 10 in response to ground reaction forces. For example, the bladder 400 may be filled with a pressurized fluid, such as air, nitrogen, helium, sulfur hexafluoride, or a liquid / gel. Therefore, the cushioning members 250a and 270, separated by the plate 300 and the fluid-filled bladder 400, can cooperate to provide gradient cushioning to the footwear 10a, which varies with the applied load (i.e., the greater the load, the more the cushioning members 250a and 270 are compressed, and therefore the better the shoe responds). The cushioning members 250a and 270 can include a density of approximately 0.20 g / cm³. 3 To approximately 0.05 g / cm 3 Density within a certain range. In some examples, the density of buffer components 250a and 270 is approximately 0.1 g / cm³. 3 Furthermore, the buffer members 250a, 270 may include a hardness in the range of about eleven (11) Shore A to about fifty (50) Shore A. One or more materials forming the buffer members 250a, 270 may be adapted to provide at least sixty percent (60%) of the energy return.

[0246] The shoe plate 300 is defined by a length extending between a first end 301 and a second end 302 (e.g., AMP 302), which may be the same as or less than the length of the cushioning members 250a and 270. The length, width, and thickness of the plate 300 may substantially occupy the volume between the top surface 254 of the first cushioning member 250 and the bottom surface 272 of the second cushioning member 270, and may extend through the forefoot portion 12, midfoot portion 14, and heel portion 16 of the sole structure 200a, respectively. In some examples, the plate 300 extends through the forefoot portion 12 and midfoot portion 14 of the sole structure 200a, but is not present in the heel portion 16. In some examples, the periphery of the shoe plate 300 is visible along the outer side 18 and / or inner side 20 of the shoe 10a. In some implementations, the top surface 254 of the first cushioning member 250a and the bottom surface 272 of the second cushioning member 270 are smooth and include surface profiles that are contoured to the opposite sides of the mating shoe plate 300 so that the shoe plate 300 fits flush with each of the cushioning members 250a, 270.

[0247] As shown above (refer to the reference) Figures 1 to 3 As described, the shoe plate 300 may include a uniform local stiffness, which may be anisotropic or non-anisotropic. For example, the plate 300 may be formed of one or more fiber layers and / or fiber bundles, the fibers including at least one of carbon fiber, boron fiber, glass fiber, and polymer fiber. Therefore, the plate 300 may provide a stiffness greater along the longitudinal direction of the sole structure than its stiffness in a direction transverse to (e.g., perpendicular to) the longitudinal axis L. For example, the stiffness of the plate 300 in the transverse direction may be at least 10% less than its stiffness in the longitudinal direction, or it may be about 10% to 20% of the stiffness of the plate 300 in the longitudinal direction (e.g., parallel to the longitudinal axis L). Furthermore, the plate 300 may include a substantially uniform thickness ranging from about 0.6 mm to about 3.0 mm, or a non-uniform thickness varying on the plate, for example, the thickness of the plate 300 in the midfoot portion 14 is greater than its thickness in the forefoot portion 12 and the heel portion 16.

[0248] Figure 6 Provided along Figure 4A partial cross-sectional view taken by line 6-6 shows a shoe plate 300 disposed between a first cushioning member 250a and a second cushioning member 270. Accordingly, the first cushioning member 250a is disposed between the outsole 210 and the shoe plate 300, and the second cushioning member 270 is disposed between the midsole 220a and the shoe plate 300. An insole 260 may be disposed within an internal cavity 102 on a footbed 224 and under the foot. The first cushioning member 250a may enclose the bladder 400 or define a cutout for receiving the bladder 400, while a portion of the plate 300 may be in direct contact with the bladder 400. In some configurations, the first cushioning member 250a defines a greater thickness in the heel portion 16 of the sole structure 200a than in the forefoot portion 12, and the top surface 254 includes a surface profile contoured to match the surface profile of the shoe plate 300 supported on the top surface 254. The second cushioning member 270 may cooperate with the first cushioning member 250a to define a space for enclosing the shoe plate 300 between the first cushioning member 250a and the second cushioning member 270. For example, a portion of the bottom surface 272 of the second cushioning member 270 and a portion of the top surface 254 of the first cushioning member 250a may be recessed to define a cavity for retaining the shoe plate 300. In some implementations, the thickness of the second cushioning member 270 is greater than the thickness of the first cushioning member 250a in the forefoot portion 12 and the midfoot portion 14, respectively. Advantageously, the increased thickness in the forefoot portion 12 and the midfoot portion 14 provided by the second cushioning member 270 increases the spacing between the MTP joint of the foot and the shoe plate 300, and thus enhances the cushioning characteristics of the shoe 10a in response to ground reaction forces during running movements / actions. In some configurations, the thickness of the second buffer member 270 at a position opposite the MTP point 320 of the plate 300 is greater than the thickness of the first buffer member 250a at the same position. In these configurations, the second buffer member 270 may have a maximum thickness defined at the position opposite the MTP point 320, which is equal to a value in the range of about 3.0 mm to about 13.0 mm. In one example, the maximum thickness is about 10.0 mm. The thickness of the second buffer member 270 may gradually decrease along the direction from the MTP point 320 to the AMP 302, such that the thickness of the second buffer member 270 near the AMP 302 is about sixty percent (60%) less than the maximum thickness near the MTP point 320. On the other hand, the first buffer member 250a may have a minimum thickness defined at a position opposite the MTP point 320, which is equal to a value in the range of about 0.5 mm to about 6.0 mm. In one example, the minimum thickness is about 3.0 mm.

[0249] The shoe plate 300 includes a curved region 310 extending through the forefoot portion 12 and the midfoot portion 14, and the shoe plate 300 may optionally include a generally flat region 312 extending from a rear point 326 at the curved region 310 through the heel portion 16 to the last point 301 of the plate 300. The radius of curvature of the curved region 310 defines a forward curved portion 322 extending between the MTP point 320 of the sole structure 200a and the AMP 302 at the toe tip, and a rear curved portion 322 extending between the MTP point 320 and the rear point 326. In some configurations, the forward curved portion 322 and the rear curved portion 324 each include the same radius of curvature mirrored with respect to the MTP point 320. In other configurations, the curved portions 322 and 324 are each associated with different radii of curvature. Thus, the curved portions 322 and 324 may each include 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 curved regions 322, 324 can range from about 200 mm to about 400 mm. In some configurations, the front curved portion 322 includes a radius of curvature that continues the curvature of the rear curved portion 324, such that the curved portions 322, 324 define the same radius of curvature and share the same vertex. Additionally or alternatively, the plate can define the radius of curvature connecting the rear curved portion 324 of the plate 300 to the generally flat region 312. As used herein, the term "generally flat" means a flat region 312 that is parallel to the ground within five (5) degrees horizontally, i.e., within five (5) degrees.

[0250] The curved portions 322 and 324 may each occupy approximately 30% (30%) of the total length of the plate 300, while the length of the flat region 312 may occupy the remaining 40% (40%) of the length of the plate 300. The forward curved portion 322 and the rear curved portion 324 of the curved region 310 provide longitudinal stiffness to the plate 300, which reduces energy loss near the MTP joint near the foot during running motion and enhances foot roll, thereby reducing lever arm distance and relieving stress on the ankle joint. AMP 302 and rear point 326 are located above the MTP point 320 and may be located approximately equal to the position height H above the MTP point 320. Furthermore, the length L of the forward curved portion 322... A And the length L of the 324-fold bend in the back section P (For example, measurements taken along a line extending approximately parallel to the longitudinal axis L between MTP point 320 and the corresponding point between AMP 302 and AMP 326) may be substantially equal to each other or may be different. See above for reference. Figures 1 to 3 As described, changing the radius of curvature of the curved region 310 makes the length L A and L PAnd / or the height (H) of the foremost point 302 and the rearmost point 306 is changed relative to the MTP point 320. In this case, the stiffness of the plate 300 can be varied to provide a custom-made shoe plate 300 tailored to the wearer's shoe size, the intended use of the shoe 10, and / or the anatomical characteristics of the wearer's foot.

[0251] Figures 7 to 9 Footwear 10b is provided, comprising an upper 100 and a sole structure 200b attached to the upper 100. Given the substantial structural and functional similarity of the components associated with footwear 10b with respect to footwear 10b, 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.

[0252] Figure 8 An exploded view of footwear 10b is provided, showing a sole structure 200b. The sole structure 200b includes an outsole 210b, a cushioning member 250b, and a midsole / pad 220b, arranged in a layered configuration and defining a longitudinal axis L. The outsole 210b includes an inner surface 214b disposed on the side of the outsole 210b opposite to the ground contact surface 212. The midsole 220b includes a bottom surface 222b disposed on the side of the midsole 220b opposite to the footbed 224. The cushioning member 250b is disposed between the inner surface 214b and the bottom surface 222b to separate the midsole 220b from the outsole 210b. For example, the cushioning member 250a includes a bottom surface 252b opposite to the inner surface 214b of the outsole 210 and a top surface 254b disposed on the side of the cushioning member 250b opposite to the bottom surface 252b and opposite the midsole 220b. The top surface 254b can be profiled to conform to the profile of the bottom surface (e.g., the sole of a foot) within the internal cavity 102. Figures 1 to 3 Like the cushioning member 250 of the product, the cushioning member 250b may define a sidewall 230b that surrounds at least a portion of the periphery of the cushioning member 250b. The sidewall 230b may define an edge that extends around the periphery of the midsole 220b when the cushioning member 250b is attached to the midsole 220b.

[0253] The cushioning member 250b can be elastically compressed between the midsole 220b and the outsole 210b, and can be formed by... Figures 1 to 3The cushioning member 250b is formed of the same one or more materials. For example, the cushioning member 250b may be formed of one or more of EVA copolymer, polyurethane, polyether, olefin block copolymer, PEBA copolymer, and / or TPU. The sole structure 200a may also include a fluid-filled bladder 400 located in at least one portion 12, 14, 16 of the sole structure between the shoe plate 300 and the first cushioning member 250a to enhance the cushioning properties of the shoe 10 in response to ground reaction forces. For example, the bladder 400 may be filled with a pressurized fluid, such as air, nitrogen, helium, sulfur hexafluoride, or a liquid / gel.

[0254] In some configurations, the cushioning member 250b defines a cavity 240b (e.g., a sleeve) in the internal portion between the top surface 254b and the bottom surface 252b, and in the heel portion 16 of the sole structure 200b. Figure 9 Provided along Figure 7 The partial cross-sectional view taken by line 9-9 shows a generally flat region 312 of the shoe plate 300 housed within the cavity 240b of the cushioning member 250b and a curved region 310 exposed from the cavity 240b between the bottom surface 252b of the cushioning member 250b and the inner surface 214b of the outsole 210b. Figure 9 The bottom surface 252b of the buffer member 250b is shown, defining an access opening 242 leading to the cavity 240b for receiving a generally flat portion 312 of the plate 300. The cavity 240b may abut against a cutout formed within the buffer member 250b for embedding a fluid-filled bladder 400. Therefore, by Figures 7 to 9 The sole structure 200b of the footwear 10b includes a bottom surface 252b of a cushioning member 250b, which is attached in the heel portion 16 to the inner surface 214b of the outsole 210b. A curved region 310 of the plate 300 extending from the cavity 240b of the cushioning member 250b at the access opening 242 directly contacts the inner surface 214 in the forefoot portion 12 and the midfoot portion 14, respectively. Therefore, the cavity 240b defined by the cushioning member 250b is operable to embed / enclose at least a portion of the plate 300 (e.g., the flat region 312) within the cavity 240b. Figures 1 to 3 Like the plate 300, the cushioning member 250b and the plate 300 can substantially occupy the entire space volume between the bottom surface 222b of the midsole 220b and the inner surface 214b of the outsole 210b.

[0255] The insole 260 can be disposed within the internal cavity 102 on the footbed 224 and under the foot. The cushioning member 250b can enclose the bladder 400 or define a cutout for receiving the bladder 400, while a portion of the plate 300 can be in direct contact with the bladder 400. The cutout for receiving the bladder 400 can abut against a cavity 240b formed by the cushioning member 250b. In some configurations, the cushioning member 250b has a greater thickness in the heel portion 16 of the sole structure 200b than in the forefoot portion 12. In some examples, the thickness of the cushioning member 250b, which separates the bottom surface 222b of the midsole 220b from the plate 300, is greater near the curved region 310 of the plate 300 than near the generally flat region 312 of the plate 300. In these examples, the cushioning member 250b is operable to increase the spacing between the plate 300 and the midsole 220b, thereby preventing the MTP joint of the foot from contacting the plate 300 during running movements / actions during use of the shoe 10b. The cushioning member 250b may be defined in the forefoot portion 12 of the sole structure 200b with a thickness ranging from about seven (7) millimeters (mm) to about twenty (20) millimeters. In one example, the thickness of the cushioning member 250b in the forefoot portion 12 is about twelve (12) millimeters. The cushioning member 250b may include a thickness of about 0.05 grams per cubic centimeter (g / cm³). 3 (approximately 0.20 g / cm³) 3 The density is within a certain range. In some examples, the density of the buffer member 250b is approximately 0.1 g / cm³. 3 Furthermore, the buffer member 250b may include a hardness in the range of about eleven (11) Shore A to about fifty (50) Shore A. One or more materials forming the buffer member 250b may be adapted to provide at least sixty percent (60%) of the energy return.

[0256] As shown above (refer to the reference) Figures 1 to 3As described, the shoe plate 300 may include a uniform local stiffness, which may be anisotropic or non-anisotropic. For example, the plate 300 may be formed from one or more fiber bundles, the fibers including at least one of carbon fiber, boron fiber, glass fiber, and polymer fiber. Therefore, the plate 300 may provide a stiffness greater along the longitudinal direction of the sole structure than its stiffness in a direction transverse to (e.g., perpendicular to) the longitudinal axis L. For example, the stiffness of the plate 300 in the transverse direction may be about 10% to 20% of the stiffness of the plate 300 in the longitudinal direction (e.g., parallel to the longitudinal axis L). Furthermore, the plate 300 may include a substantially uniform thickness ranging from about 0.6 mm to about 3.0 mm, or a non-uniform thickness varying across the plate, for example, the thickness of the plate 300 in the midfoot portion 14 is greater than the thickness in the forefoot portion 12 and the heel portion 16. In some examples, the plate 300 includes a thickness equal to about 1.0 mm.

[0257] The radius of curvature of the curved region 310 defines a forward curved portion 322 extending between the MTP point 320 of the sole structure 200b and the AMP 302 at the toe tip, and a rear curved portion 322 extending between the MTP point 320 and the rear point 326. In some configurations, the forward curved portion 322 and the rear curved portion 324 each include the same radius of curvature mirrored with respect to the MTP point 320. In other configurations, the curved portions 322 and 324 are each associated with different radii of curvature. The curved portions 322 and 324 may each occupy approximately thirty percent (30%) of the total length of the plate 300, while the length of the flat region 312 may occupy the remaining forty percent (40%) of the length of the plate 300. The forward bend 322 and the backward bend 324 of the bending region 310 provide longitudinal stiffness to the plate 300, which reduces energy loss near the MTP joint close to the foot during running motion and enhances foot roll, thereby reducing lever arm distance and relieving stress on the ankle joint. AMP 302 and the rear point 326 are located above the MTP point 320 and can be located approximately equal to the position height H above the MTP point 320. Furthermore, the length L of the forward bend 322... A and the length L of the back bend portion 324 P (For example, measurements taken along a line extending approximately parallel to the longitudinal axis L between MTP point 320 and the corresponding point between AMP 302 and AMP 326) may be substantially equal to each other or may be different. See above for reference. Figures 1 to 3 As described, changing the radius of curvature of the curved region 310 makes the length L A and L PAnd / or the height (H) of the foremost point 302 and the rearmost point 306 is changed relative to the MTP point 320. In this case, the stiffness of the plate 300 can be varied to provide a custom-made shoe plate 300 tailored to the wearer's shoe size, the intended use of the shoe 10, and / or the anatomical characteristics of the wearer's foot.

[0258] Figures 10 to 12 Footwear 10c is provided, comprising an upper 100 and a sole structure 200c attached to the upper 100. Given the substantial structural and functional similarity of the parts associated with footwear 10c with respect to footwear 10c, the same reference numerals are used hereinafter and in the accompanying drawings to identify the same parts, while the same reference numerals including letter extensions are used to identify those parts that have been modified.

[0259] Figure 11 An exploded view of footwear 10c is provided, showing a sole structure 200c. The sole structure 200c includes an outsole 210bc, a cushioning member 250c, and a midsole / pad 220c arranged in a layered configuration and defining a longitudinal axis L. The outsole 210c includes an inner surface 214c disposed on the side of the outsole 210c opposite to the ground contact surface 212. The midsole 220c includes a bottom surface 222c disposed on the side of the midsole 220c opposite to the footbed 224. The cushioning member 250c is disposed between the inner surface 214c and the bottom surface 222c to separate the midsole 220c from the outsole 210c. For example, the cushioning member 250c includes a bottom surface 252c opposite to the inner surface 214c of the outsole 210c and a top surface 254c disposed on the side of the cushioning member 250c opposite to the bottom surface 252c and opposite the midsole 220c. The top surface 254c can be profiled to conform to the profile of the bottom surface of the foot (e.g., the sole) within the internal cavity 102. Figures 1 to 3 Like the cushioning member 250 of the product, the cushioning member 250c may define a sidewall 230c that surrounds at least a portion of the periphery of the second cushioning member 250c. The sidewall 230c may define an edge that extends around the periphery of the midsole 220c when the cushioning member 250c is attached to the midsole 220c.

[0260] The cushioning member 250c can be elastically compressed between the midsole 220c and the outsole 210c, and can be formed by... Figures 1 to 3The cushioning member 250c is formed of the same one or more materials. For example, the cushioning member 250c may be formed of one or more of EVA copolymer, polyurethane, polyether, olefin block copolymer, PEBA copolymer and / or TPU. The sole structure 200c may also include a fluid-filled bladder 400 located in at least one portion 12, 14, 16 of the sole structure 200c between the shoe plate 300 and the cushioning member 250c to enhance the cushioning properties of the shoe 10c in response to ground reaction forces. For example, the bladder 400 may be filled with a pressurized fluid, such as air, nitrogen, helium, sulfur hexafluoride or a liquid / gel. The cushioning member 250c may include a concentration of about 0.05 grams per cubic centimeter (g / cm³). 3 (approximately 0.20 g / cm³) 3 The density is within a certain range. In some examples, the density of the cushioning member 250c is approximately 0.1 g / cm³. 3 Furthermore, the buffer member 250 may include a hardness in the range of about eleven (11) Shore A to about fifty (50) Shore A. One or more materials forming the buffer member 250c may be adapted to provide at least sixty percent (60%) of the energy return.

[0261] In some configurations, the cushioning member 250c defines a cavity 240c (e.g., a sleeve) in the inner portion between the top surface 254c and the bottom surface 252c, and in the forefoot portion 12 and midfoot portion 12 of the sole structure 200c, respectively. Figure 12 Provided along Figure 10 The partial cross-sectional view taken by line 12-12 shows the curved region 310 of the shoe plate 300 housed in the cavity 240c of the cushioning member 250c and the generally flat region 312 exposed from the cavity 240c between the top surface 254c of the cushioning member 250c and the bottom surface 222c of the midsole 220c. Figure 12 The top surface 254c of the buffer member 250c is shown, defining an entry opening 242c leading to the cavity 240c for receiving the curved region 310 of the plate 300. Therefore, by Figures 10 to 12The footwear 10c incorporates a sole structure 200c including a top surface 254c of a cushioning member 250c, which is attached to the bottom surface 222c of the midsole 220c in the forefoot portion 12 and the midfoot portion 14, respectively. A generally flat region 312 of the plate 300 extending from the cavity 240c of the cushioning member 250c at the entry opening 242c is in direct contact with the bottom surface 222c in the heel portion 16. The entire bottom surface 252c of the cushioning member 250c is attached to the inner surface 214c of the outsole 210c. Thus, the cavity 240c defined by the cushioning member 250c is operable to embed / enclose at least a portion of the plate 300 (e.g., the bending region 310) within the cavity 240c. In other words, the bending region 310 of the MTP joint of the plate's support foot is separated from the outsole 210c and the midsole 220c by the corresponding portions of the cushioning member 250c on opposite sides of the cavity 240c. Figures 1 to 3 Like the plate 300, the cushioning member 250c and the plate 300 can substantially occupy the entire volume of space between the bottom surface 222c of the midsole 220c and the inner surface 214c of the outsole 210c. The insole 260 can be arranged within the internal cavity 102 on the footbed 224 and under the foot. The cushioning member 250c can enclose the bladder 400 or define a cutout for receiving the bladder 400, while a portion of the plate 300 can be in direct contact with the bladder 400. In some configurations, the cushioning member 250c is defined with a greater thickness in the heel portion 16 of the sole structure 200c than in the forefoot portion 12. The cushioning member 250c can be defined with a thickness in the forefoot portion 12 of the sole structure 200c ranging from about seven (7) millimeters (mm) to about twenty (20) millimeters (mm). In one example, the thickness of the cushioning member 250c in the forefoot portion 12 is about twelve (12) millimeters (mm). In some implementations, the thickness of the cushioning member 250c in the forefoot portion 12, between the plate 300 and the bottom surface 222c of the midsole 220c, ranges from about three (3) mm to about twenty-eight (28) mm. Additionally or alternatively, the thickness of the cushioning member 250c in the forefoot portion 12, between the plate 300 and the inner surface 214c of the outsole 210c, ranges from about two (2) mm to about thirteen (13) mm.

[0262] As shown above (refer to the reference) Figures 1 to 3As described, the shoe plate 300 may include a uniform local stiffness, which may be anisotropic or non-anisotropic. For example, the plate 300 may be formed from one or more fiber bundles, the fibers including at least one of carbon fiber, boron fiber, glass fiber, and polymer fiber. Therefore, the plate 300 may provide a stiffness greater along the longitudinal direction of the sole structure than its stiffness in a direction transverse to (e.g., perpendicular to) the longitudinal axis L. For example, the stiffness of the plate 300 in the transverse direction may be about 10% to 20% of the stiffness of the plate 300 in the longitudinal direction (e.g., parallel to the longitudinal axis L). Furthermore, the plate 300 may include a substantially uniform thickness in the range of about 0.6 mm to about 3.0 mm, or a non-uniform thickness varying on the plate, for example, the thickness of the plate 300 in the midfoot portion 14 is greater than the thickness in the forefoot portion 12 and the heel portion 16.

[0263] The radius of curvature of the curved region 310 defines a forward curved portion 322 extending between the MTP point 320 of the sole structure 200a and the AMP 302 at the toe tip, and a rear curved portion 322 extending between the MTP point 320 and the rear point 326. In some configurations, the forward curved portion 322 and the rear curved portion 324 each include the same radius of curvature mirrored with respect to the MTP point 320. In other configurations, the curved portions 322 and 324 are each associated with different radii of curvature. The curved portions 322 and 324 may each occupy approximately thirty percent (30%) of the total length of the plate 300, while the length of the flat region 312 may occupy the remaining forty percent (40%) of the length of the plate 300. The forward bend 322 and the rear bend 324 of the bend region 310 provide longitudinal stiffness to the plate 300, which reduces energy loss near the MTP joint close to the foot during running motion and enhances foot roll, thereby reducing lever arm distance and alleviating stress on the ankle joint. In other configurations, the bends 322 and 324 may each occupy approximately 25% to approximately 35% (35%) of the total length of the plate 300. AMP 302 and the rear point 326 are located above the MTP point 320 and may be located approximately equal to the position height H above the MTP point 320. Furthermore, the length L of the forward bend 322... A and the length L of the back bend portion 324 P (For example, measurements taken along a line extending approximately parallel to the longitudinal axis L between MTP point 320 and the corresponding point between AMP 302 and AMP 326) may be substantially equal to each other or may be different. See above for reference. Figures 1 to 3 As described, changing the radius of curvature of the curved region 310 makes the length L A and L PAnd / or the height (H) of the foremost point 302 and the rearmost point 306 is changed relative to the MTP point 320. In this case, the stiffness of the plate 300 can be varied to provide a custom-made shoe plate 300 tailored to the wearer's shoe size, the intended use of the shoe 10, and / or the anatomical characteristics of the wearer's foot.

[0264] Figures 13 to 15 A footwear article 10d is provided, comprising an upper 100 and a sole structure 200d attached to the upper 100. Given the substantial structural and functional similarity of the parts associated with the footwear article 10d with respect to the footwear article 10d, the same reference numerals are used hereinafter and in the accompanying drawings to identify the same parts, while the same reference numerals including letter extensions are used to identify those parts that have been modified.

[0265] Figure 14 An exploded view of a footwear product 10d is provided, showing a sole structure 200d. The sole structure 200d includes an outsole 210d, a cushioning member 250d, and a midsole 220d arranged in a layered configuration and defining a longitudinal axis L. The outsole 210d includes an inner surface 214d disposed on the side of the outsole 210d opposite to the ground contact surface 212. The midsole 220d includes a bottom surface 222d disposed on the side of the midsole 220d opposite to the footbed 224. The cushioning member 250d is disposed between the inner surface 214d and the bottom surface 222d to separate the midsole 220d from the outsole 210d. For example, the cushioning member 250d includes a bottom surface 252d opposite to the inner surface 214d of the outsole 210d and a top surface 254d disposed on the side of the cushioning member 250d opposite to the bottom surface 252d and opposite the midsole 220d. The top surface 254d can be profiled to conform to the profile of the bottom surface of the foot (e.g., the sole) within the internal cavity 102. Figures 1 to 3 Like the cushioning member 250 of the article, the cushioning member 250d can define a sidewall 230d surrounding at least a portion of the periphery of the cushioning member 250d. The sidewall 230d can define an edge extending around the periphery of the midsole 220d when the cushioning member 250d is attached to the midsole 220d. The cushioning member 250d can be elastically compressed between the midsole 220d and the outsole 210d, and can be formed by... Figures 1 to 3 The cushioning member 250d is formed of the same one or more materials. For example, the cushioning member 250d may be formed of one or more of EVA copolymer, polyurethane, polyether, olefin block copolymer, PEBA copolymer and / or TPU. The cushioning member 250d may include approximately 0.05 grams per cubic centimeter (g / cm³). 3 (approximately 0.20 g / cm³) 3 Density within a certain range. In some examples, the density of the cushioning member 250d is approximately 0.1 g / cm³. 3Furthermore, the buffer member 250d may include a hardness in the range of about eleven (11) Shore A to about fifty (50) Shore A. One or more materials forming the buffer member 250d may be adapted to provide at least sixty percent (60%) of the energy return.

[0266] In some configurations, the cushioning member 250d defines a cavity 240d (e.g., a sleeve) in the inner portion between the top surface 254d and the bottom surface 252d, respectively, in the forefoot portion 12 and the midfoot portion 14 of the sole structure 200d. In these configurations, the bottom surface 252d of the cushioning member 250d tapers toward the top surface 254d to define a reduced thickness of the cushioning member 250d in the heel portion 16 compared to the thickness in the corresponding forefoot portion 12 and midfoot portion 14.

[0267] Figure 15 Provided along Figure 13 The partial cross-sectional view taken by line 15-15 shows the curved region 310 of the shoe plate 300 housed within the cavity 240d of the cushioning member 250d and the generally flat region 312 exposed from the cavity 240d between the bottom surface 254d of the cushioning member 250d and the inner surface 214d of the midsole 220d. Figures 10 to 12 The top surface 254c of the cushioning member 250c defines an entry opening 242c leading to the cavity 240c, while the bottom surface 252d of the cushioning member 250d defines an entry opening 242d leading to the cavity 240d for receiving the curved region 310 of the plate 300. Therefore, the bottom surface 252d of the cushioning member 250d is attached to the inner surface 214d of the outsole 210d in the front leg portion 12 and the middle leg portion 14, respectively, while a generally flat region 312 of the plate 300 extending from the cavity 240d of the cushioning member 250d through the entry opening 242d formed by the bottom surface 252d directly contacts the inner surface 214d in the heel portion 16. In some examples, the rear point 326 of the plate 300 is arranged within a mixing portion that is arranged between the curved region 310 and the generally flat region 312 and connects the curved region 310 to the generally flat region 312, and the bottom surface 252d of the buffer member 250d tapers upward toward the top surface 254d at a position near the mixing portion of the plate 300. Figure 15It is also shown that as the bottom surface 252d of the cushioning member 250d tapers toward the top surface 252d, the outsole 210d tapers to contact the plate 300. For example, the outsole 210d tapers to contact a generally flat area 312 of the plate 300 near the location where the plate 300 extends through the access opening 242d. Therefore, the cavity 240d defined by the cushioning member 250d is operable to embed / enclose at least a portion of the plate 300 (e.g., the curved area 310) within the cavity 240d. In other words, the curved area 310 of the MTP joint of the plate's support leg is separated from the outsole 210d and the insole 220d by corresponding portions of the cushioning member 250d on opposite sides of the cavity 240d. Figures 1 to 3 Like the plate 300, the cushioning member 250d and the plate 300 can substantially occupy the entire volume of space between the bottom surface 222d of the midsole 220d and the inner surface 214d of the outsole 210d. The insole 260 can be arranged within the internal cavity 102 on the footbed 224 and under the foot. The cushioning member 250d can be defined in the forefoot portion 12 of the sole structure 200d with a thickness ranging from about seven (7) mm to about twenty (20) mm. In one example, the thickness of the cushioning member 250d in the forefoot portion 12 is about twelve (12) mm. In some implementations, the thickness of the cushioning member 250d in the forefoot portion 12, between the plate 300 and the bottom surface 222d of the midsole 220d, ranges from about three (3) mm to about twenty-eight (28) mm. Additionally or alternatively, the thickness of the cushioning member 250d in the front foot portion 12, between the inner surface 214d of the plate 300 and the outer bottom 210d, is in the range of about two (2) mm to about thirteen (13) mm.

[0268] Figures 16 to 18 A shoe plate 300a is provided, which can replace shoe plate 300 and be combined with... Figures 1 to 15 and Figures 31 to 39 Of any one of footwear articles 10, 10a, 10b, 10c, 10d, 10e, 10f, 10g, and 10h. Given the substantial structural and functional similarity of the components associated with shoe plate 300 relative to shoe plate 300a, the same reference numerals are used in the following text and figures to identify the same components, while the same reference numerals including letter extensions are used to identify those components that have been modified.

[0269] Figure 16A top perspective view of the shoe plate 300a is provided, which defines a length extending between a first end 301 corresponding to the last point and a second end 302 corresponding to the foremost point (AMP) of the plate 300a. The terms "first end" and "last point" are used interchangeably herein. The terms "second end" and "AMP" are used interchangeably herein. The shoe plate 300a may be segmented in length to define a toe segment 362, an MTP segment 364, a bridging segment 366, and a heel segment 368. The toe segment 362 corresponds to the toes of the foot, while the MTP segment corresponds to the MTP joint connecting the metatarsals and phalanges of the foot. The toe segment 362 and the MTP segment 364 of the plate 300a may correspond to... Figures 1 to 15 The forefoot portion 12 of the sole structure 200 to 200d. The bridging section 366 corresponds to the arch area of ​​the foot and connects the MTP section 364 to the heel section 368. When the plate 300a is attached to... Figures 1 to 15 In the sole structure 200 to 200d, the bridging section 366 can correspond to the midfoot section 14, and the heel section 358 can correspond to the heel section 16. Figure 16 The shoe plate 300a is shown, which includes a curved region 310 (including segments 362, 364, 366) and a generally flat region 312 (including segment 368).

[0270] Figure 17 Provided Figure 16 A side view of the shoe plate 300a shows the MTP point 320, which is the closest point between the shoe plate 300a and 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 when the foot is received by the internal cavity 102 of the shoe 10 to 10d, the MTP point 320 can be positioned directly below the MTP joint of the foot. In other configurations, the MTP point 320 is positioned below and slightly behind the MTP joint of the foot, such that the forward flexion portion 322 is located below the MTP joint of the foot. The forward flexion portion 322 of the flexion region 310 can define the corresponding radius of curvature and length L between the MTP point 320 and AMP 302. A The back-bending portion 324 of the bending region 310 can define the corresponding radius of curvature and length L between the MTP point 320 and the back point 326. P As used in this article, L A and L P Each is measured along the horizontal reference plane RP between the MTP point 320 and the corresponding point between AMP 302 and rear point 326. In some examples, the L of the forward flexion portion 322 (including the toe segment 362 and the MTP segment 364) is measured. AApproximately 30% (30%) of the length of the sole structure, from 200 to 200d, is the L-shaped portion 324 (including the bridging segment 366). P The generally flat portion 312 (including the heel segment 368) accounts for approximately 30% (30%) of the length of the sole structure 200 to 200d, and approximately 40% (40%) of the length of the sole structure 200 to 200d. 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 to 200d, the L of the rear flex portion 324 P Within the range of approximately 25% to approximately 35% (35%) of the length of the sole structure 200 to 200d, and the generally flat area 312 includes the remaining portion of the length of the sole structure 200 to 200d.

[0271] 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 α1. Therefore, the forward bend 322 allows the toe segment 362 of plate 300a to offset the toes of the foot in a direction away from the ground. Angle α1 can include values ​​ranging from about 12 degrees to about 35 degrees. In one example, angle α1 includes 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 β1. Angle β1 can include values ​​ranging from about 12 degrees to about 35 degrees. In one example, angle β1 includes a value approximately equal to 24 degrees. In some configurations, angles α1 and β1 are substantially equal to each other, such that the radii of curvature are equal to each other and share the same vertex.

[0272] In some implementations, the rear point 326 is arranged along a blending portion 328 of the curved region 310 of the plate 300, the blending portion 328 including 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 arranged between the curved region 310 with a constant radius of curvature and the generally flat region 312 and connects the curved region 310 with a constant radius of curvature to the generally flat region 312. In some examples, the blending portion includes a substantially constant radius of curvature. The blending portion 328 may allow the generally flat region 312 of the plate to extend in a direction generally parallel to the horizontal reference plane RP (and the ground) between the first end 301 (the rear point) and the rear point 326. As a result of 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 include a position height H1 above the MTP point 320. As used herein, the position height H1 of the rear point 326 corresponds to the spacing 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 H1 may include a value ranging from about 3 mm to about 28 mm, while in other examples, the position height H1 may include a value ranging from about 3 mm to about 17 mm. In one example, the position height H1 is equal to about 17 mm. In some implementations, the rear points 301 and AMP 302 are coplanar at the junction of the blending portion 328 and the generally flat region 312.

[0273] Figure 18 Provided Figure 16 A top view of the shoe plate 300a shows a toe section 362, an MTP section 364, a bridging section 366, and a heel section 368 defined along the length of the plate 300a. An MTP point 320 may be located within the MTP section 364, which engages the toe section 362 to the bridging section 366. A heel point 326 may be arranged within the bridging section 366 at a location where the bridging section 366 engages with the heel section 368. For example, a hybrid portion 328 ( Figure 17 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.

[0274] Figures 19 to 21 A shoe plate 300b is provided, which can replace shoe plate 300 and be combined with... Figures 1 to 15 and Figures 31 to 39Any of the footwear products 10, 10a, 10b, 10c, 10d, 10e, 10f, 10g, and 10h. Given the substantial structural and functional similarity of the components associated with the shoe plate 300 relative to the shoe plate 300b, the same reference numerals are used in the following text and figures to identify the same components, while the same reference numerals including letter extensions are used to identify those components that have been modified.

[0275] Figure 19 A top perspective view of the shoe plate 300b is provided, which defines the length extending between the first end 301 of the plate 300b and the AMP 302b. The plate 300b may be segmented in length to define the toe segment 362, the MTP segment 364, the bridging segment 366, and the heel segment 368. Figure 19 The shoe plate 300b is shown, which includes a curved region 310 (including segments 362, 364, 366) and a generally flat region 312 (including segment 368).

[0276] Figure 20 Provided Figure 19 A side view of the shoe plate 300b shows the MTP point 320b of the bending region 310b of the shoe plate 300b, which is tangent to the horizontal reference plane RP and is positioned below the MTP joint of the foot when the foot is received by the internal cavity 102 of the shoe 10 to 10d. The forward bending portion 322b extending between the MTP point 320b and the AMP 302b includes a portion larger than... Figures 16 to 18 The radius of curvature of the front curved portion 322b is smaller than that of the front curved portion 322b. Therefore, the radius of curvature associated with the front curved portion 322b causes AMP 302b to extend from the MTP point 320b relative to the horizontal reference plane RP at an angle α2, which is greater than that of the front curved portion 322b. Figures 16 to 18 The angle α1 associated with the forward curvature portion 322. Therefore, the forward curvature portion 322b is related to the angle α1. Figures 16 to 18 The steeper slope of the forward bend 322 is associated with the slope of the bend, making it more consistent with... Figures 16 to 18 Compared to plate 300a, the toe section 362 of plate 300b offsets the toes of the foot further away from the ground. In other examples, the L-shaped forward bend of the forward bend 322b... A Within approximately 25% to 35% (35%) of the length of the sole structure 200 to 200d, the L of the rear flex portion 324b P Within the range of approximately 25% to approximately 35% (35%) of the length of the sole structure 200 to 200d, and the generally flat area 312 includes the remaining portion of the length of the sole structure 200 to 200d.

[0277] Similarly, the rear-bending portion 324b extending between MTP point 320b and rear point 326b includes a portion that is more than... Figures 16 to 18 The radius of curvature of the back bend 322 is smaller than that of the back bend 324b. Therefore, the radius of curvature associated with the back bend 324b causes the back point 326b to extend from the MTP point 320b relative to the horizontal reference plane RP at an angle β2, which is greater than that of the back bend 324b. Figures 16 to 18 The angle β1 associated with the back-bending portion 324. Therefore, the back-bending portion 324b is related to the angle β1. Figures 16 to 18 The steeper slope of the rear bend 322 is associated with the slope of the bend, making it more consistent with... Figures 16 to 18 Compared to plate 300a, the bridging segment 366 of plate 300b offsets the MTP joint of the foot further away from the heel towards the ground. Angle α2 can include values ​​ranging from about 12 degrees to about 35 degrees. In one example, angle α2 includes a value approximately equal to 24 degrees. Similarly, the radius of curvature associated with the rear bend 324b causes the rear point 326b to extend from the MTP point 320 relative to the horizontal reference plane RP at an angle β2. Angle β2 can include values ​​ranging from about 12 degrees to about 35 degrees. In one example, angle β1 includes a value approximately equal to 24 degrees. In some configurations, angles α2 and β2 are substantially equal to each other, such that the radii of curvature are equal to each other and share the same vertex.

[0278] The curved portions 322b and 324b may each include 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 curved regions 322b and 324b may range from about 200 mm to about 400 mm. In some configurations, the front curved portion 322b includes a radius of curvature that continues the curvature of the rear curved portion 324b, such that the curved portions 322b and 324b define the same radius of curvature and share the same vertex. Additionally or alternatively, the plate may define a radius of curvature that connects the rear curved portion 324b of the plate 300b to the generally flat region 312. As used herein, the term "generally flat" means a flat region 312 that is parallel to the ground within five (5) degrees horizontally, i.e., within five (5) degrees.

[0279] In some implementations, the rear point 326b is arranged along a blending portion 328b of the curved region 310b of the plate 300b, the blending portion 328b including a radius of curvature configured to join the curved region 310b to the generally flat region 312 at the rear curved portion 324b. Thus, the blending portion 328b is arranged between the curved region 310b with a constant radius of curvature and the generally flat region 312, connecting the curved region 310b with the generally flat region 312. In some examples, the blending portion includes a substantially constant radius of curvature. Figures 16 to 18Similar to the blending portion 328 of the curved region 310, the blending portion 328b allows the generally flat region 312 of the plate 300b to extend between the first end 301 (last point) and the rear point 326b in a direction generally parallel to the horizontal reference plane RP (and the ground). As a result of the radius of curvature of the rear curved portion 324b and the radius of curvature of the blending portion 328b, the rear point 326b may include a position height H2 above the MTP point 320, which is greater than Figures 16 to 18 The position height H1 is the rear point 326 above the MTP point 320. In some examples, the position height H2 can include a value ranging from about 3 mm to about 28 mm, while in other examples, the position height H2 can include a value ranging from about 3 mm to about 17 mm. In one example, the position height H2 is equal to about 17 mm. In some implementations, the rear point 301 and AMP 302b are coplanar at the junction of the mixing portion 328b and the generally flat region 312.

[0280] Figure 21 Provided Figure 19 A top view of the shoe plate 300b shows a toe section 362, an MTP section 364, a bridging section 366, and a heel section 368 segmented along the length of the plate 300b. An MTP point 320b may be located within the MTP section 364, which joins the toe section 362 to the bridging section 366. A heel point 326b may be arranged within the bridging section 366 at a location where the bridging section 366 engages with the heel section 368. For example, a hybrid portion 328b ( Figure 20 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 300b.

[0281] Figures 22 to 24 A shoe plate 300c is provided, which can replace shoe plate 300 and be combined with... Figures 1 to 15 and Figures 31 to 39 Any of the footwear products 10, 10a, 10b, 10c, 10d, 10e, 10f, 10g, and 10h. Given the substantial structural and functional similarity of the components associated with the shoe plate 300 to the shoe plate 300c, the same reference numerals are used in the following text and figures to identify the same components, while the same reference numerals including letter extensions are used to identify those components that have been modified.

[0282] Figure 22A top perspective view of the shoe plate 300c is provided, which defines the length extending between the first end 301 of the plate 300c and the AMP 302c. The plate 300c may be segmented in length to define the toe segment 362, the MTP segment 364, the bridging segment 366, and the heel segment 368. Figure 22 The shoe plate 300c is shown, which includes a curved region 310c (including segments 362, 364, 366) and a generally flat region 312 (including segment 368).

[0283] Figure 23 Provided Figure 22 A side view of the shoe plate 300c shows that the bending region 310c is semi-circular, such that the front bending portion 322c and the rear bending portion 324c are associated with the same radius of curvature R and share a common vertex V, such that the bending portions 322c and 324c are mirror images of the MTP point 320c. In some configurations, the radius R includes values ​​ranging from about 86 mm to about 202 mm. In other configurations, the radius R includes values ​​ranging from about 140 mm to about 160 mm. Example values ​​for the radius R may include about 87 mm, 117 mm, 151 mm, or 201 mm. The MTP point 320c is tangent to the horizontal reference plane RP, and when the foot is received by the internal cavity 102 of the shoe 10 to 10d, the MTP point 320c is located below the MTP joint of the foot. Therefore, the MTP point 320c corresponds to the center of the bending region 310c, which includes the bending portions 322c and 324c. The front bend 322c extends between MTP point 320c and AMP 302c, while the rear bend 324c extends between MTP point 320c and rear point 326c.

[0284] The forward bend portion 322c can define the length L between MTP point 320c and AMP 302c. A The length L A Essentially equal to the length L of the rear bend portion 324c between MTP point 320c and rear point 326c. P As used in this article, L A and L P Each is measured along the horizontal reference plane RP between the corresponding point MTP 320c and AMP 302c and rear point 326c. In some configurations, when the shoe plate 300c and footwear 10 to 10d associated with men's size 10 are combined, L A and L P Each is approximately 81 mm. In some examples, the L-shape of the forward bend 322c (including the toe segment 362 and the MTP segment 364) is... AApproximately 30% (30%) of the length of the sole structure, from 200 to 200d, is the L-shaped portion 324 (including the bridging segment 366). P The generally flat portion 312 (including the heel segment 368) accounts for approximately 30% (30%) of the length of the sole structure 200 to 200d, and approximately 40% (40%) of the length of the sole structure 200 to 200d. In other examples, the L-shaped portion 322c... A Within approximately 25% to 35% (35%) of the length of the sole structure 200 to 200d, the L of the rear flex portion 324c P Within the range of approximately 25% to approximately 35% (35%) of the length of the sole structure 200 to 200d, and the generally flat area 312 includes the remaining portion of the length of the sole structure 200 to 200d.

[0285] AMP 302c extends from MTP point 320c relative to the horizontal reference plane RP at an angle α3, and then point 326c extends from MTP point 320c relative to the horizontal reference plane RP at an angle β3. Since the curved portions 322c and 324c are associated with the same radius of curvature R and share a common vertex V, angles α3 and β3 are substantially equal to each other. In some examples, the values ​​of angles α3 and β3 range from about 11 degrees to about 35 degrees, and in other examples, the values ​​of angles α3 and β3 range from about 20 degrees to about 25 degrees. Example values ​​of angles α3 and β3 include about 12 degrees, 16 degrees, 22 degrees, or 57 degrees. Angle α3 corresponds to the angle at which the toe section 362 of plate 300c causes the toes of the foot to point upward and away from the ground when the foot is received by the internal cavity 102 of shoe 10 to 10d.

[0286] Furthermore, both rear point 326c and AMP 302c can each include the same positional height H3 above MTP point 320c. Figures 16 to 18 Board 300a and Figures 19 to 21 Similar to plate 300b, the position height H3 of the rear point 326c and MTP point 320c corresponds to the spacing distance extending in a direction generally perpendicular to the horizontal reference plane RP between MTP point 320c and the corresponding one of rear point 326c and AMP 302c. In some configurations, the position height H3 includes values ​​ranging from about 17 mm to about 57 mm. Example values ​​for the position height H3 may include about 17 mm, 24 mm, 33 mm, or 57 mm.

[0287] In some implementations, the rear point 326c is arranged along a blending portion 328c of the curved region 310c of the plate 300, the blending portion 328c including a radius of curvature configured to join the curved region 310c to the generally flat region 312 at the rear curved portion 324c. Thus, the blending portion 328c is arranged between the curved region 310c with a constant radius of curvature and the generally flat region 312 and connects the curved region 310c with a constant radius of curvature to the generally flat region 312. In some examples, the blending portion includes a substantially constant radius of curvature. The blending portion 328c may allow the generally flat region 312 of the plate 300c to extend between the first end 301 (the rear point) and the rear point 326c in a direction substantially parallel to the horizontal reference plane RP (and the ground). Therefore, AMP 302c and the rear point 326c may be substantially coplanar with the joint between the blending portion 328c and the generally flat region 312. Thus, the portions of the heel section 368 and the bridging section 366 extending between the first end 301 of the plate 300c and the rear point 326c can be substantially flat. When the shoe plate 300c is combined with the footwear 10 to 10d associated with men's size 10, the blending portion 328c may include a radius of curvature of approximately 133.5 mm. In some implementations, the rear point 301 and AMP 302c are coplanar at the junction of the blending portion 328c and the generally flat region 312.

[0288] Figure 24 Provided Figure 22 A top view of the shoe plate 300c shows a toe section 362, an MTP section 364, a bridging section 366, and a heel section 368 segmented along the length of the plate 300c. An MTP point 320c may be located within the MTP section 364, which joins the toe section 362 to the bridging section 366. A heel point 326b may be arranged within the bridging section 366 at a location where the bridging section 366 engages with the heel section 368. For example, a hybrid portion 328c (… Figure 23 The radius of curvature of the section allows the bridging segment 366 associated with the rear-bent portion 324 to be seamlessly joined to the heel segment 368 associated with the flat region 312 of the plate 300c. In view of the foregoing, for Figures 22 to 24 For the 300c shoe plate, the following parameters can be specified for men's shoes in size 10:

[0289] 1. R = 201 mm, α3 = 12 degrees, H3 = 17 mm, L A =81mm, the radius of curvature of the mixed part 328c is equal to 134mm;

[0290] 2. R = 151 mm, α3 = 16 degrees, H3 = 24 mm, L A=81mm, the radius of curvature of the mixed part 328c is equal to 134mm;

[0291] 3. R ​​= 117 mm, α3 = 22 degrees, H3 = 33 mm, L A =81mm, the radius of curvature of the mixed part 328c is equal to 134mm; and

[0292] 4. R = 87 mm, α3 = 35 degrees, H3 = 57 mm, L A =81mm, the radius of curvature of the mixed part 328c is equal to 134mm.

[0293] Reference Figures 1 to 24 The shoe plates 300 to 300c, with flexed regions 322 to 322c, allow the overall longitudinal stiffness of the plates 300 to 300c to reduce energy loss at the MTP joint of the wearer's foot during walking / running movements, while promoting foot rolling, thereby reducing lever arm distance and alleviating stress at the wearer's ankle joint. The radius of curvature associated with the flexed portions 322 to 322c particularly affects the longitudinal stiffness of the plates 300 to 300c and how the foot rolls during walking / running movements. In some examples, the plates 300 to 300c omit the generally flat region 312 to define the length extending between the rear points 326 to 326c and AMP 302 to 302c. MTP points 320 to 320c correspond to the closest (e.g., lowest) points of the plates 300 to 300c to the ground, and MTP points 320 to 320c can be located at or immediately following the MTP joint of the foot when the foot is received by the internal cavity 102 of the shoe 10 to 10d on top of the sole structure 200 to 200d. The sole structure 200 to 200d may include one or more cushioning members 250 to 250c, 270. Cushioning members 250 to 250c, 270 may define a maximum thickness above the top of the MTP points 320 to 320c of the plates 300 to 300c to maximize the distance between the foot's MTP joint and the MTP points 320 to 320c. The cushioning components 250 to 250c, 270 may include a high-performance (soft and low-energy-loss) foam material that has at least 60% rebound when compressed under applied load to help return energy during walking / running activities during the shoe's 10 to 10 days of use. The different geometries of the shoe plate 300 to 300c give athletes, such as runners with different running styles—e.g., forefoot strike versus heel strike—different mechanical advantages. The radii of curvature of the flex portions 322 to 322c, 324 to 324c produce different angles α1 to α3, such that the position heights H1 to H3 are different for different shoe sizes.

[0294] Figure 25A top view of shoe plate 300d is provided, which can replace shoe plate 300 and be combined with... Figures 1 to 15 and Figures 31 to 39 Of any one of footwear articles 10, 10a, 10b, 10c, 10d, 10e, 10f, 10g, and 10h. Given the substantial structural and functional similarity of the parts associated with shoe plate 300 to shoe plate 300d, the same reference numerals are used hereinafter and in the accompanying drawings to identify the same parts, while the same reference numerals including letter extensions are used to identify those parts that have been modified.

[0295] The shoe plate 300d is defined by extending between a first end 301 and a second end 302, and is segmented in length to define a toe section 362, an MTP section 364, a bridging section 366d, and a heel section 368. The bridging section 366d of the plate 300d, near the heel section 368, has a narrower width compared to the bridging sections 366 of the plates 300a, 300b, and 300c. The narrower bridging section 366d reduces the weight of the shoe plate 300d while increasing its flexibility. The MTP section 364 is associated with the widest part of the plate 300d, while the toe section 362 is slightly narrowed to support the toes of the foot.

[0296] Figure 26 A top view of shoe plate 300e is provided, which can replace shoe plate 300 and be combined with... Figures 1 to 15 and Figures 31 to 39 Any of the footwear products 10, 10a, 10b, 10c, 10d, 10e, 10f, 10g, and 10h. Given the substantial structural and functional similarity of the components associated with the shoe plate 300 relative to the shoe plate 300e, the same reference numerals are used in the following text and figures to identify the same components, while the same reference numerals including letter extensions are used to identify those components that have been modified.

[0297] Figure 26 The shoe plate 300e is shown, wherein there is no heel segment 368 associated with the generally flat area 312. The plate 300e defines a reduced length extending between a first end 301e and a second end 302, and the plate 300e is segmented in length to define a toe segment 362, an MTP segment 364, and a truncated bridging segment 366e. Here, the first end 301e of the plate 300e is associated with the rear points 326 to 326d of the plates 300 to 300d.

[0298] In some examples, the truncated bridging segment 366e is associated with a reduced length sufficient to support the tarsometatarsal joint of the foot. Thus, the plate 300e can define only the curved region 310 comprising the truncated bridging segment 366e, the MTP segment 364, and the toe segment 362. Furthermore, the plate 300e can be formed from a single continuous sheet of material.

[0299] Figure 27 A top view of shoe plate 300f is provided, which can replace shoe plate 300 and be combined with... Figures 1 to 15 and Figures 31 to 39 Any of footwear products 10, 10a, 10b, 10c, 10d, 10e, 10f, 10g, and 10h. Given the substantial structural and functional similarity of the components associated with shoe plate 300 to shoe plate 300f, 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.

[0300] The shoe plate 300f is defined to extend between a first end 301 and a second end 302 and to extend through a separate forefoot portion 12f, a midfoot portion 14, and a heel portion 16. The plate 300f includes a curved region 310 extending through the separated forefoot portion 12f and midfoot portion 14. The plate 300f may also include a generally flat region 312 extending from the curved region 310 of the plate 300f through the heel portion 16 to the first end 301.

[0301] The separate forefoot portion 12f of plate 300f includes a lateral segment 371 and a medial segment 372. In some examples, the lateral segment 371 and the medial segment 372 extend from the MTP point 320 of plate 300f, respectively. Dividing the forefoot portion 12f into the lateral segment 371 and the medial segment 372 can provide greater flexibility to plate 300f. In some examples, the medial segment 372 is wider than the lateral segment 371. In one example, the medial segment 372 is associated with the width appropriate to support the first MTP bone of the foot (e.g., the big toe) and the hallux valgus. Plate 300f can be formed from a single continuous sheet of material.

[0302] Figure 28 A top view of the 300g shoe plate is provided, which can replace the 300 shoe plate and be combined with... Figures 1 to 15 and Figures 31 to 39Any of the footwear products 10, 10a, 10b, 10c, 10d, 10e, 10f, 10g, and 10h. Given the substantial structural and functional similarity of the components associated with the shoe plate 300 relative to the shoe plate 300g, the same reference numerals are used in the following text and figures to identify the same components, while the same reference numerals including letter extensions are used to identify those components that have been modified.

[0303] The shoe plate 300g is defined to extend between a first end 301 and a second end 302 and to extend through the length of the toe-shaped forefoot portion 12g, the midfoot portion 14, and the heel portion 16 of the shoe plate 300g. The plate 300g includes a curved region 310 extending through the toe-shaped forefoot portion 12g and the midfoot portion 14. The plate 300g may also include a generally flat region 312 extending from the curved region 310 of the plate 300g through the heel portion 16 to the first end 301.

[0304] The forefoot portion 12g of the plate 300g includes a medial segment 372g with a lateral curvature 374. In some examples, the medial segment 372g extends from the MTP point 320 of the plate 300g and is associated with a width suitable for supporting the first MTP bone of the foot (e.g., the big toe). The lateral curvature 374 removes a portion of the plate 300g that would originally support the second to fifth MTP bones. The plate 300g may be formed from a single continuous sheet of material.

[0305] Figure 29 A top view of shoe plate 300h is provided, which can replace shoe plate 300 and be combined with... Figures 1 to 15 and Figures 31 to 39 Any of the footwear products 10, 10a, 10b, 10c, 10d, 10e, 10f, 10g, and 10h. Given the substantial structural and functional similarity of the components associated with the shoe plate 300 with respect to the shoe plate 300h, the same reference numerals are used in the following text and figures to identify the same components, while the same reference numerals including letter extensions are used to identify those components that have been modified.

[0306] The shoe plate 300h is defined by extending between a first end 301 and a second end 302 and extending through the annular forefoot portion 12h, the midfoot portion 14, and the heel portion 16 of the shoe plate 300h. The plate 300h includes a curved region 310 extending through the annular forefoot portion 12h and the midfoot portion 14. The plate 300h may also include a generally flat region 312 extending from the curved region 310 of the plate 300h through the heel portion 16 to the first end 301.

[0307] The annular front leg portion 12h of plate 300h includes an internal cutout region 380 formed through the front leg portion 12h of plate 300h. The cutout region 380 is surrounded by an edge 382 defined by the outer periphery of plate 300h. In some examples, the edge 382 extends from the MTP point 320 of plate 300h, and the edge 382 is configured to support the leg from below, while the internal cutout region 380 is associated with an opening region to reduce the weight of plate 300h. Plate 300b may be formed from a continuous sheet of material. In some configurations, plate 300h is formed by applying a first fiber bundle to a substrate and forming a cavity in the first fiber bundle associated with the shape of the cutout region 380 to expose the substrate. The exposed portion of the substrate can then be removed (e.g., cut away) to form the cutout region 380. Furthermore, the second fiber bundle can extend around the periphery of the cavity formed by the first fiber bundle to provide structural support for the cut area 380 when at least one of heat and pressure is applied to form the plate 300h.

[0308] Figure 30 A top view of the shoe plate 300i is provided, which can replace the shoe plate 300 and be integrated into... Figures 1 to 15 and Figures 31 to 39 Any of the footwear articles 10, 10a, 10b, 10c, 10d, 10e, 10f, 10g, and 10h. Given the substantial structural and functional similarity of the components associated with the footboard 300 with respect to the footboard 300i, the same reference numerals are used in the following text and figures to identify the same components, while the same reference numerals including letter extensions are used to identify those components that have been modified.

[0309] The shoe plate 300i is defined to extend between a first end 301 and a second end 302 and to extend through the length of the pincer-shaped forefoot portion 12i, the midfoot portion 14, and the heel portion 16 of the shoe plate 300i. The plate 300i includes a curved region 310 extending through the pincer-shaped forefoot portion 12i and the midfoot portion 14. The plate 300i may also include a generally flat region 312 extending from the curved region 310 of the plate 300i through the heel portion 16 to the first end 301.

[0310] The clamp-shaped front leg portion 12i of plate 300i includes an outer segment 371i and an inner segment 372i. In some examples, the outer segment 371i and the inner segment 372i extend from the MTP point 320 of plate 300i, respectively. Segments 371i and 372i can cooperate to define, except that opening 384 spaces segments 371i and 372i apart to allow segments 371i and 372i to flex independently of each other. Figure 29The inner cutout region 380i is similar to the cutout region of the plate 300h. Therefore, the pincer-shaped front leg portions 12i are respectively provided with outer segments 371i and inner segments 372i that can flex independently of each other. Except that the inner cutout region 380i provides a plate 300i with a reduced weight compared to the plate 300f including the separate front leg portions 12f, the outer segments 371i and inner segments 372i are similar to... Figure 27 The segments 371 and 372 of the separated front leg portion 12f are similar. Plate 300i can be formed from a continuous sheet of material.

[0311] Figure 31 and Figure 32 Footwear 10e is provided, comprising an upper 100 and a sole structure 200e attached to the upper 100. Given the substantial structural and functional similarity of the components associated with footwear 10e with respect to footwear 10e, 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.

[0312] The sole structure 200e may include an outsole 210e, a cushioning member 250e, a shoe plate 300, and a midsole / pad 220e arranged in a layered configuration. Figure 32 Provided along Figure 31 The partial cross-sectional view taken by line 32-32 shows the shoe plate 300, which is arranged between the cushioning member 250e and the midsole 220e in the corresponding midfoot portion 14 and heel portion 16, and between the outsole 210e and the midsole 220e in the forefoot portion 12. The cushioning member 250e includes a bottom surface 252e opposite to the ground 2 and a top surface 254e arranged on the side of the cushioning member 250e opposite to the bottom surface 252e and attached to the plate 300. The outsole 210e may correspond to one or more ground contact segments that can be attached to the bottom surface 252e of the cushioning member 250e and the plate 300. In some configurations, the outsole 210e is omitted, such that the bottom surface 252e of the cushioning member 250e contacts the ground 2 in the corresponding midfoot portion 14 and heel portion 16 of the sole structure 200e, while the plate 300 contacts the ground 2 in the forefoot portion 12 of the sole structure 200e, i.e., the flexural region 310 of the plate 300.

[0313] In some implementations, one or more protrusions 800 (e.g., track spikes) extend away from the plate 300 and outsole 210e in a direction toward the ground 2 to provide adhesion. The protrusions 800 may be directly attached to the plate 300 or the outsole 210e. Figure 32The illustration shows no cushioning material positioned above the MTP point 320 (e.g., between the plate 300 and the midsole 220e) or below the MTP point 320 (e.g., between the plate 300 and the outsole 210e). Therefore, cushioning material 250e is provided in the respective midfoot portion 14 and heel portion 16 to reduce the initial impact of ground reaction forces during running motions, while no cushioning material 250e is provided in the less necessary forefoot portion 12 to reduce the weight of the sole structure 200e. An exemplary shoe 10e including the sole structure 200e can be associated with track shoes for shorter distance track events. Furthermore, the insole 260 can be disposed within the internal cavity 102 on the footbed 224 of the midsole 220e and positioned under the foot.

[0314] Figure 33 and Figure 34 Footwear 10f and footwear 10e are provided, including an upper 100 and a sole structure 200f attached to the upper 100. Given the substantial structural and functional similarity of the parts associated with footwear 10 to footwear 10f, the same reference numerals are used hereinafter and in the accompanying drawings to identify the same parts, while the same reference numerals including letter extensions are used to identify those parts that have been modified.

[0315] The sole structure 200f may include an outsole 210f, a cushioning member 250f, a shoe plate 300, and a midsole / pad 220f arranged in a layered configuration. Figure 34 Provided along Figure 33 A partial cross-sectional view taken by line 34-34 shows a shoe plate 300 disposed between a cushioning member 250f and a midsole 220f, with the cushioning member 250f disposed between the plate 300 and an outsole 210f and / or the ground 2. The cushioning member 250f includes a bottom surface 252f opposite to the ground 2 and a top surface 254f disposed on the side of the cushioning member 250f opposite to the bottom surface 252f and attached to the plate 300. The outsole 210f may correspond to one or more ground contact segments that can be attached to the bottom surface 252f of the cushioning member 250f. In some configurations, the outsole 210f is omitted, such that the bottom surface 252f of the cushioning member 250f contacts the ground 2. Furthermore, an insole 260 may be disposed within an internal cavity 102 on the footbed 224 of the midsole 220f and positioned under the foot.

[0316] The cushioning member 250f may be defined in the heel portion 16 of the sole structure 200f with a greater thickness than in the forefoot portion 12. In other words, the gap or distance separating the outsole 210f and the midsole 220f 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 254f of the cushioning member 250f is smooth and includes a surface profile contoured to match the surface profile of the plate 300 so that the plate 300 and the cushioning member 250f fit flush with each other. The cushioning member 250f may be defined in the forefoot portion 12 of the sole structure in the range of eight (8) mm to about nine (9) mm and includes a thickness of eight mm and nine mm. Therefore, the thickness of the cushioning member 250f relative to the bending region 310 of the plate 300 may be only thick enough to prevent the plate 300 from directly contacting the ground 2 during running.

[0317] In some implementations, one or more protrusions 800 (e.g., track spikes) extend away from the plate 300 and outsole 210f in a direction toward the ground 2 to provide adhesion. The protrusions 800 may be directly attached to the plate 300, the cushioning member 250f, or the outsole 210f.

[0318] Figure 35 and Figure 36 Footwear 10g is provided, comprising an upper and a sole structure 200g attached to the upper 100. Given the substantial structural and functional similarity of the parts associated with footwear 10g with respect to footwear 10g, the same reference numerals are used hereinafter and in the accompanying drawings to identify the same parts, while the same reference numerals including letter extensions are used to identify those parts that have been modified.

[0319] Figure 35 A top perspective view of a footwear 10g is provided, showing a sole structure 200g. This sole structure 200g includes an outsole 210bg, a cushioning member 250g, a shoe plate 300, and a midsole / pad 220g, arranged in a layered configuration and defining a longitudinal axis L. In some configurations, the periphery of the shoe plate 300 is visible from the outside of the shoe 10g along the outer side 18 and the inner side 20, respectively. In these configurations, the shoe 10g can be designed for its intended use in walking.

[0320] Figure 36 Provided along Figure 35 A partial cross-sectional view taken by line 36-36 shows a shoe plate 300, which is arranged between a cushioning member 250g and a midsole 220, and the cushioning member 250g is arranged between the plate 300 and an outsole 210g. An insole 260 can be arranged within an internal cavity 102 on a footbed 224 and positioned under the foot. Although not included... Figure 36 In the configuration, but Figures 1 to 3 The fluid-filled bladder 400 can also be combined with the sole structure 200g to provide additional cushioning. The outsole 210g includes a ground contact surface 212g and an inner surface 214g disposed on the side of the outsole 210g opposite to the ground contact surface 212g and opposite to the bottom surface 252g of the cushioning member 250g. The cushioning member 250g includes a bottom surface 252g and a top surface 254g disposed on the side of the cushioning member 250g opposite to the bottom surface 252g.

[0321] The sole structure 200g, in addition to including multiple openings 255 formed through the outsole 210g and cushioning member 250g to expose various parts of the plate 300 when viewed from the bottom of the shoe 10g, is otherwise similar to... Figures 1 to 3 The sole structure is basically the same as that of the 200. Figure 36 A plurality of openings 255 are shown located in the heel portion 16 and the forefoot portion 12. Other configurations may include more or fewer openings 255 in the heel portion 16 and / or the forefoot portion 12, and openings in the midfoot portion 14. In some implementations, only one of portions 12, 14, and 16 includes an opening 255. Each opening 255 may be formed through the outsole 210g and the cushioning member 250g and extend in a direction generally perpendicular to the longitudinal axis L. Advantageously, the openings 255 can be operated to reduce the overall weight of the sole structure by 200g to provide a lighter footwear by 10g. The openings 255 may similarly be formed through... Figures 1 to 15 and Figures 33 to 36 The sole structure is formed by any of the 200 to 200f.

[0322] Figures 37 to 39 A footwear article 10h is provided, comprising an upper 100 and a sole structure 200h attached to the upper 100. Given the substantial structural and functional similarity of the parts associated with the footwear article 10h with respect to the footwear article 10h, the same reference numerals are used hereinafter and in the accompanying drawings to identify the same parts, while the same reference numerals including letter extensions are used to identify those parts that have been modified.

[0323] The sole structure 200h may include an outsole 210 arranged in a layered configuration, a first cushioning member 250h, a plate formed by a fluid-filled bladder 400h, and a midsole / pad 220h. Figure 38An exploded view of the footwear 10h is provided, showing the sole structure 200h (e.g., outsole 210, cushioning member 250h, and midsole 220h) defining a longitudinal axis L. The outsole 210h includes an inner surface 214h disposed on the side of the outsole 210h opposite to the ground contact surface 212. The midsole 220h includes a bottom surface 222h disposed on the side of the midsole 220h opposite to the footbed 224 and opposite the inner surface 214h of the outsole 210h.

[0324] A cushioning member 250h and a fluid-filled bladder 400h are arranged between an inner surface 214h and a bottom surface 222h to separate the midsole 220h from the outsole 210h. For example, the cushioning member 250h includes a bottom surface 252 received by the inner surface 214h of the outsole 210h and a top surface 254h arranged on the side of the cushioning member 250h opposite to the bottom surface 252 and opposite the midsole 220h to support the bladder 400 thereon. In some examples, a sidewall 230h surrounds at least a portion of the periphery of the cushioning member 250h and spaces the cushioning member 250h from the midsole 220h to define a cavity 240h between the cushioning member 250h and the midsole 220h. For example, the sidewall 230h may define an edge of at least a portion of the periphery of the top surface 254h, which has a defined profile around the cushioning member 250h, to support the foot during walking or running activities during use of the shoe 10. When the cushioning member 250 is attached to the midsole 220, the edge can extend around the periphery of the midsole 220.

[0325] In some configurations, a fluid-filled bladder-like element 400h is positioned on the top surface 254h of the cushioning member 250h and below the midsole 220h to reduce energy loss at the MTP joint during running movements, while enhancing foot roll with the shoe 10h for ground contact. Figures 1 to 3 Like the shoe plate 300, the fluid-filled bladder 400h has a stiffness greater than that of the cushioning member 250h and the outsole 210h. The fluid-filled bladder 400h may define at least a portion of the length extending through the sole structure 200h. In some examples, the length of the bladder 400h extends through the forefoot portion 12, midfoot portion 14, and heel portion 16 of the sole structure 200h. In other examples, the length of the bladder 400h extends through the forefoot portion 12 and midfoot portion 14, and is not present in the heel portion 16.

[0326] The cushioning member 250h can be elastically compressed between the midsole 220h and the outsole 210h. The cushioning member 250h can be formed from a sheet of polymer foam, which can be formed from... Figures 1 to 3The cushioning member 250h is formed of the same one or more materials. For example, the cushioning member 250h may be formed of one or more of EVA copolymer, polyurethane, polyether, olefin block copolymer, PEBA copolymer and / or TPU. A fluid-filled bladder 400h may also enhance the cushioning properties of the shoe 10h in response to ground reaction forces. For example, the bladder 400h may be filled with a pressurized fluid, such as air, nitrogen, helium, sulfur hexafluoride, or a liquid / gel.

[0327] The length of the fluid-filled bladder 400h may be the same as or less than the length of the cushioning member 250h. The length, width, and thickness of the bladder 400h may substantially occupy the volume of the space (e.g., cavity 240h) between the top surface 254h of the cushioning member 250h and the bottom surface 222h of the midsole 220h, and may extend through the forefoot portion 12, midfoot portion 14, and heel portion 16 of the sole structure 200h, respectively. In some examples, the bladder 400h extends through the forefoot portion 12 and midfoot portion 14 of the sole structure 200h, but is not present in the heel portion 16. In some examples, the sidewall 403 of the bladder 400h is visible along the outer lateral portion 18 and / or inner lateral portion 20 of the shoe 10h. In some implementations, the top surface 254h of the cushioning member 250h and the bottom surface 222h of the midsole 220h are smooth and include surface profiles contoured to the opposite sides of the matching capsule 400h so that the capsule 400h fits flush with the cushioning member 250h and the midsole 220h.

[0328] A fluid-filled bladder 400h defines an internal cavity that contains pressurized fluid while providing a durable sealing partition for retaining the pressurized fluid therein. The bladder 400h may include an upper partition portion 401 opposite to the bottom surface 222h of the midsole 220h and a lower partition portion 402 disposed on the side of the bladder 400h opposite to the upper partition portion 401 and opposite to the top surface 254h of the cushioning member 250h. A sidewall 403 extends around the periphery of the bladder 400h and connects the upper partition portion 401 to the lower partition portion 402.

[0329] In some configurations, the internal cavity of the fluid-filled bladder 400h also accommodates a tethering element 500 having an upper plate attached to the upper partition portion 401, a lower plate attached to the lower partition portion 402, and a plurality of tethers 530 extending between the upper and lower plates of the tethering element 500. The tethering element 500 can be secured to the bladder 400h using adhesive bonding or thermal bonding. The tethering element 500 is operable to prevent the bladder 400h from expanding outward or otherwise expanding due to fluid pressure within its internal cavity. That is, the tethering element 500 can limit the expansion of the bladder 400h under pressure to maintain the desired shape of the surfaces of the partition portions 401 and 402.

[0330] Figure 39 Provided along Figure 37 A partial cross-sectional view taken by lines 39-39 shows a fluid-filled bladder 400h disposed between a cushioning member 250h and a midsole 220h, and the cushioning member 250h is disposed between an outsole 210h and the bladder 400h. An insole 260 may be disposed within an internal cavity 102 on a footbed 224 and under the foot. In some configurations, the cushioning member 250h defines a greater thickness in the heel portion of the sole structure 200h than in the forefoot portion 12, and the top surface 254h includes a surface profile contoured to match the surface profile of the bladder 400h supported on the top surface 254h. The cushioning member 250h may cooperate with the midsole 220h to define a space for enclosing the bladder 400h between the cushioning member 250h and the midsole 220h.

[0331] Similar to the shoe plate 300 to 300i, the bladder 400h includes a curved region 410 extending through the forefoot portion 12 and the midfoot portion 14, and the bladder 400h may optionally include a generally flat region 412 extending from a rear point at the curved region 410 relative to the AMP of the bladder 400h through the heel portion 16, the AMP of the bladder 400h being arranged near the toe tip of the sole structure 200h. The curved region may have radii of curvature defining a front curved portion 422 and a rear curved portion 424, the front curved portion 422 and the rear curved portion 424 correspondingly to... Figures 1 to 3The corresponding one of the forward bend 322 and the rear bend 324 of the shoe plate 300 is similar. In some configurations, the bends 422 and 424 each include the same radius of curvature, which is mirrored about the MTP point 420, associated with the point of arrangement of the pocket 400h closest to the outsole 210h. In other configurations, the bends 422 and 424 are associated with different radii of curvature. The bends 422 and 424 may each occupy approximately thirty percent (30%) of the total length of the pocket 400h, while the length of the flat region 412 may occupy the remaining forty percent (40%) of the length of the pocket 400h. The forward bend 422 and the rear bend 424 of the bend region 410 provide longitudinal stiffness to the pocket 400, which reduces energy loss near the MTP joint of the foot during running motion and enhances foot rolling, thereby reducing lever arm distance and relieving stress on the ankle joint. Although Figures 37 to 39 Example shoe 10h incorporates a curved fluid-filled bladder 400h between cushioning member 250h and midsole 220h in place of the shoe plate 300, but the curved fluid-filled bladder 400h may replace the plate 300 in any of the footwear products 10 to 10g described above.

[0332] The shoe plates 300 to 300i described above can be manufactured using fiber sheets or textiles including pre-impregnated (i.e., “pre-impregnated”) fiber sheets or textiles. Alternatively or additionally, the shoe plates 300 to 300i can be manufactured by strands (e.g., fiber bundles) formed from multiple filaments of one or more types of fibers by attaching the fiber bundles to a substrate or to each other to produce a plate having fiber strands arranged primarily at predetermined angles or positions. When using fiber strands, the type of fibers included in the strands can include synthetic polymer fibers, which can be melted and re-cured to bind other fibers present in the strands and optional other components—such as stitching or substrate, or both stitching and substrate. Alternatively or additionally, the fiber strands and optional other components—such as stitching or substrate, or both stitching and substrate—can be bound by applying resin after the fiber strands have been attached to the substrate and / or the fiber strands have been bound to each other. The above process is described below.

[0333] Reference Figures 40A to 40E and Figure 41The shoe plate 300 to 300i 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 fibers 602 can include at least one of carbon fibers, boron fibers, glass fibers, and other polymer fibers forming the unidirectional sheet or multiaxial fabric. The polymer fibers can compositionally include polyurethane, polyamide, polyester, polyether, polyurethane copolymer, polyamide copolymer, polyester copolymer, polyether copolymer, and any combination thereof. The polyurethane can be thermoplastic polyurethane (TPU). The polymer fibers can compositionally include polyethylene terephthalate (PET). The polymer fibers can compositionally include aromatic polyamides. The polymer fibers can compositionally include poly(p-phenylene-2,6-benzodiazole) (PBO).

[0334] Fibers such as carbon fiber, aramid fiber, and boron fiber can provide high Young's modulus, while glass fiber (e.g., fiberglass) 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 in sheets 600a and 600e are multiaxial fabrics. Furthermore, each of sheets 600a to 600e may include fibers 602 formed of the same material, or alternatively, one or more of sheets 600a to 600e may include fibers 602 formed of a material different from the fibers 602 of the other sheets 600a to 600e.

[0335] During the manufacture of sheets 300 to 300i, 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 various sheets 600a to 600e are obtained by cutting from the stacked sheets. Figures 40A to 40E The shape shown is as described. In this case, 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 sheets 600a to 600e are stacked one on top of the other, the longitudinal axis of the fibers 602 is positioned at different angles relative to the longitudinal axis of the plates 300 to 300i.

[0336] In one configuration Figure 40A The angle (Φ) shown is 0 degrees (0°). Figure 40B The angle (Φ) shown is -15 degrees (-15°). Figure 40C The angle (Φ) shown is -30 degrees (-30°). Figure 40D The angle (Φ) shown is 15 degrees (15°), and Figure 40E The angle (Φ) shown is 30 degrees (30°). When manufacturing plates 300 to 300i, the layers are stacked such that when sheets 600a to 600e are cut from the stacked layers, the sheets 600a to 600e have Figures 40A to 40E The shape shown and the sheet 600a to 600e are as follows Figure 41 The stacking sequence 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 final top 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 provided at an angle (Φ) of 0° relative to the longitudinal axis (L), more than two sheets 600a at an angle (Φ) of 0° can be provided. For example, eight (8) sheets 600a can be provided.

[0337] Once the laminates are stacked and cut into sheets 600a to 600e, the stacks are subjected to heat and pressure to impart a specific shape of the sheets 600a to 600e to the stacked sheets 300 to 300i, as will be described in detail below. Furthermore, when using pre-impregnated resin fibers, subjecting the stacks to heat and pressure can melt or soften the pre-impregnated resin, bonding the laminates together and holding them in a specific shape. Alternatively or additionally, liquid resin can be applied to the laminates to bond the sheets together and, in some cases, to solidify the fibers, thereby increasing the tensile strength of the sheets once the resin has cured.

[0338] Reference Figures 42A to 42E and Figure 43The shoe plates 300 to 300i are shown to be formed by attaching fiber strands to a substrate. In other words, the shoe plates 300 to 300i are formed from one or more strands 702 of fibers arranged in a selected pattern to impart anisotropic stiffness and gradient load paths throughout the plates 300 to 300i. The fiber strands 702 can be attached to the same substrate 704 or separate substrates 704 and embroidered in a layered configuration. If the fiber strands 702 are applied to separate substrates 704, the individual substrates 704 are stacked on top of each other when each substrate 704 is supplied with fiber strands 702. On the other hand, if only one substrate 704 is used when forming the plates 300 to 300i, the first fiber strand 702 is applied to the substrate 704, while additional fiber strands (i.e., layers) 702 are applied on top of the first fiber strand 702. Finally, plates 300 to 300i can be formed using single continuous strands 702 of fiber, whereby the strands 702 are first applied and attached to the substrate 704 and then stacked on top of themselves to form... Figure 43 The layered configuration is shown. Although each of the above processes can be used to form plates 300 to 300i, the following process will be described as forming a single substrate 704 with individual strands 702 of applied fibers. Figure 43 The configuration shown in the diagram is such that each strand 702a to 702e forms layers 700a to 700e of the preform plate.

[0339] Each strand 702 may refer to a bundle of fibers, monofilaments, yarns, or polymer-prepreg bundles. For example, strand 702 may include multiple carbon fibers and multiple resin fibers that, upon activation, cure the carbon fibers and hold them relative to each other in a desired shape and position. As used herein, the term "bundle" refers to a bundle (i.e., multiple) of filaments (e.g., fibers) 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 backing attached to at least one fiber strand 702. Substrate 704 may be formed of a thermosetting polymer material or a thermoplastic polymer material, and substrate 704 may be a textile (e.g., knitted, woven, or nonwoven), injection-molded article, organic sheet, or thermoformed article. 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., fiberglass) and polymer fiber (e.g., synthetic fiber) provide medium modulus.

[0340] When forming plates 300 to 300i, the first strand 702c can be applied to the substrate 704. In other words, the first strand 702c can be applied directly to the substrate 704, or the first strand 702c can be sewn to the substrate 704 to hold the first strand 702c in the desired position. In one configuration, the first strand 702c is applied to the substrate 704 such that the strand 702c is positioned relative to the longitudinal axis (L) of the substrate 704. Figure 42C The angle (Φ) is shown as -30 degrees (-30°). For example, another thread or a second thread 702d can be applied to the first thread 702c by sewing, and the other thread or the second thread 702d can be formed relative to the longitudinal axis (L) of the substrate 704. Figure 42B The angle (Φ) is shown as -15 degrees (-15°). The third strand 702a can be positioned relative to the longitudinal axis (L) of the base 704 at... Figure 42A An angle (Φ) of zero degrees (0°) is applied to the second strand. The fourth strand 702b can be positioned relative to the longitudinal axis (L) of the substrate 704 at... Figure 42D An angle (Φ) of -15 degrees (-15°) is applied to the third strand, as shown in the diagram. The final fifth strand 702e can be positioned relative to the longitudinal axis (L) of the base 704 at... Figure 42E The first strand 702c is shown as being applied to the second strand at an angle (Φ) of 30 degrees (30°). The second strand is shown and described as being applied to the second strand at an angle (Φ) relative to the longitudinal axis (L) of the substrate 704. Figure 42C The angle (Φ) is applied as -30 degrees (-30°), and the fifth line 702e is shown and described as being relative to the longitudinal axis (L) of the base 704. Figure 42E The angle (Φ) is shown as 30 degrees (30°) applied, but these angles (Φ) can be alternatively -15 degrees (-15°) and 15 degrees (15°).

[0341] The strands 702a to 702e form various layers 700a to 700e of the preformed plates 300 to 300i. Once the layers 700a to 700e are formed, they are subjected to heat and pressure to activate the pre-impregnated resin of the individual strands 702a to 702e and further impart the specific shape of the plates 300 to 300i to the layers 700a to 700e, as will be described in detail below.

[0342] As mentioned above, using layered processing ( Figure 43 The board 300 to 300i formed by the prepreg fiber sheet includes a higher density than that formed by the prepreg fiber sheet. Figure 41The formed plate 300 to 300i has one less layer. In other words, the layering process can be achieved using only the longitudinal axis (L) relative to the substrate 704. Figure 42A The single layer 700a is shown as an angle (Φ) of zero degrees (0°). Although the layering process uses one less layer when forming the plates 300 to 300i, the resulting plates 300 to 300i have approximately the same properties as those formed using prepreg fiber sheets (i.e., stiffness, thickness, etc.).

[0343] Special reference Figure 44 and Figure 45 The forming of plates 300 to 300i is described in conjunction with mold 800. Mold 800 includes a first mold half 802 and a second mold half 804. Mold halves 802 and 804 include a mold cavity 806 having the shape of one of the respective plates 300 to 300i, so as to allow mold 800 to impart the desired shape of a particular plate 300 to 300i to stacked sheets 600a to 600e or layers 700a to 700e.

[0344] 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 mold halves 802 and 804. At this time, the mold 800 closes by moving the mold halves 802 and 804 toward each other or by moving one of the mold halves 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 arranged 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 a 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.

[0345] It should be noted that although sheets 600a to 600e and layers 700a to 700e are described as comprising resin material, sheets 600a to 600e and layers 700a to 700e may be additionally supplied 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. The injected resin may include thermoplastic and / or thermosetting materials. Additionally or alternatively, the injected resin may include other materials used to increase the ductility of the shoe plate.

[0346] Figure 46 A top view is provided of an example base 400 for forming any of the shoe plates 300 to 300i described above. The base 1400 may be substantially thin, flat, and flexible. The base 1400, or at least a portion thereof, may be formed from a thermosetting polymer material or a thermoplastic polymer material. In some configurations, the base 1400 comprises a textile that may be knitted, woven, or nonwoven. The base 1400 may also optionally be formed from an injection-molded article, a thermoformed article, or an organic sheet. The base 1400 may be cut into the desired shape defined by the perimeter 1402. In some examples, the base 1400 is cut within an internal portion to form... Figure 29 The cut portion of the shoe plate is 380 or 300h. Figure 30 The cutout portion of the 300i shoe plate is the same as that of the 380i.

[0347] Figure 47 Provides attachment / attachment to Figure 46The top surface 1410 of the substrate 1400 is shown in a top view of the first bundles 1300, 1310 of fibers 1350 forming a first layer on the substrate 1400. The first bundles 1310 (i.e., the first strand portion) form a first cavity 1316 in the foreleg portion 12 and a second cavity 1318 in the heel portion 16 of the substrate 1400. In some examples, the first bundles 1310 of fibers 1350 include a plurality of first segments 1312, each of which extends between two different locations along the substrate to form a first layer on the substrate and define cavities 1316, 1318 therein that expose the substrate 1400. For example, a portion of the first segment 1312 may extend between two different locations along the periphery 1402 of the substrate 1400 in a region where cavities 1316, 1318 are not present. The remaining portions of the first segment 1312 extend between a first location along the periphery 1402 of the substrate 1400 and a second location in an interior region of the substrate 1400, the second location being associated with the boundary of one of the cavities 1316, 1318. The first segments 1312 may be arranged adjacent to each other and generally parallel. In some examples, the first segments 1312 are applied to the substrate 1400 at a first angle relative to the longitudinal axis L of the substrate 1400. The first filament bundle 1310 of the fiber 1350 may also include a first circumferential portion 1313 arranged near the periphery 1402 of the substrate 1400, the first circumferential portion 1313 being operable to connect adjacent first segments 1312. Figure 47 The first filament bundle 1310 of fiber 1350 is shown, which includes a curved path that changes direction based on the anatomical features of the foot.

[0348] In some configurations, a first bundle 1310 of fiber 1350 is attached to substrate 1400 via a first stitch 1314. For example, the first stitch 1314 may zigzag across the first bundle 1310 between first attachment sites on substrate 1400. The first stitch 1314 may penetrate substrate 1400 at the first attachment sites. Here, the attachment sites may be spaced apart from the first bundle 1310 along the periphery 1402 of substrate 1400 and around the portions of substrate 1400 exposed within cavities 1316, 1318. The first stitch 1314 may be formed of the same material as substrate 1400, or the first stitch 1314 may be formed of a different material than the material forming substrate 1400, such that the first stitch 1314 is associated with a higher melting point than substrate 1400. Providing the suture 1314 with a higher melting point than the substrate 1400 allows the suture 1314 to melt after the substrate 1400 when heat is applied, thereby enabling the suture 1314 to retain the first bundle 1310 of the fiber 1350 when the substrate 1400 begins to melt. In some examples, the first suture 1314 or at least a portion of the first suture 1314 is formed of resin.

[0349] Figure 48 Provides layered configuration for attaching / attaching to Figure 46 The substrate 1400 is shown in top view as a first bundle 1310, a second bundle 1320, and a third bundle 1330 of fibers 1350 forming an embroidered preform. This embroidered preform can be heated, molded, and cured to form any of the curved and substantially rigid shoe plates 300 to 300i. Other configurations may include attaching / attaching to different substrates 1400 and being stacked to provide each bundle 1310, 1320, 1330 of the stacked substrates 1400. The substrates 1400 and / or bundles 1310, 1320, 1330 may be trimmed before at least one of heat and pressure is applied to form the shoe plates 300 to 300i.

[0350] Figure 49 Provided Figure 48An exploded view of the embroidered prefab shows each of the base 1400, the first filament bundle 1310, the second filament bundle 1320, and the third filament bundle 1330, such that each filament bundle 1310, 1320, and 1330 is formed by individual and corresponding strands / bundles of fiber 1350. For example, at least one of the first filament bundle 1310, the second filament bundle 1320, and the third filament bundle 1330 is formed by corresponding continuous strands of fiber 1350. However, in other configurations, filament bundles 1310, 1320, and 1330 may all be formed by the same continuous strands / bundles of fiber 1350. The filament bundles 1310, 1320, and 1330 may be attached to the top surface 1410 of the base 1400 without penetrating the bottom surface 1412 disposed on the side of the base 1400 opposite to the top surface 1410.

[0351] In some examples, a first filament bundle 1310 is associated with a first shape, and a second filament bundle 1320 is associated with a second shape different from the first shape. Similarly, a third filament bundle 1330 is associated with a third shape that may differ from the first and second shapes. Therefore, the layer associated with at least two of the filament bundles 1310, 1320, and 1330 can be anisotropic. Other configurations may include a first shape that is substantially the same as the second and / or third shape. In some implementations, at least two of the filament bundles 1310, 1320, and 1330 have substantially the same length. In contrast, other implementations include at least two of the filament bundles 1310, 1320, and 1330 having different lengths. For example, Figure 48 and Figure 49 The example illustrates a first filament bundle 1310, a second filament bundle 1320, and a third filament bundle 1330 of fiber 1350. The first filament bundle 1310 defines a length extending through the front leg portion 12, the middle leg portion 14, and the heel portion 16. The second filament bundle 1320 defines a second length, shorter than the first length, extending through the front leg portion 12 and the middle leg portion 14. The third filament bundle 1330 defines a third length, shorter than the second length, extending within the front leg portion 12 and the middle leg portion 14 of the substrate 1400. Each filament bundle 1310, 1320, and 1330 can be designed to emphasize corresponding performance characteristics that differ from those provided by the other filament bundles 1310, 1320, and 1330. Furthermore, the layered configuration of the filament bundles 1310, 1320, and 1330 can provide varying thicknesses across the front leg portion 12, middle leg portion 14, and heel portion 16 of the entire base 1400.

[0352] In some implementations, a second bundle 1320 (i.e., a second strand portion) is disposed on a first layer (e.g., a first bundle 1310) and includes second segments 1322, each extending between two different locations along the periphery 1402 of the substrate 1400 to form a second layer on the first layer. The second segments 1322 may converge with the first segments 1312. The first bundle 1310 and the second bundle 1320 of fiber 1350 may be formed of the same or different materials. For example, the first bundle 1310 and / or the second bundle 1320 may include at least one of carbon fiber, boron fiber, glass fiber, and polymer fiber. In some examples, the second bundle 1320 of fiber 1350 includes approximately the same number of fibers 1350 as the first bundle 1310 of fiber 1350. In other examples, the second bundle 1350 of fiber 1350 comprises a different number of fibers 1350 than the first bundle 1350 of fiber 1350. Similar to the first bundle 1310, the second bundle 1320 of fiber 1350 may include a second surrounding portion 1323 arranged near the periphery 1402 of the substrate 1400, which serves to connect adjacent second segments 1322. In some configurations, when a layered configuration is subjected to pressure (e.g., molding) to bind the fibers 450 to form the shoe plate 300, or when a layered configuration forming an embroidered preform is subjected to pressure (e.g., molding) to bind the fibers 1350 to form the shoe plate 300 to 300i, one or more of the surrounding portions 1323 extend beyond the periphery 1402 of the substrate 1400 and create pinch points. Therefore, Figure 48 A second bundle 1320 of fibers 1350 is shown being cut along the periphery 1402 of the substrate 1400 to remove the surrounding portion 1323, thereby eliminating the presence of a compression point when pressure is applied to form the finished shoe plate 300 to 300i. Thus, adjacent second segments 1322 can be disconnected at the periphery of the substrate 1400 when the corresponding surrounding portion 1323 is removed (e.g., by cutting).

[0353] The second bundle 1320 of fiber 1350 can be attached to substrate 1400 via a second suture 1324, which can zigzag across the second bundle 1320 between second attachment locations on substrate 1400. In some examples, the second suture 1324 penetrates substrate 1400 at the second attachment location. Additionally or alternatively, the second suture 1324 can extend through the first bundle 1310 of fiber 1350. In other words, the second suture 1324 can attach the second bundle 1320 of fiber 1350 to substrate 1400 by crossing the second bundle 1320 of fiber 1350, extending through the first bundle 1310 of fiber, and penetrating substrate 1400 at the second attachment location.

[0354] In some cases, the first suture 1314 and / or the second suture 1324 are formed of resin. Additionally or alternatively, at least one of the first suture 1314 and the second suture 1324 is formed of the same material as the substrate 1400. In some configurations, at least one of the first suture 1314 and the second suture 1324 has a higher melting point than the substrate 1400. Here, the higher melting point allows the sutures 1314, 1324 to melt after the substrate 1400 begins to melt during heat treatment, such that the corresponding filament bundles 1310, 1320 are held in place by the sutures 1314, 1324. The sutures 1314, 1324 may also comprise a material compatible with the optionally injected polymer used for compression molding and / or vacuum molding.

[0355] The third bundle 1330 (i.e., the third strand portion) is disposed on the second layer (e.g., the second bundle 1320) and includes a third segment 1332, each of the third segments 1322 extending between two different locations along the periphery 1402 of the substrate 1400 to form a third layer on the second layer. Similar to the first segment 1312 of the first bundle 1310, the corresponding second segment 1322 of the second bundle 1320 and the third segment 1332 of the third bundle 1330 can each be arranged adjacent to each other and substantially parallel. Figure 48 The second segment 1322 of the second bundle 1320 of fiber 1350 is shown to be applied to the substrate at a second angle relative to the longitudinal axis of the substrate 1400, which is different from the first angle associated with the first segment 1312 of the first bundle 1310 of fiber 1350. Although Figure 48 It is also shown that a third segment 1332 of the third filament bundle 1330 is applied to the substrate 1400 at a third angle relative to the longitudinal axis of the substrate 1400. This third angle is different from the first angle associated with the first segment 1312 and the second angle associated with the second segment 1322, but the third angle may be the same as one of the first and second angles but different from the other. In other words, other configurations may include a third filament bundle 1330 having a third segment 1332 that converges only with one of the first segment 1312 and the second segment 1322.

[0356] In some configurations, the third filament bundle 1330 of fiber 1350 is attached to substrate 1400 via a third suture 1334, which may zigzag across the third filament bundle 1330 between third attachment locations on substrate 1400. In some examples, the third suture 1334 penetrates substrate 1400 at the third attachment location. Additionally or alternatively, the third suture 1334 may extend through at least one of the first filament bundle 1310 and the second filament bundle 1320 of fiber 1350. In other words, the third suture 1334 can attach the third filament bundle 1330 of fiber 1350 to substrate 1400 by crossing the third filament bundle 1330 of fiber 1350, extending through the first filament bundle 1310 and / or the second filament bundle 1320, and penetrating substrate 1400 at the third attachment location.

[0357] Reference Figure 50 A close-up illustration shows a portion of a first bundle of fibers 1300, 1310 attached to a substrate 1400 via a first suture 1314. The first bundle of fibers 1310 is disposed on the top surface 1410 of the substrate 1400, and the first suture 1314 (e.g., in a zigzag pattern) crosses the first bundle of fibers 1310 and penetrates the substrate 1400 at a first attachment position 1315 spaced apart from the first bundle of fibers 1310. The substrate 1400 and the first suture 1314 may be formed of a thermoplastic polymer material that melts during heat treatment. The first suture 1314 may be formed of a first thermoplastic polymer material, and the substrate 1400 may be formed of a second thermoplastic polymer material having a lower melting temperature than the first thermoplastic polymer material. Thus, when the substrate 400 begins to melt during heat treatment, the first suture 1314 can hold the first bundle of fibers 1350 in place without melting. The fibers 1350 associated with the first filament bundle 1310 may include non-polymer fibers 1352 and polymer fibers 1354. For example, non-polymer fibers 1352 may include carbon fibers, glass fibers, aramid fibers, and / or boron fibers. On the other hand, polymer fibers 1354 may include thermoplastic polymer fibers having a higher melting temperature than the thermoplastic polymer material used to form the substrate 1400 and / or the first suture 1314. Furthermore, the thermoplastic polymer material used to form the substrate 1400 may include a melting temperature lower than the degradation temperature associated with the non-polymer fibers 1352 (e.g., carbon fibers).

[0358] Figure 51 Provided along Figure 50The cross-sectional view taken by lines 51-51 shows a first stitch 1314 attaching a first bundle 1310 of fibers 1350 to the top surface 1410 of the substrate 1400. The first stitch 1314 may penetrate the surfaces 1410, 1412 of the substrate 1400 and cross the first bundle 1310 in a zigzag pattern between the first attachment locations 1315. Non-polymer fibers 1352 (e.g., carbon fibers) and polymer fibers 1354 (e.g., thermoplastic polymer fibers) may be included in a circular cross-section blended together with each other along the entire length of the first bundle 1310.

[0359] One or more embroidery preforms formed from fiber bundles 1310, 1320, and 1330 of fiber 1350 can be combined with Figure 41 A series of stacked prepreg fiber sheets 600a to 600e or bonded to each forming Figure 43 In the individual strands 702a to 702e of layers 700a to 700e, the stiffness characteristics imparted by the finished shoe plates 300 to 300i are adjusted. For example, in addition to Figure 41 The sequentially stacked fiber sheets 600a to 600e shown are either Figure 43 In addition to or in place of any of the layers 700a to 700e, one or more embroidery prefabricated layers may be provided.

[0360] Figure 52 Another bundle 1300a is provided to be attached to the substrate 1400 and to form a first layer on the substrate 1400. The bundle 1300a of the fiber 1350 includes a pattern of segments 1302 arranged adjacent to each other and generally parallel to each other. Figures 47 to 49 A first segment 1312 of the first bundle 1310 of fiber 1350 defines cavities 1316, 1318 of the exposed substrate 1400, but segment 1302 extends continuously between two different locations along the periphery 1402 of the substrate 1400 to form a first layer covering the substrate 400 without defining any cavities; that is, segment 1302 extends across the substrate 1400 between an outer and inner portion. Segment 1302 may extend in a direction converging with the longitudinal axis of the substrate 1400. (Refer to...) Figure 53 , Figure 52The detailed view within the dashed circle 53 shows a filament bundle 1300a, which includes a periphery 1402 arranged near the substrate 1400 for connecting adjacent segments 1302 with a surrounding portion 1303. Furthermore, the filament bundle 1300a of fibers 1350 can be attached to the substrate 1400 via stitches 1304, which can zigzag across the filament bundle 1300a between attachment points 1305 located on the substrate 1400. In some examples, the surrounding portion 1303 extending beyond the periphery 1402 is removed to define the periphery of plates 300 to 300i, and the presence of compression points is eliminated when the preform is subjected to pressure (e.g., molding).

[0361] Figure 54 and Figure 55 An exploded view is provided for forming an embroidered preform of any of the shoe plates 300 to 300i that are incorporated into any of the footwear products 10 to 10h. Figure 54 ) and side-by-side views ( Figure 55 The embroidered prefabricated component associated with the shoe plate 300 to 300i includes a base 1400 arranged in a layered configuration, a first bundle 1310a of fiber 1350, a second bundle 1320a of fiber 1350, and a third bundle 1330a of fiber 1350. Bundles 1310a, 1320a, and 1330a may be formed from the same continuous strands / bundles of fiber 1350, or at least one of bundles 1310a, 1320a, and 1330a may be formed from different continuous strands / bundles of fiber 1350. Figure 48 and Figure 49 Like the filament bundles 1310, 1320, and 1330, the filament bundles 1310a, 1320a, and 1330a can be attached to the top surface 1410 of the substrate 1400 via sutures 1314, 1324, and 1334 without penetrating the bottom surface 1412 of the substrate 1400. The sutures 1314, 1324, and 1334 cross the corresponding filament bundles 1310a, 1320a, and 1330a between attachment positions disposed on the substrate 1400. The filament bundles 1310a, 1320a, and 1330a of the fiber 1350 can similarly include at least one of carbon fiber, boron fiber, glass fiber, and polymer fiber. In other configurations, at least a portion of the sutures 1314, 1324, and 1334 penetrates the bottom surface 1412 of the substrate 1400.

[0362] The first bundle 1310a of fiber 1350 includes first segments 1312a, each of which extends between two different locations along the periphery 1402 of substrate 1400 to form a first layer on substrate 1400 (e.g., on top surface 1410). The first segments 1312a are arranged adjacent to each other and generally parallel to each other. Figure 55The first segment 1312a is shown to be applied to the base 1400 at a first angle α1 relative to the longitudinal axis L of the base 1400.

[0363] The second bundle 1320a of fiber 1350 includes a second segment 1322a, each extending between two different locations along the periphery 1402 of substrate 1400 to form a second layer on the first layer. Here, the second segment 1322a converges with the first segment 1312a, and the second segments 1322a are arranged adjacent to each other and generally parallel. For example, the second segment 1322a may be applied to the first layer at a second angle α2 relative to the longitudinal axis L of substrate 1400, different from the first angle α1. In some examples, the first layer associated with the first bundle 1310a and the second layer associated with the second bundle 1320a are anisotropic to impart gradient stiffness and gradient load paths across the entire plate 300 to 300i.

[0364] The third filament bundle 1330a of fiber 1350 includes a third segment 1332a, each of which extends between two different locations along the periphery 1402 of substrate 1400 to form a third layer on the second layer. Here, the third segment 1332a converges with the first segment 1312a and the second segment 1322a, and the third segments 1332a are arranged adjacent to each other and generally parallel. For example, the third segment 1332a may be applied to the second layer at a third angle α3 relative to the longitudinal axis L of substrate 1400, different from the first angle α1 and the second angle α2. Other configurations may include attaching each filament bundle 1310a, 1320a, 1330a to a separate corresponding substrate and stacking the substrates to form a substrate stack, such that the first filament bundle 1310a is arranged between the bottom substrate and the intermediate substrate, the second filament bundle 1320a is arranged between the intermediate substrate and the top substrate, and the third filament bundle is arranged on the top substrate.

[0365] Figures 56 to 59 An embroidered preform is provided for forming any one of the shoe plates 300 to 300i for incorporation into any one of the footwear products 10 to 10h. Figure 56A top view of a prefabricated component is provided, comprising a first bundle 1310b of fibers 1350 and a second bundle 1320b of fibers disposed on a top surface 1410 of a substrate 1400. The bundles 1310b and 1320b can be attached to the substrate 1400 at corresponding attachment locations, the stitches penetrating the substrate 1400 through the top surface 1410 and the bottom surface 1412. The first bundle 1310b (i.e., the first strand portion) can define a plurality of first segments 1312b, each extending between two different locations along the substrate 1400 to form a layer on the substrate 1400 and define a first cavity 1316b located in a front leg portion 12 of the substrate 1400 and a second cavity 1318b located in a rear leg portion 16. The second filament bundle 1320b is operable as an external reinforcing region arranged along the periphery 1402 of the substrate 1400, such that the fibers 1350 of the second filament bundle 1320b surround a first segment 1312b associated with the first filament bundle 1310b of the fibers 1350. The preform panel may optionally include a third filament bundle 1330b of the fibers 1350, which serves as an internal reinforcing region surrounding a first cavity 1316b in the front foot portion 12. Here, the external and internal reinforcing regions defined by the second and third filament bundles 1320b and 1330b can provide additional reinforcement or structural support for the first segment 1312b of the first filament bundle 1310b in the region between the first cavity 1316b and the periphery 1402 of the substrate 1400. This example shows a third filament bundle 1330b forming a third cavity 1336b, which is spaced apart from the second cavity 318b but aligned with the first cavity 1316b to expose the substrate 1400. Although not shown in... Figure 56 As shown, the preform plate may also include a fourth fiber bundle, which is operable to serve as a corresponding internal reinforcement region surrounding the second cavity 1318b in the heel portion 16 in the same manner as the third fiber bundle 1330b reinforces the first segment 1312b surrounding the first cavity 1316b.

[0366] Reference Figure 57 ,along Figure 56The cross-sectional view taken by lines 57-57 shows a second bundle 1320b of fibers 1350 arranged along the periphery 1402 of the substrate 1400 to provide an external reinforcing region for the first bundle 1310b of fibers 1350. The bundles 1310b and 1320b may have substantially the same length or may have different lengths. In some implementations, the bundles 1310b and 1320b are formed of the same material. For example, the fibers 1350 associated with the bundles 1310b and 1320b may include at least one of non-polymer fibers 1352 (e.g., carbon fibers, glass fibers, and / or aramid fibers, and / or boron fibers) and polymer fibers 1354. As mentioned above, the polymer fibers 1354 may include thermoplastic polymer fibers having a higher melting temperature than the thermoplastic polymer material used to form the substrate 1400 (if any). In other implementations, the bundles 1310b and 1320b are formed of different materials.

[0367] Figure 58 Provided along Figure 56 An alternative cross-sectional view taken by line 57-57 shows a polymer material 1520 providing an external reinforcing region for the first filament bundle 1310b of fiber 1350. Here, polymer material 1520 may comprise a single strand (i.e., having a circular cross-section) of material that replaces the second filament bundle 1320b of fiber 1350 by extending along the periphery 1402 of substrate 1400. Polymer material 1520 may comprise a thermoplastic or thermosetting polymer material having a melting temperature higher than that of the polymer material forming substrate 1400, such that polymer material 1520 reinforces the first filament bundle 1310b of fiber 1350 along the periphery 1402 of substrate 1400 as substrate 1400 begins to melt.

[0368] Figure 59 Provided along Figure 56 Another alternative cross-sectional view taken by line 57-57 shows a first bundle 1310b of fibers 1350 attached to a substrate 1400a, the substrate 1400a having a top surface 1410 opposite to the first bundle 1310b and a bottom surface 1412 disposed on the side of the substrate 1400a opposite to the top surface 1410. A second bundle 1320b or polymer material 1520 is attached to... Figures 56 to 58 The substrate 1400a provides an external reinforcement region for the first bundle 1310b of the fiber 1350. The substrate 1400a includes a fold 1414 along the periphery 1402a to double the thickness of the substrate 1400a for providing an external reinforcement region for the first bundle 1310b of the fiber 1350.

[0369] Reference Figures 60 to 62A mold is provided, comprising an upper mold portion 82 and a lower mold portion 84, for molding an embroidered preform 1300, 1400 comprising one or more bundles 1300 of fibers 1350 attached to one or more substrates 1400 to form any one of shoe plates 300 to 300i. As described above, plates 300 to 300i (see plate 300) may define a curved / concave portion 310 and a generally flat portion 312 for bonding to Figures 1 to 15 and Figures 31 to 39 In any of the footwear products 10 to 10h. Therefore, the upper mold portion 82 may include a contact surface 86 having a surface profile that imparts a shape to the embroidered preforms 1300, 1400 to provide a curved / concave portion 310 when the embroidered preforms are compressed between the mold portions 82, 84. Similarly, the lower mold portion 84 may include a contact surface 88 having a surface profile that imparts a shape to the embroidered preforms 1300, 1400 to provide a curved / concave portion 310 when the embroidered preforms are compressed between the mold portions 82, 84. In some examples, the lower mold portion 84 is fixed, and the upper mold portion 82 translates toward the lower mold portion 84 to close the mold 80, thereby compressing the embroidered preforms 1300, 1400 between the upper mold portion 82 and the lower mold portion 84. In other examples, the lower mold portion 84 and the upper mold portion 82 may each translate toward each other, or only the lower mold portion 84 may translate toward the upper mold portion 82.

[0370] Figure 60 The illustration shows the mold 80 open and embroidery preforms 1300, 1400 positioned between the upper mold portion 82 and the lower mold portion 80. The embroidery preforms 1300, 1400 may include one or more bundles 1300 of fibers 1350 attached to a substrate 1400. The substrate 1400 and the bundles 1300 may be substantially flexible. For example, the bundles 1300 may be attached to the substrate 1400 without penetrating it to form one or more layers on the top surface 1410 of the substrate 1400. For example, the bundles 300 may be attached to the substrate 1400 via a thread 1304 that crosses the bundles 1300 and penetrates the substrate 1400 and / or passes through at attachment positions 1305 spaced apart from the bundles 1300. In some examples, the thread 1304 is formed of resin.

[0371] In some configurations, one or more filament bundles 1300 may include Figure 48 and Figure 49The first bundle 1310, the second bundle 1320, and the third bundle 1330 are attached to the substrate 1400 to form corresponding first, second, and third layers on the top surface 1410 of the substrate. In these examples, the bundles 1310, 1320, and 1330 may be formed from the same continuous strands of fibers 1350, or at least one of the bundles 1310 may be formed from different strands of fibers 1350. Therefore, one or more bundles 1310, 1320, and 1330 may be formed from the same or different materials, may include substantially the same or different numbers of fibers 1350, may include substantially the same or different lengths, may include substantially the same or different thicknesses, and may include at least one of carbon fiber, boron fiber, glass fiber, and polymer fiber. Although Figure 48 and Figure 49 Depicts 1310, 1320, and 1330 arranged in a layered configuration on a single substrate 1400, but other configurations include attaching each filament bundle 1310, 1320, and 1330 to a corresponding substrate 1400 to form a substrate stack. In these configurations, the substrate stack can be positioned between an upper die portion 82 and a lower die portion 84 and subjected to heat and pressure. Figure 61 To make the stack conform to the shape of at least one of the corresponding contact surfaces 86, 88, and the base stack is cured to provide a shoe plate 300 to 300i having a curved portion 310 and a generally flat portion 312. Figure 62 ).

[0372] In some implementations, embroidered preforms 1300, 1400 are infused with a liquid material 1650 that coats / encapsulates the outer portion of at least one filament bundle 1300 and partially penetrates the inner portion of at least one filament bundle 1300 to bond at least one filament bundle 1300 to a substrate 1400 and / or other filament bundles 1300. In these implementations, the liquid material 1650 may comprise a thermosetting material applied to the preforms 1300, 1400 in a molten state. The thermosetting material may comprise at least one of epoxy resins, polyurethanes, polymerizable compositions, and prepolymers. Furthermore, one or more polymers, such as rubbers and / or block copolymers, may be added to the liquid material 1650 to increase ductility upon curing. Additionally or alternatively, a resin material 1652 may be incorporated into at least one filament bundle 1300 to aid in bonding / attaching at least one filament bundle 1300 to the substrate 1400.

[0373] The mold 80 can be closed by translating at least one of the upper mold portion 82 and the lower mold portion 84 toward the other of the upper mold portion 82 and the lower mold portion 84. Figure 61The diagram illustrates the closing of the mold 80 and the application of pressure to the embroidered preforms 300 and 400 by subjecting them to at least one of compression molding and vacuum molding while enclosed between mold portions 82 and 84. Furthermore, the mold 80 may simultaneously apply heat to help conform the embroidered preforms 1300 and 1400 to the shape of at least one of the corresponding contact surfaces 86 and 88 and to solidify the embroidered preforms 1300 and 1400 to provide the desired shape and structural rigidity to the shoe plates 300 to 300i. The upper mold portion 82 and / or the lower mold portion 84 may include a plurality of conduits configured to guide heated liquid, such as water, through the corresponding mold portions 82 and 84. Here, the heated liquid raises the overall temperature of the corresponding mold portions 82, 84, and the preforms 1300, 1400 conduct heat from the mold portions 82, 84, thereby raising the temperature of the preforms 1300, 1400 to a temperature suitable for melting and / or solidifying one or more materials associated with the preforms 1300, 1400. In some implementations, the preforms 1300, 1400 are heated before being placed in the mold 80.

[0374] In some configurations, the substrate 1400 is formed of a thermoplastic film attached to at least one filament bundle 1300 via a stitch 1304 that penetrates the substrate 1400 at an attachment location 1305. In examples where more than one substrate 1400 forms a stack, at least one of the substrates 1400 may be formed of a thermoplastic film. At least a portion of the stitch 1304 may be formed of the same material as the substrate 1400. Thus, at least a portion of the stitch 1304 may be formed of the same thermoplastic material as the thermoplastic film forming the substrate 1400. In these configurations, applying heat to the embroidery preforms 1300, 1400 when the mold 80 is closed can operate to thermoform the thermoplastic film and the thermoplastic stitch 1304 to bond at least one filament bundle 1300 of the fiber 1350 to the substrate. Furthermore, closing the mold 80 can apply pressure to the embroidery preforms 1300, 1400. In some configurations, the thermoplastic suture 1304 has a higher melting point than the thermoplastic film, such that the suture 1305 melts after the thermoplastic film, thereby allowing the suture 1304 to hold at least one bundle of fibers 1300 in place on the substrate 1400 as the thermoplastic film of the substrate 1400 begins to melt. Furthermore, in configurations where the resin material 1652 is incorporated into at least one bundle of fibers 1300, when at least a portion of the suture is formed of resin, heat and pressure, in addition to the suture 1304, also activate the resin material 1652 to bind the fibers 1350 associated with the at least one bundle of fibers 1300.

[0375] In an implementation where liquid material 1650 (e.g., a thermosetting material with or without added stretch-enhancing polymer) is injected into at least one bundle 1300 of fiber 1350, a closed mold 180 applying at least one of heat and pressure includes subjecting the embroidery preform to at least one of vacuum molding and compression molding to solidify the liquid material 1650 (e.g., to solidify the thermosetting material), such that at least one bundle 300 is bonded to the substrate 1400 and / or other bundles 1300.

[0376] Reference Figure 62 The mold 80 is opened by translating the upper mold portion 82 away from the lower mold portion 84 and / or translating the lower mold portion 84 away from the upper mold portion 82. The liquid material 1650 (thermosetting material) injected into the filament bundle 300 and / or the thermoplastic material forming the base 1400 and / or the stitching are cured to form a shoe plate 300 to 300i with the desired shape. Thereafter, the shoe plate 300 to 300i can be bonded to the footwear 10 to 10h.

[0377] The aforementioned process can be used to form shoe plates and cushioning elements that can be used to manufacture custom shoes. For example, various foot dimensions can be recorded to determine the appropriate dimensions of shoe plates and cushioning components to be incorporated into the footwear. Furthermore, data associated with foot behavior (gate) can be obtained to determine whether the foot indicates toe-on or heel-on strike. 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. Additionally, 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.

[0378] Custom-made shoe plates also allow for the customization of the plate's stiffness 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 stiffness of the plate for that athlete. Here, the plate's stiffness can vary depending on the athlete's strength or the size / condition of their tendons. Additionally or alternatively, the plate's 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 the 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 a suitable stiffness.

[0379] In some examples, a method of manufacturing the shoe plate 300 includes the steps of: providing a plurality of stacked sheets (or tows); fusing the plurality of stacked sheets to form a monolithic layer; and thermoforming the monolithic layer to form the plate 300. The method may also include providing an upper 100 defining an internal cavity 102 and inserting the plate into the internal cavity 102. The method may further include: providing a midsole 220 extending from the forefoot portion 12 to the heel portion 16; positioning the shoe plate 300 on the upper portion of the midsole 220; securing the upper 100 to the midsole 220; and securing the outsole 210 to the midsole 220 to form a footwear article.

[0380] The following items provide exemplary configurations of the plates for the aforementioned footwear products and exemplary configurations of methods for manufacturing the plates for footwear products.

[0381] Item 1: A sole structure for a footwear article having an upper, the sole structure comprising an outsole and a plate disposed between the outsole and the upper. The plate includes a foremost point disposed in the forefoot region of the sole structure, a last point disposed closer to the heel region of the sole structure than the foremost point, and a concave portion extending between the foremost point and the last point and including a constant radius of curvature from the foremost point to the metatarsophalangeal (MTP) point of the sole structure, the MTP point being opposite the MTP joint of the foot during use. A first cushioning layer may be disposed between the concave portion and the upper. The plate may be formed from a first bundle of fibers forming a first layer, a second bundle of fibers forming a second layer, and a third bundle of fibers forming a third layer, whereby the first bundle, the second bundle, and the third bundle of fibers are positioned at different angles relative to the longitudinal axis of the plate along its length.

[0382] Item 2: According to the sole structure described in Item 1, wherein the foremost point and the last point are coplanar.

[0383] Item 3: The sole structure according to Item 2, wherein the plate includes a generally flat portion disposed in the heel region of the sole structure, and the last point is located within the generally flat portion.

[0384] Item 4: The sole structure according to Item 1, wherein the plate includes a generally flat portion disposed in the heel region of the sole structure, and the last point is located within the generally flat portion.

[0385] Item 5: The sole structure according to Item 4 further includes a mixed portion disposed between the concave portion and the generally flat portion and connecting the concave portion and the generally flat portion.

[0386] Item 6: The sole structure according to Item 5, wherein the hybrid portion includes a substantially constant curvature.

[0387] Item 7: The sole structure according to Item 5, wherein, for men's footwear of size 10 (10), the mixed portion includes a radius of curvature equal to about 134 millimeters (mm).

[0388] Item 8: The sole structure according to Item 5, wherein the foremost point and the last point are coplanar at the junction of the mixed portion and the generally flat portion.

[0389] Item 9: The sole structure according to any one of items 3 to 8 further includes a second cushioning layer disposed between the generally flat portion and the upper.

[0390] Item 10: The sole structure according to Item 9 further includes a third buffer layer disposed between the outsole and the plate.

[0391] Item 11: The sole structure according to Item 10, wherein the third cushioning layer is disposed in the heel area.

[0392] Item 12: The sole structure according to Item 10, wherein the third cushioning layer extends from the heel region to the forefoot region.

[0393] Item 13: The sole structure according to Item 12, wherein the second cushioning member has a thickness of about 3.0 mm to about 13.0 mm at the position opposite to the MTP point, and the third cushioning member has a thickness of about 0.5 mm to about 6.0 mm at the position opposite to the MTP point.

[0394] Item 14: The sole structure according to any one of items 9 to 12, wherein at least one of the first cushioning member, the second cushioning member, and the third cushioning member comprises from about 0.05 grams per cubic centimeter (g / cm³). 3 (approximately 0.20 g / cm³) 3 Its density, hardness from about eleven (11) Shore A to about fifty (50) Shore A, and at least sixty percent (60%) of its energy return.

[0395] Item 15: The sole structure according to any one of items 9 to 12 further includes at least one fluid-filled chamber disposed between the plate and the upper and / or between the outsole and the plate.

[0396] Item 16: The sole structure according to Item 15, wherein the at least one fluid filling chamber is disposed within at least one of the second cushioning layer and the third cushioning layer.

[0397] Item 17: The sole structure according to any of the preceding items, wherein the MTP point is positioned at approximately 30% (30%) of the total length of the plate from the foremost point, and the last point is positioned at approximately 30% (30%) of the total length of the plate from the MTP point.

[0398] Item 18: The sole structure according to any of the preceding items, wherein the MTP point is positioned at approximately 81 mm from the foremost point on the plate, and the last point is positioned at approximately 81 mm from the foremost point on the plate.

[0399] Item 19: The sole structure according to any of the preceding items, wherein the MTP point is positioned at approximately 25% to 35% (35%) of the total length of the plate from the foremost point, and the last point is positioned at approximately 25% to 35% (35%) of the total length of the plate from the MTP point.

[0400] Item 20: The sole structure according to any of the preceding items, wherein the center of the radius of curvature is located at the MTP point.

[0401] Item 21: The sole structure according to any of the preceding items, wherein the constant radius of curvature extends from the foremost point through the MTP point.

[0402] Item 22: The sole structure according to Item 1, wherein the constant radius of curvature extends from the foremost point through the MTP point to a distance of at least forty percent (40%) of the total length of the plate from the foremost point.

[0403] Item 23: The sole structure according to any of the preceding items, wherein the outsole includes a ground contact surface and an inner surface formed on the side of the outsole opposite to the ground contact surface, the inner surface being directly attached to the plate.

[0404] Item 24: The sole structure according to Item 23, wherein the inner surface is attached to the plate near the concave portion.

[0405] Item 25: The sole structure according to any of the preceding items, wherein the plate includes a thickness from about 0.6 mm to about 3.0 mm.

[0406] Item 26: The sole structure according to any of the preceding items, wherein the plate comprises a Young's modulus equal to at least seventy (70) gigapascals (GPa).

[0407] Item 27: The sole structure according to any of the preceding items, wherein the foremost point and the rearmost point of the plate each include a positional height equal to about three (3) millimeters (mm) to about twenty-eight (28) millimeters from the MTP.

[0408] Item 28: The sole structure according to any of the preceding items, wherein the foremost point and the rearmost point of the plate each include a positional height from the MTP of about seventeen (17) mm to about fifty-seven (57) mm.

[0409] Item 29: The sole structure according to any of the preceding items, wherein the foremost point extends from the MTP point at an angle of about twelve (12) degrees to about thirty-five (35) degrees relative to the horizontal reference plane.

[0410] Item 30: The sole structure according to any of the preceding items, wherein the last point extends from the MTP point at an angle of about twelve (12) degrees to about thirty-five (35) degrees relative to the horizontal reference plane.

[0411] Item 31: A sole structure for a footwear article having an upper, the sole structure comprising an outsole and a plate disposed between the outsole and the upper. The plate includes a foremost point disposed in the forefoot region of the sole structure, a last point disposed closer to the heel region of the sole structure than the foremost point, and a curved portion extending between and connecting the foremost and last points, and including a curved portion with a constant radius of curvature from the foremost point to the metatarsophalangeal (MTP) point of the sole structure, the MTP point being opposite the MTP joint of the foot during use. A first cushioning layer may be disposed between the curved portion and the upper. The plate may be formed from a first bundle of fibers forming a first layer, a second bundle of fibers forming a second layer, and a third bundle of fibers forming a third layer, whereby the first, second, and third bundles of fibers are positioned at different angles relative to the longitudinal axis of the plate along its length.

[0412] Item 32: The sole structure according to Item 31, wherein the foremost point and the rearmost point are coplanar.

[0413] Item 33: The sole structure according to Item 32, wherein the plate includes a generally flat portion disposed in the heel region of the sole structure, and the last point is located within the generally flat portion.

[0414] Item 34: The sole structure according to Item 31, wherein the plate includes a generally flat portion disposed in the heel region of the sole structure, and the last point is located within the generally flat portion.

[0415] Item 35: The sole structure according to item 34 further includes a mixed portion disposed between the curved portion and the generally flat portion and connecting the curved portion and the generally flat portion.

[0416] Item 36: The sole structure according to Item 35, wherein the hybrid portion includes a substantially constant curvature.

[0417] Item 37: The sole structure according to Item 24, wherein, for men's footwear of size 10 (10), the mixed portion includes a radius of curvature equal to about 134 millimeters (mm).

[0418] Item 38: The sole structure according to Item 35, wherein the foremost point and the last point are coplanar at the junction of the mixed portion and the generally flat portion.

[0419] Item 39: The sole structure according to any one of items 33 to 38 further includes a second cushioning layer disposed between the generally flat portion and the upper.

[0420] Item 40: The sole structure according to Item 39 further includes a third cushioning layer disposed between the outsole and the plate.

[0421] Item 41: The sole structure according to Item 40, wherein the third cushioning layer is disposed in the heel area.

[0422] Item 42: The sole structure according to Item 40, wherein the third cushioning layer extends from the heel region to the forefoot region.

[0423] Item 43: The sole structure according to Item 42, wherein the second cushioning member has a thickness of from about 3.0 mm to about 13.0 mm at the position opposite to the MTP point, and the third cushioning member has a thickness of from about 0.5 mm to about 6.0 mm at the position opposite to the MTP point.

[0424] Item 44: The sole structure according to any one of items 39 to 43, wherein at least one of the first cushioning member, the second cushioning member, and the third cushioning member comprises from about 0.05 grams per cubic centimeter (g / cm³). 3 (approximately 0.20 g / cm³) 3 Its density, hardness from about eleven (11) Shore A to about fifty (50) Shore A, and at least sixty percent (60%) of its energy return.

[0425] Item 45: The sole structure according to any one of items 39 to 42 further includes at least one fluid-filled chamber disposed between the plate and the upper and / or between the outsole and the plate.

[0426] Item 46: The sole structure according to Item 45, wherein the at least one fluid filling chamber is disposed within at least one of the second cushioning layer and the third cushioning layer.

[0427] Item 47: The sole structure according to any of the preceding items, wherein the MTP point is positioned at approximately 30% (30%) of the total length of the plate from the foremost point, and the last point is positioned at approximately 30% (30%) of the total length of the plate from the MTP point.

[0428] Item 48: The sole structure according to any of the preceding items, wherein the MTP point is positioned at approximately 81 mm from the foremost point on the plate, and the last point is positioned at approximately 81 mm from the foremost point on the plate.

[0429] Item 49: The sole structure according to any of the preceding items, wherein the MTP point is positioned at approximately 25% to 35% (35%) of the total length of the plate from the foremost point, and the last point is positioned at approximately 25% to 35% (35%) of the total length of the plate from the MTP point.

[0430] Item 50: The sole structure according to any of the preceding items, wherein the center of the radius of curvature is located at the MTP point.

[0431] Item 51: The sole structure according to any of the preceding items, wherein the constant radius of curvature extends from the foremost point through the MTP point.

[0432] Item 52: The sole structure according to Item 31, wherein the constant radius of curvature extends from the foremost point through the MTP point to at least forty percent (40%) of the total length of the plate from the foremost point.

[0433] Item 53: The sole structure according to any of the preceding items, wherein the outsole includes a ground contact surface and an inner surface formed on the side of the outsole opposite to the ground contact surface, the inner surface being directly attached to the plate.

[0434] Item 54: The sole structure according to Item 53, wherein the inner surface is attached to the plate near the curved portion.

[0435] Item 55: The sole structure according to any of the preceding items, wherein the plate comprises a thickness from about 0.6 mm to about 3.0 mm.

[0436] Item 56: The sole structure according to any of the preceding items, wherein the plate comprises a Young's modulus equal to at least seventy (70) gigapascals (GPa).

[0437] Item 57: The sole structure according to any of the preceding items, wherein the foremost point and the rearmost point of the plate each include a positional height equal to about three (3) millimeters (mm) to about twenty-eight (28) millimeters from the MTP.

[0438] Item 58: The sole structure according to any of the preceding items, wherein the foremost point and the rearmost point of the plate each include a positional height from the MTP of about seventeen (17) mm to about fifty-seven (57) mm.

[0439] Item 59: The sole structure according to any of the preceding items, wherein the foremost point extends from the MTP point at an angle of about twelve (12) degrees to about thirty-five (35) degrees relative to the horizontal reference plane.

[0440] Item 60: The sole structure according to any of the preceding items, wherein the last point extends from the MTP point at an angle of about twelve (12) degrees to about thirty-five (35) degrees relative to the horizontal reference plane.

[0441] Item 61: A sole structure for a footwear article having an upper, the sole structure including an outsole and a plate disposed between the outsole and the upper. The plate includes a foremost point disposed in the forefoot region of the sole structure, a last point disposed closer to the heel region of the sole structure than the foremost point, and a curved portion extending between and connecting the foremost point and the last point, and including a circular curvature from the foremost point to the metatarsophalangeal (MTP) point of the sole structure, the MTP point being opposite the MTP joint of the foot during use. A first cushioning layer may be disposed between the curved portion and the upper. The plate may be formed from a first bundle of fibers forming a first layer, a second bundle of fibers forming a second layer, and a third bundle of fibers forming a third layer, whereby the first bundle of fibers, the second bundle of fibers, and the third bundle of fibers are positioned at different angles relative to the longitudinal axis of the plate along its length.

[0442] Item 62: The sole structure according to Item 61, wherein the foremost point and the rearmost point are coplanar.

[0443] Item 63: The sole structure according to Item 62, wherein the plate includes a generally flat portion disposed in the heel region of the sole structure, and the last point is located within the generally flat portion.

[0444] Item 64: The sole structure according to Item 61, wherein the plate includes a generally flat portion disposed in the heel region of the sole structure, and the last point is located within the generally flat portion.

[0445] Item 65: The sole structure according to Item 64 further includes a mixed portion disposed between the curved portion and the generally flat portion and connecting the curved portion and the generally flat portion.

[0446] Item 66: The sole structure according to Item 65, wherein the hybrid portion includes a substantially constant curvature.

[0447] Item 67: The sole structure according to Item 65, wherein, for men's footwear of size 10 (10), the mixed portion includes a radius of curvature equal to about 134 millimeters (mm).

[0448] Item 68: The sole structure according to Item 65, wherein the foremost point and the last point are coplanar at the junction of the mixed portion and the generally flat portion.

[0449] Item 69: The sole structure according to any one of items 63 to 68 further includes a second cushioning layer disposed between the generally flat portion and the upper.

[0450] Item 70: The sole structure according to Item 69 further includes a third cushioning layer disposed between the outsole and the plate.

[0451] Item 71: The sole structure according to Item 70, wherein the third cushioning layer is disposed in the heel area.

[0452] Item 72: The sole structure according to Item 70, wherein the third cushioning layer extends from the heel region to the forefoot region.

[0453] Item 73: The sole structure according to Item 72, wherein the second cushioning member has a thickness of from about 3.0 mm to about 13.0 mm at the position opposite to the MTP point, and the third cushioning member has a thickness of from about 0.5 mm to about 6.0 mm at the position opposite to the MTP point.

[0454] Item 74: The sole structure according to any one of items 69 to 73, wherein at least one of the first cushioning member, the second cushioning member, and the third cushioning member comprises from about 0.05 grams per cubic centimeter (g / cm³). 3 (approximately 0.20 g / cm³) 3 Its density, hardness from about eleven (11) Shore A to about fifty (50) Shore A, and at least sixty percent (60%) of its energy return.

[0455] Item 75: The sole structure according to any one of items 69 to 72 further includes at least one fluid-filled chamber disposed between the plate and the upper and / or between the outsole and the plate.

[0456] Item 76: The sole structure according to Item 75, wherein the at least one fluid filling chamber is disposed within at least one of the second cushioning layer and the third cushioning layer.

[0457] Item 77: The sole structure according to any of the preceding items, wherein the MTP point is positioned at approximately 30% (30%) of the total length of the plate from the foremost point, and the last point is positioned at approximately 30% (30%) of the total length of the plate from the MTP point.

[0458] Item 78: The sole structure according to any of the preceding items, wherein the MTP point is positioned at approximately 81 mm from the foremost point on the plate, and the last point is positioned at approximately 81 mm from the foremost point on the plate.

[0459] Item 79: The sole structure according to any of the preceding items, wherein the MTP point is positioned at approximately 25% to 35% (35%) of the total length of the plate from the foremost point, and the last point is positioned at approximately 25% to 35% (35%) of the total length of the plate from the MTP point.

[0460] Item 80: The sole structure according to any of the preceding items, wherein the center of the circular curvature is located at the MTP point.

[0461] Item 81: The sole structure according to any of the preceding items, wherein the circular curvature extends from the foremost point through the MTP point.

[0462] Item 82: The sole structure according to Item 61, wherein the circular curvature extends from the foremost point through the MTP point to a total length of at least forty percent (40%) of the plate from the foremost point.

[0463] Item 83: The sole structure according to any of the preceding items, wherein the outsole includes a ground contact surface and an inner surface formed on the side of the outsole opposite to the ground contact surface, the inner surface being directly attached to the plate.

[0464] Item 84: The sole structure according to Item 83, wherein the inner surface is attached to the plate near the curved portion.

[0465] Item 85: The sole structure according to Item 83 further includes a second cushioning layer disposed on the side of the plate opposite to the first cushioning layer, the second cushioning layer forming at least a portion of the outsole.

[0466] Item 86: The sole structure according to any of the preceding items, wherein the plate comprises a thickness from about 0.6 mm to about 3.0 mm.

[0467] Item 87: The sole structure according to any of the preceding items, wherein the plate comprises a Young's modulus equal to at least seventy (70) gigapascals (GPa).

[0468] Item 88: The sole structure according to any of the preceding items, wherein the foremost point and the rearmost point of the plate each include a positional height from the MTP equal to about three (3) millimeters (mm) to about twenty-eight (28) millimeters.

[0469] Item 89: The sole structure according to any of the preceding items, wherein the foremost point and the rearmost point of the plate each include a positional height from the MTP of about seventeen (17) mm to about fifty-seven (57) mm.

[0470] Item 90: The sole structure according to any of the preceding items, wherein the foremost point extends from the MTP point at an angle of about twelve (12) degrees to about thirty-five (35) degrees relative to the horizontal reference plane.

[0471] Item 91: The sole structure according to any of the preceding items, wherein the last point extends from the MTP point at an angle of about twelve (12) degrees to about thirty-five (35) degrees relative to the horizontal reference plane.

[0472] Item 92: A plate for a footwear article having a sole structure, the plate comprising a foremost point disposed in the forefoot region of the sole structure, a last point disposed closer to the heel region of the sole structure than the foremost point, and a concave portion extending between the foremost point and the last point and including a constant radius of curvature from the foremost point to the metatarsophalangeal (MTP) point of the sole structure, the MTP point being opposite the MTP joint of the foot during use. The plate may be formed from a first bundle of fibers forming a first layer, a second bundle of fibers forming a second layer, and a third bundle of fibers forming a third layer, whereby the first bundle, the second bundle, and the third bundle of fibers are positioned at different angles relative to the longitudinal axis of the plate along its length.

[0473] Item 93: The plate according to Item 92, wherein the foremost point and the last point are coplanar.

[0474] Item 94: The plate according to Item 93, wherein the plate includes a generally flat portion disposed in the heel region of the sole structure, the last point being located within the generally flat portion.

[0475] Item 95: The plate according to Item 92, wherein the plate includes a generally flat portion disposed in the heel region of the sole structure, the last point being located within the generally flat portion.

[0476] Item 96: The plate according to item 95 further includes a mixed portion disposed between the concave portion and the generally flat portion and connecting the concave portion and the generally flat portion.

[0477] Item 97: The plate according to Item 96, wherein the mixed portion comprises a substantially constant curvature.

[0478] Item 98: The plate according to Item 96, wherein, for men's footwear of size 10 (10), the mixed portion includes a radius of curvature equal to about 134 millimeters (mm).

[0479] Item 99: The plate according to Item 96, wherein the foremost point and the last point are coplanar at the junction of the mixed portion and the generally flat portion.

[0480] Item 100: The board according to any of the preceding items, wherein the MTP point is located at approximately 30% (30%) of the total length of the board from the foremost point, and the last point is located at approximately 30% (30%) of the total length of the board from the MTP point.

[0481] Item 101: The plate according to any of the preceding items, wherein the MTP point is positioned at approximately 81 millimeters (mm) of the total length of the plate from the foremost point, and the last point is positioned at approximately 81 millimeters (mm) of the total length of the plate from the foremost point.

[0482] Item 102: The board according to any of the preceding items, wherein the MTP point is located at approximately 25% to 35% (35%) of the total length of the board from the foremost point, and the last point is located at approximately 25% to 35% (35%) of the total length of the board from the MTP point.

[0483] Item 103: The plate according to any of the preceding items, wherein the center of the radius of curvature is located at the MTP point.

[0484] Item 104: The plate according to any of the preceding items, wherein the constant radius of curvature extends from the foremost point through the MTP point.

[0485] Item 105: The plate according to Item 104, wherein the constant radius of curvature extends from the foremost point through the MTP point to a distance of at least forty percent (40%) of the total length of the plate from the foremost point.

[0486] Item 106: The plate according to any of the preceding items, wherein the plate comprises a thickness from about 0.6 millimeters (mm) to about 3.0 millimeters.

[0487] Item 107: A plate according to any of the preceding items, wherein the plate comprises a Young's modulus equal to at least seventy (70) gigapascals (GPa).

[0488] Item 108: The sole structure according to any of the preceding items, wherein the foremost point and the rearmost point of the plate each include a positional height equal to about three (3) millimeters (mm) to about twenty-eight (28) millimeters from the MTP.

[0489] Item 109: The sole structure according to any of the preceding items, wherein the foremost point and the rearmost point of the plate each include a positional height from the MTP of about seventeen (17) mm to about fifty-seven (57) mm.

[0490] Item 110: The sole structure according to any of the preceding items, wherein the foremost point extends from the MTP point at an angle of about twelve (12) degrees to about thirty-five (35) degrees relative to the horizontal reference plane.

[0491] Item 111: The sole structure according to any of the preceding items, wherein the last point extends from the MTP point at an angle of about twelve (12) degrees to about thirty-five (35) degrees relative to the horizontal reference plane.

[0492] Item 112: A plate for a footwear article having a sole structure, the plate comprising a foremost point disposed in the forefoot region of the sole structure, a last point disposed closer to the heel region of the sole structure than the foremost point, and a curved portion extending between and connecting the foremost point and the last point, and including a curved portion with a constant radius of curvature from the foremost point to the metatarsophalangeal (MTP) point of the sole structure, the MTP point being opposite the MTP joint of the foot during use. The plate may be formed from a first bundle of fibers forming a first layer, a second bundle of fibers forming a second layer, and a third bundle of fibers forming a third layer, whereby the first bundle, the second bundle, and the third bundle of fibers are positioned at different angles relative to the longitudinal axis of the plate along its length.

[0493] Item 113: The plate according to Item 112, wherein the foremost point and the last point are coplanar.

[0494] Item 114: The plate according to Item 113, wherein the plate includes a generally flat portion disposed in the heel region of the sole structure, the last point being located within the generally flat portion.

[0495] Item 115: The plate according to Item 112, wherein the plate includes a generally flat portion disposed in the heel region of the sole structure, the last point being located within the generally flat portion.

[0496] Item 116: The plate according to Item 115, wherein the curved portion includes a mixed portion disposed between and connecting the constant radius of curvature and the generally flat portion.

[0497] Item 117: The plate according to Item 107, wherein the hybrid portion comprises a substantially constant curvature.

[0498] Item 118: The plate according to Item 116, wherein, for men's footwear of size 10 (10), the mixed portion includes a radius of curvature equal to about 134 millimeters (mm).

[0499] Item 119: The plate according to Item 107, wherein the foremost point and the last point are coplanar at the junction of the mixed portion and the generally flat portion.

[0500] Item 120: The plate according to any of the preceding items, wherein the MTP point is positioned at approximately thirty percent (30%) of the total length of the plate from the foremost point.

[0501] Item 121: The plate according to any of the preceding items, wherein the MTP point is positioned at approximately 81 millimeters (mm) of the total length of the plate from the foremost point, and the last point is positioned at approximately 81 millimeters (mm) of the total length of the plate from the foremost point.

[0502] Item 122: The board according to any of the preceding items, wherein the MTP point is located at approximately 25% to 35% (35%) of the total length of the board from the foremost point, and the last point is located at approximately 25% to 35% (35%) of the total length of the board from the MTP point.

[0503] Item 123: The plate according to any of the preceding items, wherein the center of the radius of curvature is located at the MTP point.

[0504] Item 124: The plate according to any of the preceding items, wherein the constant radius of curvature extends from the foremost point through the MTP point.

[0505] Item 125: The plate according to Item 124, wherein the constant radius of curvature extends from the foremost point through the MTP point to a distance of at least forty percent (40%) of the total length of the plate from the foremost point.

[0506] Item 126: The plate according to any of the preceding items, wherein the plate comprises a thickness from about 0.6 mm to about 3.0 mm.

[0507] Item 127: A plate according to any of the preceding items, wherein the plate comprises a Young's modulus equal to at least seventy (70) gigapascals (GPa).

[0508] Item 128: The plate according to any of the preceding items, wherein the foremost point and the last point of the plate each include a positional height from the MTP equal to about three (3) millimeters (mm) to about twenty-eight (28) millimeters.

[0509] Item 129: The plate according to any of the preceding items, wherein the foremost point and the last point of the plate each include a positional height from the MTP of about seventeen (17) millimeters (mm) to about fifty-seven (57) millimeters.

[0510] Item 130: The plate according to any of the preceding items, wherein the foremost point extends from the MTP point at an angle of about twelve (12) degrees to about thirty-five (35) degrees relative to the horizontal reference plane.

[0511] Item 131: The plate according to any of the preceding items, wherein the last point extends from the MTP point at an angle of about twelve (12) degrees to about thirty-five (35) degrees relative to the horizontal reference plane.

[0512] Item 132: A plate for a footwear article having a sole structure, the plate comprising a foremost point disposed in the forefoot region of the sole structure, a last point disposed closer to the heel region of the sole structure than the foremost point, and extending between and connecting the foremost point and the last point, and including a circular curvature from the foremost point to the metatarsophalangeal (MTP) point of the sole structure, the MTP point being opposite the MTP joint of the foot during use. The plate may be formed from a first bundle of fibers forming a first layer, a second bundle of fibers forming a second layer, and a third bundle of fibers forming a third layer, whereby the first bundle, the second bundle, and the third bundle of fibers are positioned at different angles relative to the longitudinal axis of the plate along its length.

[0513] Item 133: The plate according to Item 114, wherein the foremost point and the last point are coplanar.

[0514] Item 134: The plate according to Item 133, wherein the plate includes a generally flat portion disposed in the heel region of the sole structure, the last point being located within the generally flat portion.

[0515] Item...

Claims

1. A method for forming a footwear article, the method comprising: The first strand is attached to a flexible substrate to form a first layer on the substrate; Positioning the substrate on the surface of the first mold to change the shape of the substrate; Applying at least one of heat and pressure to the first thread portion and the base to make the base conform to the shape of the first mold surface; and incorporating the base into the footwear, wherein the base includes a foremost point disposed in the forefoot region, a last point disposed closer to the heel region than the foremost point, and a concave portion extending between the foremost point and the last point and including a constant radius of curvature from the foremost point to the metatarsophalangeal point of the footwear, the metatarsophalangeal point being opposite the metatarsophalangeal joint of the foot during use.

2. The method of claim 1, further comprising attaching a second strand portion to the substrate to form a second layer on the substrate.

3. The method according to claim 2, wherein, Attaching the second strand portion to the substrate includes attaching the second strand portion adjacent to the first strand portion.

4. The method according to any one of claims 2-3, wherein, Attaching the second strand portion to the substrate includes stacking at least a portion of the second strand portion on the first strand portion.

5. The method according to any one of claims 2-4, further comprising forming the first strand portion and the second strand portion from the same continuous strand.

6. The method according to any one of claims 2-5, further comprising forming the first strand portion and the second strand portion from the same material.

7. The method according to any one of claims 2-5, further comprising forming the first strand portion and the second strand portion from different materials.

8. The method according to any one of claims 1-7, further comprising forming the first strand portion from a first bundle of fibers.

9. The method according to claim 8, wherein, The formation of the first strand portion from the first bundle of the fibers includes forming the first strand portion from at least one of carbon fiber, boron fiber, glass fiber, and polymer fiber.

10. The method according to any one of claims 2-7, further comprising forming the second strand portion from a second bundle of fibers.

11. The method according to claim 10, wherein, The second strand portion formed by the second bundle of the fibers includes the second strand portion being formed by at least one of carbon fiber, boron fiber, glass fiber and polymer fiber.

12. The method according to claim 11, wherein, The second strand portion formed by the second bundle of the fiber includes providing the same number of fibers as the first bundle of the fiber.

13. The method according to claim 11, wherein, The second strand portion formed by the second bundle of the fiber includes providing a different number of fibers than the first bundle of the fiber.

14. The method according to any one of claims 2-7 and 10-13, further comprising providing the first strand portion and the second strand portion having different lengths.

15. The method according to any one of claims 2-7 and 10-13, further comprising providing the first strand portion and the second strand portion having the same length.

16. The method according to any one of claims 2-7 and 10-15, wherein, Attaching the first strand portion to the substrate and attaching the second strand portion to the substrate, at least one of the first layer and the second layer, includes forming a cavity in at least one of the first layer and the second layer.

17. The method of claim 16, further comprising exposing the substrate within the cavity.

18. The method according to any one of claims 2-7 and 10-17, further comprising providing the first strand portion and the second strand portion having different thicknesses.

19. The method according to any one of claims 2-7 and 10-17, further comprising providing the first strand portion and the second strand portion having the same thickness.

20. The method according to any one of claims 2-7 and 10-19, further comprising providing the first layer and the second layer having different thicknesses.

21. The method according to any one of claims 2-7 and 10-19, further comprising providing the first layer and the second layer having the same thickness.

22. The method according to claim 1, wherein, Making the base conform to the shape of the first mold surface includes providing the base with a front foot portion, a middle foot portion, and a heel portion.

23. The method according to any one of claims 2-6, further comprising attaching the first strand portion to the substrate via a first suture and attaching the second strand portion to the substrate via a second suture.

24. The method according to claim 23, wherein, Attaching the first strand portion to the substrate via a first suture and the second strand portion to the substrate via a second suture includes using sutures formed of resin.

25. The method according to claim 23, wherein, Attaching the first strand portion to the substrate via a first suture and attaching the second strand portion to the substrate via a second suture includes using sutures formed of the same material as the substrate.

26. The method according to claim 23, wherein, Attaching the first strand portion of the thread to the substrate via a first suture and attaching the second strand portion of the thread to the substrate via a second suture includes using a suture having a higher melting point than the substrate.

27. The method according to claim 1, wherein, Applying heat and pressure includes activating the resin material bonded to the first strand portion.

28. The method of claim 1, further comprising injecting liquid material into the first strand portion.

29. The method according to claim 28, wherein, Applying heat and pressure includes subjecting the substrate and the first strand portion to at least one of vacuum molding and compression molding to solidify the liquid material.

30. The method according to claim 29, wherein, Curing the liquid material includes curing the thermosetting material.

31. The method according to claim 30, wherein, Curing thermosetting materials includes curing at least one of epoxy resins, polyurethanes, polymerizable compositions, and prepolymers.

32. The method according to claim 28, wherein, Injecting liquid material into the first strand portion includes adding a polymer to the liquid material to increase the ductility of the liquid material upon curing.

33. The method according to claim 32, wherein, Adding a polymer to the liquid material includes adding at least one of rubber and block copolymer.

34. The method of claim 1, further comprising forming the substrate from a thermoplastic film.

35. The method of claim 34, further comprising attaching a portion of the first strand to the thermoplastic film via a suture.

36. The method according to claim 35, wherein, Attaching the first strand of thread to the thermoplastic film via sutures includes using sutures formed of a thermoplastic material.

37. The method of claim 36, wherein, Applying at least one of heat and pressure to the first strand portion and the substrate includes thermoforming the thermoplastic film and the thermoplastic suture to bond the first strand portion to the substrate.

38. The method according to any one of claims 1-37, wherein, Applying heat and pressure includes subjecting the substrate and the first strand portion to at least one of vacuum molding and compression molding.

39. A method for forming a footwear article, the method comprising: The first strand is attached to a flexible substrate to form a first layer on the substrate; Position the second strand portion on the first layer to form the second layer on the first layer; Positioning the substrate on the surface of the first mold to change the shape of the substrate; At least one of heat and pressure is applied to the first strand portion, the second strand portion, and the base to make the base conform to the shape of the first mold surface; and the base is incorporated into the footwear, the base including a foremost point disposed in the forefoot region, a last point disposed closer to the heel region than the foremost point, and a concave portion extending between the foremost point and the last point and including a constant radius of curvature from the foremost point to the metatarsophalangeal point of the footwear, the metatarsophalangeal point being opposite the metatarsophalangeal joint of the foot during use.

40. The method according to claim 39, wherein, Attaching the first strand portion to the flexible substrate includes attaching the first strand portion to the flexible substrate via a first seam, the first seam crossing the first strand portion and penetrating the substrate at a first attachment location spaced apart from the first strand portion.

41. The method according to any one of claims 39-40, wherein, Positioning the second strand portion on the first layer includes attaching the second strand portion to the flexible substrate via a second seam, the second seam crossing the second strand portion, extending through the first strand portion, and penetrating the substrate at a second attachment location.

42. The method of claim 39, further comprising attaching the second strand portion to the second substrate to form a second layer on the second substrate, wherein, Positioning the second strand portion on the first layer includes positioning the second substrate on the first layer.

43. The method according to any one of claims 39-42, further comprising forming the first strand portion and the second strand portion from the same continuous strand.

44. The method according to any one of claims 39-43, further comprising forming the first strand portion from a first bundle of fibers including at least one of carbon fiber, boron fiber, glass fiber and polymer fiber.

45. The method according to any one of claims 39-44, further comprising forming the second strand portion from a second bundle of fibers including at least one of carbon fiber, boron fiber, glass fiber and polymer fiber.

46. ​​The method according to claim 45, wherein, The second strand portion formed by the second bundle of the fiber includes providing the same number of fibers as the first bundle of the fiber.

47. The method according to claim 45, wherein, The second strand portion formed by the second bundle of the fiber includes providing a different number of fibers than the first bundle of the fiber.

48. The method according to any one of claims 39-47, further comprising providing a surrounding portion disposed near the periphery of the first strand portion and the second strand portion, the surrounding portion connecting adjacent first segments and adjacent second segments.

49. The method of claim 48, further comprising removing at least one portion of the surrounding portion that extends beyond the periphery of the substrate to define an outer edge of the substrate.

50. The method according to any one of claims 39-49, further comprising providing segments with different densities for the first layer and the second layer.

51. The method according to any one of claims 39-50, wherein, Attaching the first strand portion includes applying a first segment of the first strand portion to the substrate at a first angle relative to the longitudinal axis of the substrate, and positioning the second strand portion includes applying a second segment of the second strand portion to the first layer at a second angle relative to the longitudinal axis of the substrate, which is different from the first angle.

52. The method of claim 51, further comprising positioning a third strand portion on the second layer, wherein positioning the third strand portion on the second layer comprises positioning third segments of the third strand portion on the second layer such that each third segment extends between two different locations along the periphery of the substrate to form a third layer on the second layer, the third segments converging with the first segments and the second segments, and the third segments being arranged adjacent to and parallel to each other.

53. The method according to any one of claims 39-52, wherein, Applying heat and pressure includes activating the polymer resin bonded to the first strand portion and the second strand portion.

54. The method according to any one of claims 39-53, further comprising injecting a liquid material into the first strand portion, the second strand portion and the substrate, wherein the liquid material is a thermosetting material.

55. The method according to claim 54, wherein, Applying heat and pressure includes subjecting the first strand portion, the second strand portion, and the substrate to at least one of vacuum molding and compression molding to cure the thermosetting material.

56. The method of claim 39, further comprising forming the substrate from a thermoplastic film.

57. The method according to claim 56, wherein, Attaching the first strand portion includes attaching the first strand portion to the thermoplastic film using a suture formed of a thermoplastic material.

58. The method according to any one of claims 39-57, wherein, Applying at least one of heat and pressure to the first strand portion, the second strand portion, and the substrate includes subjecting the first strand portion, the second strand portion, and the substrate to at least one of vacuum molding and compression molding.

59. The method according to any one of claims 39-58, wherein, Attaching the first strand portion to the substrate and positioning the second strand portion to the substrate includes forming a cavity in at least one of the first layer and the second layer.

60. The method of claim 59, further comprising exposing the substrate within the cavity.

61. The method of claim 59, further comprising removing the exposed portion of the substrate located within the cavity.

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