Sole structure for an article of footwear

Abstract

The sole structure includes a midsole, an outsole, and a plate disposed between the plate and the outsole. The plate includes a first portion having an arched shape extending through a forefoot region and a midfoot region, and a planar second portion connected to the first portion along a connecting portion and extending at an angle to the connecting portion in a first plane. The plate includes a first channel extending from a first end of the plate along the first portion and toward the second portion. A second channel extends from a second end of the plate along the second portion and toward the first portion. The first channel separates the plate into a first pair of tabs formed at the first end, and the second channel separates the plate into a second pair of channels formed at the second end.

Description

[0001] Cross-references to related applications

[0002] This PCT international application claims priority to U.S. Patent Application No. 17 / 496,730, filed October 7, 2021, which claims priority to U.S. Provisional Patent Application No. 63 / 090,120, filed October 9, 2020, pursuant to 35 U.S.SC §119(e), the disclosures of which are incorporated herein by reference in their entirety.

[0003] field

[0004] This disclosure generally relates to sole structures for footwear articles.

[0005] background

[0006] This section provides background information on this disclosure and is not necessarily prior art.

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

[0008] A shoe sole structure typically comprises a layered arrangement extending between the ground surface and the upper. For example, a sole structure may include a midsole and an outsole. The midsole is typically positioned between the outsole and the upper, providing cushioning for the foot. The midsole may include pressurized fluid-filled chambers that elastically compress under applied loads to cushion the foot by reducing ground reaction forces. The outsole provides abrasion resistance and traction with the ground surface and may be formed of rubber or other materials that impart durability and abrasion resistance, as well as enhanced traction with the ground surface.

[0009] Attached Figure

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

[0011] Figure 1 This is a lateral side view of a footwear article, including an example of a sole structure based on the principles of this disclosure;

[0012] Figure 2 yes Figure 1 Perspective view of the top-front portion of the sole structure;

[0013] Figure 3 yes Figure 1 Perspective view of the bottom-rear portion of the sole structure;

[0014] Figure 4 yes Figure 1 A top view of the shoe sole structure;

[0015] Figure 5 It is along Figure 4 The line 5-5 is cut off. Figure 1 A cross-sectional view of the shoe sole structure;

[0016] Figure 6 It is along Figure 4 The line 6-6 in the middle is cut off Figure 1 A cross-sectional view of the shoe sole structure;

[0017] Figure 7 It is along Figure 4 The line 7-7 is cut from Figure 1 A cross-sectional view of the shoe sole structure;

[0018] Figure 8 It is along Figure 4 The line 8-8 in the middle is cut off Figure 1 A cross-sectional view of the shoe sole structure;

[0019] Figure 9 yes Figure 1 A perspective view of an example of a shoe sole structure plate;

[0020] Figure 10 yes Figure 9 The top view of the slab; and

[0021] Figure 11 yes Figure 9 Side view of the board.

[0022] Throughout the accompanying figures, the corresponding reference numerals indicate the corresponding parts.

[0023] Detailed description

[0024] The exemplary configurations will now be described more fully with reference to the accompanying drawings. These 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 examples of specific 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 these specific details are not required, that the exemplary configurations may be implemented in many different forms, and that the specific details and exemplary configurations should not be construed as limiting the scope of this disclosure.

[0025] The terminology used herein is for the purpose of describing particular exemplary configurations only and is not intended to be restrictive. As used herein, the singular articles “a,” “an,” and “the” may also be intended to include plural forms unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having” are inclusive and therefore specify the presence of features, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and / or groups thereof. Unless specifically identified as the 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 shown. Alternative or alternative steps may be employed.

[0026] When an element or layer is referred to as “on another element or layer,” “joined to,” “connected to,” “attached to,” or “linked to” another element or layer, it may be directly on, joined to, connected to, attached to, or linked to another element or layer, or there may be an intermediate element or layer. Conversely, when an element is referred to as “directly on another element or layer,” “directly joined to,” “directly connected to,” “directly attached to,” or “directly linked to” another element or layer, there may not be an intermediate element or layer. 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.

[0027] The terms first, second, third, etc., may be used herein to describe various elements, components, regions, layers, and / or segments. These elements, components, regions, layers, and / or segments should not be limited by these terms. These terms may be used only to distinguish one element, component, region, layer, or segment from another. Terms such as “first,” “second,” and other numerical terms do not imply sequence or order unless the context clearly indicates otherwise. Therefore, the first element, first component, first region, first layer, or first segment discussed below may be referred to as the second element, second component, second region, second layer, or second segment without departing from the teachings of the example configuration.

[0028] In one configuration, the sole structure for footwear articles includes a plate extending from a first end portion disposed at a front end portion of the sole structure to a second end portion disposed at a rear end portion of the sole structure, the plate including a first channel formed in the first end portion and extending toward the second end portion in a first direction and a second channel formed in the second end portion and extending toward the first end portion in a second direction.

[0029] The sole structure may include one or more of the following optional features. For example, both the first channel and the second channel may be elongated and / or may include the same shape. Additionally or alternatively, the first channel may extend at a first oblique angle relative to the longitudinal axis of the plate, and the second channel may extend at a second oblique angle relative to the longitudinal axis of the plate. The longitudinal axes of the first channel may converge with the longitudinal axes of the second channel.

[0030] The plate may include an inclined portion extending from the heel area of ​​the plate to the rear end and extending in a direction away from the ground contact surface of the sole structure, wherein a second channel is formed in the inclined portion.

[0031] In one configuration, the first channel may be longer than the second channel, and / or at least one of the first and second channels may include a parallelogram shape.

[0032] The plate can be placed between the midsole and the outsole, and can have greater rigidity than the midsole.

[0033] Footwear items can be combined with the above-mentioned boards.

[0034] In another configuration, the plate for footwear includes a main body having a first portion comprising an arcuate shape and a second portion extending at an angle to the first portion in a first plane. A first channel extends from a first end of the main body along the first portion and toward the second portion. A second channel extends from a second end of the main body along the second portion and toward the first portion.

[0035] The sole structure may include one or more of the following optional features. For example, a first channel may extend along a first longitudinal axis from a first end to a terminal end of the first channel. In this configuration, the first longitudinal axis may converge with the longitudinal axis of the plate. Additionally, the first portion may include a tapered portion extending from the first portion and terminating at the terminal end of the first channel. The tapered portion may be aligned with the first channel and may include a width similar to that of the first channel, which is measured in a direction substantially transverse to the longitudinal axis of the plate.

[0036] The second channel may extend along a second longitudinal axis from the second end to the end of the second channel. The second longitudinal axis may emanate from the longitudinal axis of the plate. The second portion may include a tapered portion extending from the first portion and terminating at the end of the second channel. The tapered portion may be aligned with the second channel and may include a width similar to that of the second channel, which is measured in a direction substantially transverse to the longitudinal axis of the plate.

[0037] In one configuration, the first channel may be longer than the second channel. Additionally or alternatively, at least one of the first and second channels may include a polygonal shape. Furthermore, both the first and second channels may be elongated and / or the first and second channels may include the same shape.

[0038] The first channel can separate the first end of the plate into a first pair of tabs. Additionally or alternatively, the second channel can separate the second end of the plate into a second pair of tabs.

[0039] Details of one or more embodiments of this disclosure are set forth in the accompanying drawings and the description below. Other aspects, features, and advantages will become apparent from the specification, drawings, and claims.

[0040] refer to Figure 1 The footwear article 10 includes a sole structure 100 and an upper 200 attached to the sole structure 100. The footwear 10 may also include a forefoot portion 12 associated with the foremost point of the footwear 10, and a rearfoot portion 14 corresponding to the rearmost point of the footwear 10. The longitudinal axis A of the footwear 10... 10 The length of the footwear 10 from the front end 12 to the rear end 14 extends parallel to the ground surface and generally divides the footwear 10 into a medial side 16 and an outer side 18. Thus, the medial side 16 and the outer side 18 correspond to opposite sides of the footwear 10 and extend from the front end 12 to the rear end 14. As used herein, the longitudinal direction refers to the direction extending from the front end 12 to the rear end 14, while the lateral direction refers to the direction transverse to the longitudinal direction and extending from the medial side 16 to the outer side 18.

[0041] Footwear 10 can be divided into one or more regions. These regions may include a forefoot region 20, a midfoot region 22, and a heel region 24. The forefoot region 20 corresponds to the metatarsophalangeal (MTP) joint of the foot and can be further subdivided into a toe section 20 corresponding to the metatarsophalangeal joint. T and the ball portion associated with the metatarsals of the foot 20 B The midfoot area 22 can correspond to the arch area of ​​the foot, and the heel area 24 can correspond to the posterior part of the foot (including the calcaneus).

[0042] refer to Figure 1 and Figure 2 The sole structure 100 includes a midsole 102 configured to provide cushioning and responsive properties to the sole structure 100, and an outsole 104 configured to provide a ground contact surface for the footwear article 10. Unlike conventional sole structures that include a unitary midsole, the midsole 102 of this example is composite-formed and includes multiple sub-components. For example, the midsole 102 includes a plate 106 enclosed within a cushioning element 108. Specifically, the cushioning element 108 may include an upper cushioning member 110 and a lower cushioning member 112 configured to position and retain the plate 106 within the midsole 102. The outsole 104 is formed as a single component that at least partially encloses the lower portion of the midsole 102. The sub-components 104, 106, 110, and 112 of the sole structure 100 are assembled and fixed to each other using various joining methods, including adhesive bonding and fusion.

[0043] Reference Figures 2-11 The plate 106 includes a top side 120, a bottom side 122 formed on the side of the plate 106 opposite to the top side 120, and a peripheral edge 124 extending from the top side 120 to the bottom side 122 and defining the peripheral contour of the plate 106. The distance from the top side 120 to the bottom side 122 defines the thickness of the plate 106, as discussed in more detail below. The top side 120 is configured to face the upper 200 and engage with the upper cushioning member 110 of the sole interlayer 102, while the bottom side 122 of the plate 106 is configured to face away from the upper 200 and engage with the lower cushioning member 112. (See reference...) Figure 1 and Figure 8 A portion of the peripheral edge 124 may be exposed between the upper cushioning member 110 and the lower cushioning member 112 along each of the inner side 16 and the outer side 18 of the sole structure 100, such that the peripheral edge 124 defines a portion of the outer periphery of the sole structure 100.

[0044] The plate 106 of the sole structure 100 may be referred to as a "full-length" plate 106, which extends substantially along the entire length of the sole structure 100. For example, the plate 106 extends along the length of the sole structure 100 through each of the forefoot region 20, the midfoot region 22, and the heel region 24. In the illustrated example, the plate 106 extends from a first end 126 adjacent to the forefoot region 12 to a second end 128 adjacent to the heel region 14. More specifically, the first end 126 of the plate terminates at the toe portion 20 of the forefoot region 20. TInside, the second end 128 extends completely through the heel area 24. Thus, the second end 128 of the plate 106 is exposed at the rear end 14 between the upper cushioning member 110 and the lower cushioning member 112.

[0045] Plate 106 can be described as comprising an arched first portion and an inclined second portion, the arched first portion defining a body 130 of plate 106 extending from a first end 126, and the inclined second portion defining a tail 132 extending from the body 130 to a second end 128. The body 130 and tail 132 extend laterally along the heel region 24 (i.e., transverse to the longitudinal axis A). 10 The joints 134 of the two portions are connected together. As discussed in more detail below, the body 130 can be described as having a contoured or arched profile along the longitudinal direction and including a first channel 136 extending from the first end 126 toward the tail 132. Conversely, the tail 132 has a straight profile extending along the longitudinal direction and includes a second channel 138 extending from the second end 128 toward the body 130.

[0046] Reference Figures 5-7 and Figures 9-11 The main body 130 of plate 106 includes a composite curvature extending along the longitudinal direction. Figure 5 and Figure 11 ), and is basically straight along the lateral direction ( Figure 6 and Figure 7 As shown, the body 130 includes a concave portion 140 extending from a first end 126 and along the forefoot region 20, a convex portion 142 extending from the concave portion 140 and through the midfoot region 22, and a substantially straight portion 144 extending from the convex portion 142 to a connecting portion 134 in the heel region 24. For clarity, the terms "concave" and "convex" are used with reference to the outline of the top side 120 of the plate 106. Therefore, it should be understood that the corresponding portions of the plate 106 formed by the bottom side 122 can be referred to as "convex" and "concave," respectively.

[0047] like Figure 11 As shown, the concave portion 140 of the main body 130 extends continuously from the first end 126 to the first transition portion 145, which is generally formed between the forefoot region 20 and the midfoot region 22. Therefore, the position of the concave portion 140 corresponds to a portion of the phalanges and metatarsals of the foot, and includes the MTP axis A associated with the MTP joint of the foot. MTPAn extended groove. The concave portion 140 is tangent to the convex portion 142 at the first transition portion 145, such that the curvature of the body 130 is substantially continuous through the forefoot region 20 and the midfoot region 22. The convex portion 142 extends from the first transition portion 145 between the forefoot region 20 and the midfoot region 22 to a second transition portion 145 between the midfoot region 22 and the heel region 24. Here, the straight portion 144 extends from the second transition portion 145 to the connecting portion 134 formed between the body 130 and the heel 132. The straight portion 144 of the body 130 is tangent to the convex portion 142 at the second transition portion 145, such that the curvature of the top side 120 of the plate 106 transitions from convex to concave.

[0048] The tail 132 of plate 106 connects to the straight portion 144 of body 130 along connecting portion 134 and extends from connecting portion 134 to the second end 128 of plate 106. As shown, tail 132 is substantially straight and extends from connecting portion 134 at an oblique angle relative to the straight portion 144 of body 130. Thus, unlike the adjacent portions 140, 142, 144 of body 130 that are tangent to each other and continuous, connecting portion 134 forms a distinct transition between body 130 and tail 132. In the illustrated example, tail 132 is straight in both the longitudinal and lateral directions, such that tail 132 is substantially planar. As shown, connecting portion 134 is located at a point on plate 106 corresponding to the calcaneus of the foot, such that body 130 and tail 132 bend around the calcaneus along connecting portion 134.

[0049] Continue to refer to Figure 11 It can be relative to the horizontal reference plane P 126 Describing the outline of plate 106, when plate 106 is incorporated into sole structure 100 and sole structure 100 is stationary relative to ground surface, the horizontal reference plane P 126 The first end 126 extends through the plate 106. As shown, the entire body 130 of the plate 106 is located below the first end 126 of the plate 106. Here, the convex portion 142 of the body 130, along the direction from the first transition portion 145 to the second transition portion 145, is aligned with the reference plane P of the first end 126. 126 Convergence. Then, the straight portion 144 of the main body 130 converges from the reference plane P. 126 The direction diverges from the second transition portion 145 to the connecting portion 134, such that the connecting portion 134 is disposed on the reference plane P associated with the first end portion 126. 126 Below. The tail portion 132 extends from the connecting portion 134 toward the reference plane P. 126 Extend upwards and align with the reference plane P 126 The plates intersect, causing the second end 128 of plate 106 to be positioned on the reference plane P. 126And above the first end 126. In other words, the first portion of the tail 132 is disposed below the first end 126 of the plate 106, and the second portion of the tail 132 extends above the first end 126 of the plate 106.

[0050] like Figure 10 As shown, each end 126, 128 of the plate 106 may have an offset or truncated profile. Here, the peripheral edge 124 of the plate 106 extends along a substantially continuous arched profile along each of the inner side 16 and outer side 18 corresponding to the profile of the foot. However, the peripheral edge 124 defines an offset curvature along the first end 126, such that the portion of the peripheral edge 124 defining the first end 126 is configured to be offset inward from the outer periphery of the sole structure 100, as... Figure 4 As shown. Conversely, the second end 128 of the plate 106 coincides with the outer periphery of the sole structure 100, but has a truncated profile formed by the straight portion of the peripheral edge 124 extending laterally across the plate 106.

[0051] Continue to refer to Figure 10 The first channel 136 and the second channel 138 extend longitudinally from opposite ends 126, 128 of the plate 106. Each channel 136, 138 completely penetrates the thickness T of the plate 106. 106 Formed and extending from open ends 146, 148 formed in peripheral edge 124 to distal end ends 150, 152 formed within plate 106. Each channel 136, 138 may have a corresponding longitudinal axis A. 136 A 138 An elongated profile extends from the open ends 146, 148 to the end ends 150, 152. In the illustrated example, each channel 136, 138 has a pair of straight sides extending between the open ends 146, 148 and the corresponding end ends 150, 152. As shown, the sides of the channels 136, 138 are parallel, such that each channel 136, 138 has a constant width W along the longitudinal direction. 136 W 138 The end portions 150 and 152 are straight, giving each channel 136 and 138 a parallelogram shape at its outer perimeter. Optionally, the end portions 150 and 152 of each channel 136 and 138 may be perpendicular to the longitudinal axis A. 10 And they are parallel to each other.

[0052] The first channel 136 runs along the longitudinal axis A 136 Extending from the open end 146 at the first end 126 of the plate 106 to the portion substantially located at the toe 20 T And plantar part 20 B MTP axis A betweenMTP The end portion is 150. For example... Figure 4 As shown, the first channel 136 is relative to the longitudinal axis A of the footwear item 10. 10 With the first oblique angle θ 136 The orientation is such that the open end 146 is closer to the inner surface 16 than the end end 150. The second channel 138 is along the longitudinal axis A. 138 The open end 146 extends from the second end 128 of the plate 106 to the end 152 at the connecting portion 134 in the heel region 24. For example... Figure 4 As shown, the second channel 138 is relative to the longitudinal axis A of the footwear item 10. 10 With the second oblique angle θ 138 The orientation is such that the open end 146 is closer to the inner surface 16 than the end end 150. Therefore, the second channel 138 extends toward the first channel 136 at a transverse angle. However, although channels 136 and 138 extend laterally toward each other, the end ends 150 and 152 of each of channels 136 and 138 are parallel to each other and substantially perpendicular to the longitudinal axis A. 10 .

[0053] Still refer to Figure 10 Each of channels 136 and 138 separates plate 106 into a corresponding pair of tabs 154a, 154b, 156a, and 156b. For example, the first channel 136 separates the concave portion 140 of body 130 into toe portion 20. T The plate 106 has an inner tab 154a and an outer tab 154b. Similarly, the second channel 138 separates the tail 132 of the plate 106 into an inner tab 156a and an outer tab 156b. The inner tabs 154a, 156a are configured to bend independently of the outer tabs 154b, 156b at each of the first end 126 and the second end 128 of the plate 106, thereby providing improved flexibility to the plate 106 in the lateral direction while cooperating to provide a combination of stiffness and support in the longitudinal direction. Alternatively, the plate 106 may include a flexure 158 formed between each pair of tabs 154a, 154b, 156a, 156b near each end 150, 152. Here, each flexure 158 is formed by a flexure parallel to the respective longitudinal axis A. 136 A 138 A tapered portion of plate 106 is formed, extending to and terminating at end 152.

[0054] Plate 106 comprises one or more materials (e.g., polymeric materials and / or composite materials) that provide relatively high strength and stiffness. In some examples, plate 106 is a composite material made using fiber sheets or textiles (including pre-impregnated (i.e., "pre-impregnated") fiber sheets or textiles). Alternatively or additionally, plate 106 may be manufactured from strands comprising multiple filaments of one or more types of fibers (e.g., fiber bundles) 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 predetermined positions. When fiber strands are used, the type of fibers included in the strands may include synthetic polymer fibers that can be melted and re-cured to consolidate other fibers present in the strands and optionally other components (such as sutures or a substrate or both). Alternatively or additionally, the fibers of the strands and optionally other components (such as sutures or a substrate or both) may be consolidated by applying resin after the fiber strands have been attached to the substrate and / or to each other.

[0055] In some configurations, plate 106 may be formed from one or more layers of fiber bundles and / or fiber layers, including at least one of carbon fiber, boron fiber, glass fiber, and polymer fiber. In certain configurations, the fibers include carbon fiber, or glass fiber, or a combination of both. The fiber bundles may be attached to a substrate. The fiber bundles may be attached by stitching or using an adhesive. Alternatively or concurrently, the fiber bundles and / or fiber layers may be bonded using thermosetting polymers and / or thermoplastic polymers. Thus, plate 106 may have tensile or flexural strength in a transverse direction substantially perpendicular to the longitudinal axis of the footwear article (i.e., the axis extending from the fore-end 12 to the rear-end 14). The stiffness of plate 106 may be selected for a particular wearer based on the wearer's tendon flexibility, calf muscle strength, and / or metatarsophalangeal (MTP) joint flexibility. Furthermore, the stiffness of plate 106 may also be adjusted based on the athlete's running motion. In other configurations, plate 106 is formed from one or more layers / ply of unidirectional tape. In some examples, each layer in the stack has a different orientation than the layer disposed below it. The plate may be formed from unidirectional tape, including at least one of carbon fiber, boron fiber, glass fiber, and polymer fiber. In some examples, one or more materials forming plate 106 result in plate 106 having a Young's modulus of at least 70 gigapascals (GPa).

[0056] In some embodiments, plate 106 includes a substantially uniform thickness T 106 In some examples, the thickness T of plate 106 106 The range is from approximately 0.6 mm to approximately 3.0 mm. In one example, the thickness T of plate 106 is... 106It is essentially equal to 1.0 mm. In other embodiments, the thickness T of plate 106 is... 106 The non-uniformity allows the plate 106 to have a thickness T in one region 20, 22, 24 of the sole structure 100 compared to other regions 20, 22, 24. 202 Larger thickness T 106 .

[0057] As described above, plate 106 is positioned and held within cushioning element 108 of sole interlayer 102 between upper cushioning member 110 and lower cushioning member 112. Each of upper cushioning member 110 and lower cushioning member 112 may comprise an elastomeric material having a lower stiffness than plate 106. Thus, plate 106 provides rigidity along the length of sole interlayer 102, and cushioning element 108 provides resilience and cushioning.

[0058] like Figure 2 and Figure 3 As shown, the upper cushioning member 110 extends from a first end 160 at the front end 12 to a second end 162 at the rear end 14. The upper cushioning member 110 includes an outer side 164 facing the upper 200 and defining the footbed of the sole structure 100, an inner side 166 formed on the side opposite to the outer side 164 and configured to engage with the top side 120 of the plate 106, and a peripheral side surface 168 extending between the outer side 164 and the inner side 166 and defining the peripheral side of the sole interlayer 102.

[0059] like Figure 3 As shown, the inner side 166 of the upper buffer member 110 includes an upper receiving portion 170 configured to receive the top side 120 of the receiving plate 106. The outer peripheral upper receiving portion 170 corresponds to the peripheral edge 124 of the plate 106 and the channels 136, 138, such that the top side 120 of the plate 106 mates with the upper receiving portion 170. Here, the upper receiving portion 170 may include a pair of upper ribs 172, 174 configured to mate with the channels 136, 138, respectively. For example, the first rib 172 extends from the first end 160 of the upper buffer member 110 and is received within the upper portion of the first channel 136. Figure 6 The second rib 174 extends from the second end 162 of the upper buffer member 110 and is received within the upper portion of the second channel 138. Figure 8 As described above, the upper receiving portion 170 may extend through at least one of the outer side 18 and the inner side 16 of the upper cushioning member 110, such that the peripheral edge 124 of the plate 106 is exposed along the outer periphery of the sole interlayer 102.

[0060] Still refer to Figure 2 and Figure 3 The lower cushioning member 112 extends from a first end 176 at the front end 12 to a second end 178 at the rear end 14. The lower cushioning member 112 includes an outer side 180 facing the outsole 104 and defining the ground contact surface of the sole structure 100; an inner side 182 formed on the side opposite to the outer side 180 and configured to engage with the bottom side 122 of the plate 106; and a peripheral side surface 184 extending between the outer side 180 and the inner side 182 and defining the peripheral side of the sole interlayer 102. Figure 5 As best shown, the outer side 180 of the lower cushioning member 110 is substantially convex and defines a first radius of curvature in the forefoot region 20, a second radius of curvature in the midfoot region 22 that is tangent to and larger than the first radius of curvature, and a third radius of curvature in the heel region 24 that is tangent to the second radius of curvature and smaller than both the first and second radii of curvature. Therefore, the outer side 180 provides transitional contact with the ground surface along the length of the sole structure 100 during the stance phase of the gait cycle.

[0061] like Figure 2 As shown, the inner side 182 of the lower buffer member 112 includes a lower receiving portion 186 configured to receive the bottom side 122 of the receiving plate 106. The outer periphery of the lower receiving portion 186 corresponds to the peripheral edge 124 of the plate 106 and the channels 136, 138, such that the bottom side 122 of the plate 106 mates with the lower receiving portion 186. Here, the lower receiving portion 186 may include a pair of lower ribs 188, 190, which are configured to mate with the channels 136, 138, respectively. For example, the first rib 188 extends from the first end 176 of the lower buffer member 112 and is received within the lower portion of the first channel 136. Figure 6 The second rib 190 extends from the second end 178 of the lower buffer member 112 and is received within the lower portion of the second channel 138. Therefore, the upper ribs 172, 174 and the lower ribs 188, 190 cooperate to fill the respective channels 136, 138 and maintain alignment between the ends of the buffer members 110, 112 and the ends of the plate 106. Furthermore, the upper ribs 172, 174 contact the lower ribs 188, 190 respectively within the channels 136, 138, and may also engage or otherwise attach to each other at the interface between the upper ribs 172, 174 and the lower ribs 188, 190.

[0062] As described above, the cushioning members 110, 112 comprise elastic polymer materials (such as foam or rubber) to impart cushioning, responsiveness, and energy distribution properties to the wearer's foot. In some examples, the upper cushioning member 110 may be formed of a first foam material, and the lower cushioning member 112 may be formed of a second foam material. For example, the upper cushioning member 110 may be formed of a foam material that provides greater cushioning and impact distribution, while the lower cushioning member 110 may be formed of a foam material with greater stiffness, or vice versa.

[0063] Example elastic polymer materials used for cushioning members 110, 112 may include materials based on foaming or molding of one or more polymers, such as one or more elastomers (e.g., thermoplastic elastomers (TPEs)). One or more polymers may include aliphatic polymers, aromatic polymers, or mixtures thereof; and may include homopolymers, copolymers (including terpolymers), or mixtures thereof.

[0064] In some aspects, one or more polymers may include olefin homopolymers, olefin copolymers, or blends thereof. Examples of olefin polymers include polyethylene, polypropylene, and combinations thereof. In other aspects, one or more polymers may include one or more ethylene copolymers, such as ethylene-vinyl acetate (EVA) copolymers, EVOH copolymers, ethylene-ethyl acrylate copolymers, ethylene-unsaturated monofatty acid copolymers, and combinations thereof.

[0065] In another aspect, one or more polymers may include one or more polyacrylates, such as polyacrylic acid, esters of polyacrylic acid, polyacrylonitrile, polyacrylate acetate, polymethyl acrylate, polyethyl acrylate, polybutyl acrylate, polymethyl methacrylate, and polyvinyl acetate; including derivatives thereof, copolymers thereof, and any combination thereof.

[0066] In other aspects, one or more polymers may include one or more ionomer polymers. In these aspects, the ionomer polymers may include polymers having carboxylic acid functional groups, sulfonic acid functional groups, their salts (e.g., sodium, magnesium, potassium, etc.) and / or their anhydrides. For example, the ionomer polymers may include one or more fatty acid-modified ionomer polymers, polystyrene sulfonates, ethylene-methacrylic acid copolymers, and combinations thereof.

[0067] In another aspect, one or more polymers may include one or more styrene block copolymers, such as acrylonitrile-butadiene-styrene block copolymers, styrene-acrylonitrile block copolymers, styrene-ethylene-butene-styrene block copolymers, styrene-ethylene-butadiene-styrene block copolymers, styrene-ethylene-propylene-styrene block copolymers, styrene-butadiene-styrene block copolymers, and combinations thereof.

[0068] In another aspect, one or more polymers may include one or more polyamide copolymers (e.g., polyamide-polyether copolymers) and / or one or more polyurethanes (e.g., crosslinked polyurethanes and / or thermoplastic polyurethanes). Alternatively, one or more polymers may include one or more natural rubbers and / or synthetic rubbers, such as butadiene and isoprene.

[0069] When the elastic polymer material is a foaming polymer material, the foaming material can be foamed using a physical foaming agent that transforms into a gas based on changes in temperature and / or pressure, or using a chemical foaming agent that forms a gas when heated above its activation temperature. For example, a chemical foaming agent can be an azo compound, such as azodicarbonamide, sodium bicarbonate, and / or isocyanate.

[0070] In some embodiments, the foamed polymer material may be a cross-linked foamed material. In these embodiments, peroxide-based cross-linking agents, such as dicumyl peroxide, may be used. Furthermore, the foamed polymer material may include one or more fillers, such as pigments, modified or natural clay, modified or unmodified synthetic clay, talc, glass fiber, glass powder, modified or natural silica, calcium carbonate, mica, paper, wood chips, and the like.

[0071] Elastic polymer materials can be formed using molding processes. In one example, when the elastic polymer material is a molded elastomer, the uncured elastomer (e.g., rubber) can be mixed with optional fillers and curing packages (such as sulfur-based or peroxide-based curing packages) in a Banbury mixer, calendered, formed into shape, placed in a mold, and vulcanized.

[0072] In another example, when the elastic polymer material is a foaming material, the material can foam during a molding process, such as injection molding. The thermoplastic polymer material can be melted in the barrel of an injection molding system and combined with a physical or chemical foaming agent and optional crosslinking agent, and then injected into a mold under conditions that activate the foaming agent to form molded foam.

[0073] Optionally, when the elastic polymer material is a foaming material, the foaming material can be compression molded foam. Compression molding can be used to change the physical properties of the foam (e.g., density, stiffness, and / or hardness), or to change the physical appearance of the foam (e.g., fusing two or more pieces of foam to form a foam shape), or both.

[0074] The compression molding process ideally begins by forming one or more foam preforms (e.g., by injection molding of polymer material and foaming the polymer material, by forming foamed particles or beads, by cutting foamed sheets, and similar operations). Compression molded foam can then be manufactured by placing one or more preforms formed from foamed polymer material into a compression mold and applying sufficient pressure to one or more preforms to compress them within a closed mold. Once the mold is closed, sufficient heat and / or pressure are applied to one or more preforms within the closed mold for a sufficiently long duration to alter the preforms by forming a surface layer on the outer surface of the compression molded foam, fusing individual foam particles together, permanently increasing the density of the foam, or any combination thereof. After heating and / or applying pressure, the mold is opened, and the molded foam article is removed from the mold.

[0075] The outsole 104 of the sole structure 100 is formed of an elastic polymer material configured to provide adhesive friction and abrasion resistance. As shown, the outsole 104 is formed as a unitary body encapsulating the lower portion of the sole interlayer 102. Therefore, the outsole 104 completely covers the outer side 180 of the lower cushioning member 112 and extends upward at least partially around the peripheral side surface 184 of the lower cushioning member 112. The outsole 104 may also include a toe cap 192, which extends above the peripheral side surface 168 of the upper cushioning member 110 in the forefoot region 20 and extends onto the upper 200. Thus, the outsole 104 provides an elastic protective shell along the bottom of the sole structure 100 and around the forefoot portion 12 of the upper 200. The outsole 104 may include a plurality of adhesive friction elements 194 that extend along the bottom and around the toe cap 192 to provide improved grip during flat and inclined movements.

[0076] The sole structure 100 disclosed herein includes several features that, individually and in combination, provide improved performance for the sole structure 100—particularly in all-terrain environments such as hiking trails. For example, the full-length plate 106 of the sole structure 100 provides longitudinal stiffness along the length of the foot, which improves gait efficiency by maximizing stability and minimizing energy loss. The plate 106, formed with a contoured body 130, adapts to the natural curvature of the foot, while the straight tail 132 provides stability along the posterior side of the calcaneus. Including channels 136, 138 at one or both ends 126, 128 of the plate 106 allows the plate 106 to maintain longitudinal stability and performance while simultaneously allowing some torsional compliance along uneven terrain or during lateral movements. The plate 106 is encapsulated within a cushioning element 108, which provides shock dissipation and further adapts to uneven terrain. The outsole 104 is formed as an integral structure encapsulating the lower portion of the sole structure 100 to provide improved resistance to abrasion, puncture and moisture, while also maximizing adhesion friction.

[0077] The following terms provide an exemplary construction of the sole structure for footwear articles as described above.

[0078] Clause 1. A sole structure for footwear articles, the sole structure comprising: a plate extending from a first end disposed at a front end of the sole structure to a second end disposed at a rear end of the sole structure, the plate including a first channel formed in the first end and extending toward the second end in a first direction and a second channel formed in the second end and extending toward the first end in a second direction.

[0079] Clause 2. The sole structure as described in Clause 1, wherein both the first channel and the second channel are elongated.

[0080] Clause 3. The sole structure according to any one of the preceding clauses, wherein the first channel and the second channel comprise the same shape.

[0081] Clause 4. The sole structure according to any one of the preceding clauses, wherein the first channel extends at a first oblique angle relative to the longitudinal axis of the plate, and the second channel extends at a second oblique angle relative to the longitudinal axis of the plate.

[0082] Clause 5. The sole structure according to Clause 4, wherein the longitudinal axis of the first channel converges with the longitudinal axis of the second channel.

[0083] Clause 6. The sole structure according to any one of the preceding clauses, wherein the plate includes an inclined portion extending from the heel region of the plate to the rear end and extending in a direction away from the ground contact surface of the sole structure, the second channel being formed in the inclined portion.

[0084] Clause 7. The sole structure according to any one of the preceding clauses, wherein the first channel is longer than the second channel.

[0085] Clause 8. The sole structure according to any one of the preceding clauses, wherein at least one of the first channel and the second channel comprises a parallelogram shape.

[0086] Clause 9. The sole structure according to any one of the preceding clauses further includes a sole interlayer and an outsole, the plate being disposed between the sole interlayer and the outsole and having a greater rigidity than the sole interlayer.

[0087] Clause 10. A footwear article incorporating a board according to any one of the preceding clauses.

[0088] Clause 11. A board for footwear articles, the board comprising: a main body including a first portion having an arcuate shape and a planar second portion extending at an angle to the first portion in a first plane; a first channel extending from a first end of the main body along the first portion and toward the second portion; and a second channel extending from a second end of the main body along the second portion and toward the first portion.

[0089] Clause 12. The plate according to Clause 11, wherein the first channel extends along a first longitudinal axis from the first end to the end of the first channel.

[0090] Clause 13. The plate according to Clause 12, wherein the first longitudinal axis converges with the longitudinal axis of the plate.

[0091] Clause 14. The plate according to Clause 12, wherein the first portion includes a tapered portion extending from the first portion and terminating at the end of the first channel.

[0092] Clause 15. The plate according to Clause 14, wherein the tapered portion is aligned with the first channel and includes a width similar to the first channel, the width being measured in a direction substantially transverse to the longitudinal axis of the plate.

[0093] Clause 16. The plate according to any one of the preceding clauses, wherein the second channel extends along a second longitudinal axis from the second end to the end of the second channel.

[0094] Clause 17. The plate according to Clause 16, wherein the second longitudinal axis emanates from the longitudinal axis of the plate.

[0095] Clause 18. The plate according to Clause 16, wherein the second portion includes a tapered portion extending from the first portion and terminating at the end of the second channel.

[0096] Clause 19. The plate according to Clause 18, wherein the tapered portion is aligned with the second channel and includes a width similar to the second channel, the width being measured in a direction substantially transverse to the longitudinal axis of the plate.

[0097] Clause 20. The plate according to any one of the preceding clauses, wherein the first channel is longer than the second channel.

[0098] Clause 21. The plate according to any one of the preceding clauses, wherein at least one of the first channel and the second channel comprises a polygonal shape.

[0099] Clause 22. The plate according to any one of the preceding clauses, wherein the first channel and the second channel are both elongated.

[0100] Clause 23. The plate according to any one of the preceding clauses, wherein the first channel and the second channel comprise the same shape.

[0101] Clause 24. The plate according to any one of the preceding clauses, wherein the first channel separates the first end of the plate into a first pair of tabs.

[0102] Clause 25. The plate according to Clause 24, wherein the second channel separates the second end of the plate into a second pair of tabs.

[0103] The foregoing description has been provided for illustrative and descriptive purposes. It is not intended to be exhaustive or limiting of this disclosure. Individual elements or features of a particular configuration are generally not limited to that particular configuration, but are interchangeable where applicable and can be used in the chosen configuration, even if not explicitly shown or described. Individual elements or features of a particular configuration may also vary in many ways. Such variations are not considered to depart from this disclosure, and all such modifications are intended to be included within the scope of this disclosure.

Claims

1. A sole structure for footwear articles, the sole structure comprising: A plate extending from a first end portion disposed at the front end portion of the sole structure to a second end portion disposed at the rear end portion of the sole structure, the plate comprising: The first part is arched and the second part is sloping; A first channel having a constant width extends from a first end along a first portion and in a first direction toward a second end to a terminal end of the first channel, wherein the first portion includes a first tapered portion extending from the first portion and terminating at the terminal end of the first channel, the width of the first tapered portion being similar to the constant width of the first channel; and A second channel having a constant width extends from the second end along the second portion and in a second direction toward the first end to the end end of the second channel, wherein the second portion includes a second tapered portion extending from the second portion and terminating at the end end of the second channel, the width of the second tapered portion being similar to the constant width of the second channel.

2. The sole structure according to claim 1, wherein: Both the first channel and the second channel are elongated; and / or The plate includes only two channels, and each channel includes a pair of straight sides.

3. The sole structure according to claim 1, wherein the first channel and the second channel have the same shape.

4. The sole structure of claim 1, wherein the first channel extends at a first oblique angle relative to the longitudinal axis of the plate, and the second channel extends at a second oblique angle relative to the longitudinal axis of the plate.

5. The sole structure according to claim 4, wherein the longitudinal axis of the first channel converges with the longitudinal axis of the second channel.

6. The sole structure of claim 1, wherein the inclined second portion extends from the heel region of the plate to the rear end and extends in a direction away from the ground contact surface of the sole structure, and the second channel is formed in the inclined second portion.

7. The sole structure according to claim 1, wherein the first channel is longer than the second channel.

8. The sole structure according to claim 1, wherein at least one of the first channel and the second channel comprises a parallelogram shape.

9. The sole structure according to claim 1 further includes a sole interlayer and an outsole, wherein the plate is disposed between the sole interlayer and the outsole and has a greater hardness than the sole interlayer.

10. A footwear article incorporating a plate according to claim 1.

11. A board for footwear articles, said board comprising: The main body includes a first portion having an arcuate shape and a second planar portion extending at an angle to the first portion in a first plane; A first channel having a constant width extends from a first end of the main body along the first portion and in a direction toward the second portion to the end end of the first channel, wherein the first portion includes a first tapered portion extending from the first portion and terminating at the end end of the first channel, the width of the first tapered portion being similar to the constant width of the first channel; as well as A second channel having a constant width extends from a second end of the main body along the second portion and in a direction toward the first portion to the end end of the second channel, wherein the second portion includes a second tapered portion extending from the second portion and terminating at the end end of the second channel, the width of the second tapered portion being similar to the constant width of the second channel.

12. The plate of claim 11, wherein the first channel extends along a first longitudinal axis from the first end to the end portion of the first channel.

13. The plate according to claim 12, wherein the first longitudinal axis converges with the longitudinal axis of the plate.

14. The plate of claim 11, wherein the plate comprises only two channels, and wherein each channel comprises a pair of straight sides.

15. The plate of claim 11, wherein the first tapered portion is aligned with the first channel, and the width of the first tapered portion is measured in a direction substantially transverse to the longitudinal axis of the plate.

16. The plate of claim 11, wherein the second channel extends along a second longitudinal axis from the second end to the end portion of the second channel.

17. The plate according to claim 16, wherein the second longitudinal axis radiates from the longitudinal axis of the plate.

18. The plate of claim 11, wherein the second taper is aligned with the second channel, and the width of the second taper is measured in a direction substantially transverse to the longitudinal axis of the plate.

19. The plate of claim 11, wherein the first channel is longer than the second channel.

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