Footwear sole structure with embedded plate and upper

Abstract

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

Description

Technical Field

[0001] This application claims priority and benefit to U.S. Provisional Patent Application No. 63 / 080,283, filed on September 18, 2020. Technical Field

[0003] This teaching generally relates to a sole structure for footwear articles, and more specifically, to a footwear sole structure having an embedded plate. background

[0004] This section provides background information about the contents of this disclosure, which is not necessarily prior art.

[0005] Footwear items consist of an upper and a sole structure. The upper can be formed from 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 of the upper around the foot. The bottom portion of the upper, closest to the foot, is attached to the sole structure.

[0006] The sole structure comprises a layered arrangement extending between the ground surface and the upper. One layer of the sole structure includes an outsole that provides abrasion resistance and traction with the ground surface. The outsole may be formed of rubber or other materials that impart durability and abrasion resistance, as well as enhanced traction with the ground surface. Another layer of the sole structure includes a midsole layer disposed between the outsole and the upper. The midsole layer provides cushioning for the foot and is at least partially formed of a polymer foam material that elastically compresses under applied load to cushion the foot by attenuating ground reaction forces. The midsole layer may define a bottom surface on a side opposite the outsole and a footbed on the opposite side, the profile of which may be configured to conform to the profile of the bottom surface of the foot. The sole structure may also include an insole or sockliner for enhanced comfort, which is located within a cavity near the bottom portion of the upper.

[0007] It is known that during running, the metatarsophalangeal (MTP) joints of the foot absorb energy when they dorsiflex. Since the foot does not move through plantar flexion until it leaves the ground, the MTP joints return a small portion of the absorbed energy to the running motion, thus contributing to energy expenditure during running. Embedding a flat, rigid plate with longitudinal stiffness within the sole structure increases the overall stiffness of the sole structure. Brief description of the attached diagram

[0008] Figure 1 This is a schematic illustration of a lateral side view of a footwear article according to an embodiment of the present disclosure.

[0009] Figure 2 It is a schematic illustration of an exterior view of a footwear article according to another aspect of this disclosure.

[0010] Figure 3 This is a schematic illustration of an exterior view of a footwear article according to another aspect of the present disclosure, wherein the midsole is configured as a drop-in midsole and is provided only in the heel area of ​​the sole structure.

[0011] Figure 4 This is a schematic illustration of an exterior view of a footwear article according to another aspect of the present disclosure, wherein the sole interlayer is configured as an embedded sole interlayer and extends through the heel area, midfoot area and forefoot area of ​​the sole structure.

[0012] Figure 5 This is a schematic illustration of an exterior view of a footwear article according to another aspect of the present disclosure, wherein the sole interlayer is configured as an embedded sole interlayer and includes two separate sole interlayer portions spaced apart from each other.

[0013] Figure 6 This is a schematic illustration of an exterior view of a footwear article according to another aspect of the present disclosure, wherein the sole interlayer is configured as an embedded sole interlayer and is provided only in the forefoot region of the sole structure.

[0014] Figure 7 This is a flowchart of a method for manufacturing footwear.

[0015] describe

[0016] This disclosure describes a footwear item that can be used in football (or, in the United States, soccer), running, basketball, and / or other sports.

[0017] In one aspect of this disclosure, a sole structure includes an outsole defining an inner outsole surface and an outer outsole surface opposite to the inner outsole surface. The inner outsole surface is spaced apart from the outer outsole surface along a first direction. The sole structure also includes a sole interlayer disposed on the outsole and a footwear plate directly coupled to the sole interlayer. The footwear plate comprises a composite material. The footwear plate includes a first plate portion, a second plate portion connected to the first plate portion, and a third plate portion connected to the second plate portion. The second plate portion is connected between the first plate portion and the third plate portion. The second plate portion is angled relative to the first plate portion and the third plate portion such that the first plate portion is spaced apart from the third plate portion along the first direction to enhance the stability of the sole structure while minimizing energy loss when the sole structure contacts the ground surface.

[0018] The midsole includes a midsole material. The composite material has a first stiffness. The midsole material has a second stiffness, and the first stiffness may be greater than the second stiffness.

[0019] The midsole defines an inner midsole surface and an outer midsole surface opposite to the inner midsole surface. The inner midsole surface faces the upper. The outer midsole surface faces away from the upper. The midsole defines a midsole through-hole extending from the inner midsole surface to the outer midsole surface. A second plate is partially disposed within the midsole through-hole. A first plate is partially disposed in the forefoot region of the sole structure. A third plate is partially disposed in the heel region of the sole structure. A second plate is partially disposed in the midfoot region of the sole structure.

[0020] The third plate is positioned on top of the midsole layer. The second plate is positioned between the inner and outer surfaces of the midsole layer. The through-holes in the midsole layer are angled relative to the inner and outer surfaces of the midsole layer.

[0021] The midsole defines a longitudinal recess in the midsole that communicates with the midsole perforations, and this longitudinal recess is adjacent to the outsole. The longitudinal recess is located in the forefoot region of the sole structure. A first plate portion is at least partially disposed within the longitudinal recess to maximize energy return during toe-off. The first plate portion is spaced apart from a second plate portion along a second direction. The second direction is perpendicular to the first direction. The outsole extends along the second direction.

[0022] The outsole defines an inner outsole surface and an outer outsole surface opposite to the inner outsole surface. The inner outsole surface faces the upper. The outer outsole surface faces away from the upper. A third plate portion is in direct contact with the inner outsole surface of the outsole. The longitudinal recess of the outsole midsole extends along a second direction. The second direction is perpendicular to the first direction.

[0023] The midsole defines an inner midsole surface and an outer midsole surface opposite to the inner midsole surface. The inner midsole surface faces the upper. The outer midsole surface faces away from the upper. The midsole defines a midsole opening extending from the inner midsole surface into the midsole. The midsole opening does not extend through the entire thickness of the midsole. A second plate portion is disposed within the midsole opening, and a third plate portion is disposed on top of the inner midsole surface at the heel area of ​​the sole structure.

[0024] The first plate is located in the forefoot area of ​​the sole structure. The first plate is located inside the sole interlayer and is closer to the inner sole interlayer surface than the outer sole interlayer surface.

[0025] The midsole is constructed as an embedded midsole, which is completely located within the internal cavity of the upper. The third plate is located within the midsole, and the first plate is located within the outsole.

[0026] The midsole is located only in the heel area of ​​the sole structure. The midsole extends through the heel area, midfoot area, and forefoot area. The midsole includes a first midsole portion and a second midsole portion, which are spaced apart from each other along a longitudinal axis to define a gap between them, and this gap receives a second plate portion of the footwear plate.

[0027] In one aspect of this disclosure, a footwear article includes an upper defining an internal cavity and an ankle opening communicating with the internal cavity. The footwear article also includes a sole structure coupled to the upper. The sole structure includes a forefoot region, a midfoot region, and a heel region, the midfoot region being disposed between the forefoot region and the heel region. The sole structure includes an outsole defining an inner outsole surface and an outer outsole surface opposite to the inner outsole surface. The inner outsole surface is spaced apart from the outer outsole surface along a first direction. The sole structure also includes a sole interlayer disposed on the outsole, and a footwear plate coupled to the sole interlayer. The footwear plate includes a composite material and includes a first plate portion, a second plate portion directly connected to the first plate portion, and a third plate portion directly connected to the second plate portion. The second plate portion is connected between the first plate portion and the third plate portion. The second plate is tilted at an angle relative to the first and third plates, such that the first plate is spaced apart from the third plate along a first direction, to enhance the stability of the sole structure and minimize energy loss of the sole structure when the footwear comes into contact with the ground surface.

[0028] The midsole defines an inner midsole surface and an outer midsole surface opposite to the inner midsole surface. The inner midsole surface faces the upper. The outer midsole surface faces away from the upper. The midsole defines a midsole through-hole extending from the inner midsole surface to the outer midsole surface. A second plate is partially disposed within the midsole through-hole. A first plate is partially disposed in the forefoot region of the sole structure. A third plate is partially disposed in the heel region of the sole structure. A second plate is partially disposed in the midfoot region of the sole structure.

[0029] The third plate is positioned on top of the midsole layer, and the second plate is positioned between the inner and outer surfaces of the midsole layer. The through-holes in the midsole layer are angled relative to the inner and outer surfaces of the midsole layer.

[0030] The midsole defines a longitudinal recess in the midsole that communicates with the midsole perforations. This longitudinal recess is adjacent to the outsole and is located in the forefoot region of the sole structure. A first plate portion is at least partially disposed within the longitudinal recess to maximize energy return during toe-off.

[0031] The outsole defines an inner outsole surface and an outer outsole surface opposite to the inner outsole surface. The inner outsole surface faces the upper. The outer outsole surface faces away from the upper. A third plate portion is in direct contact with the inner outsole surface of the outsole. The longitudinal recess of the outsole midsole extends along a second direction. The second direction is perpendicular to the first direction.

[0032] The midsole defines an inner midsole surface and an outer midsole surface opposite to the inner midsole surface, with the inner midsole surface facing the upper. The outer midsole surface faces away from the upper. The midsole defines a midsole opening extending from the inner midsole surface into the midsole, the midsole opening not extending through the entire thickness of the midsole, and a second plate portion is disposed within the midsole opening of the midsole, and a third plate portion is disposed on top of the inner midsole surface at the heel area of ​​the sole structure.

[0033] The first plate is located in the forefoot area of ​​the sole structure. The first plate is located inside the sole interlayer and is closer to the inner sole interlayer surface than the outer sole interlayer surface.

[0034] The midsole is configured as an embedded midsole, entirely situated within an internal cavity of the upper. A third plate portion is disposed within the midsole, and a first plate portion is disposed within the outsole. The midsole may be disposed only in the heel area of ​​the sole structure. The midsole extends through the heel area, midfoot area, and forefoot area. The midsole includes a first midsole portion and a second midsole portion, spaced apart from each other along a longitudinal axis to define a gap between the first and second midsole portions. This gap receives the second plate portion of the footwear plate.

[0035] This disclosure also describes a method of manufacturing a footwear article. The method includes inserting a footwear plate through an opening in the sole interlayer to directly attach the footwear plate to the sole interlayer. The opening in the sole interlayer is a through-hole extending along the entire thickness of the sole interlayer. Alternatively, the opening in the sole interlayer extends along a portion of the thickness of the sole interlayer. The footwear plate comprises a composite material. The footwear plate includes a first plate portion, a second plate portion connected to the first plate portion, and a third plate portion connected to the second plate portion. The second plate portion is connected between the first plate portion and the third plate portion. The second plate portion is angled relative to the first and third plate portions such that the first plate portion is spaced apart from the third plate portion along a first direction. The method also includes attaching the sole interlayer to an outsole. The outsole extends along a longitudinal axis. The first direction is perpendicular to the longitudinal axis. A sole structure includes a sole interlayer and an outsole. The sole structure has a forefoot region, a heel region, and a midfoot region between the forefoot region and the heel region. The opening in the sole interlayer is located in the midfoot region of the sole structure. The method also includes attaching the upper to the sole structure.

[0036] The above-mentioned features and advantages, as well as other features and advantages, of this teaching will become apparent when understood in conjunction with the accompanying drawings and in the following detailed description of the mode of implementing this teaching.

[0037] 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.

[0038] 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.

[0039] 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.

[0040] 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.

[0041] refer to Figure 1Footwear article 10 includes an upper 100 and a sole structure 200 attached to the upper 100. Footwear article 10 (and its components, such as the upper 100 and sole structure 200) may be divided into one or more portions. These portions may include a forefoot region 12, a midfoot region 14, and a heel region 16. During use of footwear 10, the forefoot region 12 may correspond to the toes and the joints connecting the metatarsals and phalanges of the foot. The forefoot region 12 may correspond to the metatarsophalangeal (MTP) joint of the foot. The midfoot region 14 may correspond to the arch region of the foot. During use of footwear article 10, the heel region 16 may correspond to the posterior portion of the foot, including the calcaneus. The midfoot region 14 is therefore located between the forefoot region 12 and the heel region 16. Footwear 10 may include a lateral side and a medial side, which correspond to opposite sides of footwear 10 and extend through portions 12, 14, and 16.

[0042] The upper 100 includes an inner surface defining an internal cavity 102 that, during use of the footwear article 10, receives and secures the foot for support on the sole structure 200. Ankle opening 104 in the heel region 16 provides an entrance to the internal cavity 102. For example, 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 (such as laces) extend along the upper 100 to adjust the fit of the internal cavity 102 around the foot while accommodating both entry and exit of the foot from the internal cavity. The upper 100 may include holes 106 (such as eyelets) and / or other engagement features (such as fabric or mesh loops) that receive fasteners 107. Fastener 107 may include shoelaces, straps, cords, hooks and loops, or any other suitable type of fastener 107. The upper 100 may also include a heel cup in the heel area 16 to support the heel of the footwear user.

[0043] The upper 100 may include a tongue portion 110 extending between the internal cavity 102 and the perforation 106. The upper 100 may be formed of one or more materials (i.e., upper materials) stitched or adhesively bonded together to form the internal cavity 102. Suitable materials for the upper may include, but are not limited to, textiles, fabrics, foams, leather, and synthetic leather. These materials may be selected and positioned to impart properties of durability, breathability, abrasion resistance, flexibility, and comfort.

[0044] In some embodiments, the sole structure 200 may include an outsole 204 configured to contact the ground. The sole structure 200 is oriented (e.g., elongated) along a longitudinal axis L that extends longitudinally between the forefoot end 13 of the forefoot region 12 and the rearfoot end 15 of the heel region 16. The outsole 204 may be a one-piece structure to enhance its structural integrity, or the outsole 204 may be a plurality of discrete outsole components to enhance adhesion friction at specific discrete locations of the sole structure 200.

[0045] The outsole 204 typically provides abrasion resistance and traction with the ground during use of the footwear article 10, and includes a main outsole body 210. The main outsole body 210 includes a lower surface / ground engagement surface 212 and an opposite upper surface / inner surface 214. The outsole 204 also includes one or more traction elements 215, such as spikes, cleats, and / or treads, each traction element being configured to enhance the traction of the footwear article 10 when the outsole 204 contacts the ground. The outsole 204 may be formed of one or more materials that impart durability and abrasion resistance as well as enhanced traction with the ground surface. For example, the outsole 204 may be formed of a polymeric material including at least one of rubber, polyurethane, ionomers, and / or engineering plastics. For example, at least a portion of the outsole 204 may include rubber.

[0046] In some examples, one or more adhesion friction elements 215 (e.g., cleats, treads, and / or anti-slip studs) extend directly from the main outsole body 210 in a direction away from the upper 100 to provide adhesion friction with a ground surface such as turf and enhance the structural integrity of the outsole 204. For example, in some embodiments, each adhesion friction element 215 may be attached to the main outsole body 210 of the outsole 204 and extend in a vertical direction V perpendicular to or at least substantially perpendicular to the longitudinal axis L of the sole structure 200. The longitudinal axis L is parallel to the longitudinal direction LG. The longitudinal direction LG is perpendicular to the vertical direction V. The vertical direction V may be referred to as the first direction, and the longitudinal direction LG may be referred to as the second direction. In the example shown, the adhesion friction element 215 extends through the heel region 16, midfoot region 14, and forefoot region 12 of the sole structure 200 to provide adhesion friction along the entire sole structure 200. However, it is envisioned that the adhesion friction element 215 can be positioned at spaced locations along the outsole 204 to provide adhesion friction in high-wear areas of the sole structure 200.

[0047] The sole structure 200 may include a midsole 206 for providing cushioning to the footwear user. For this purpose, the midsole 206 may be made of a polymeric material such as rubber or foam. As a non-limiting example, the midsole 206 may be made wholly or partially of ethylene vinyl acetate (EVA) foam to enhance the cushioning of the sole structure 200. The midsole 206 may extend continuously along the forefoot region 12, midfoot region 14, and heel region 16 to provide cushioning along the entire foot of the footwear wearer. The midsole 206 is disposed on the outsole 204 and includes a midsole body 208 having an inner midsole surface 209 and an outer midsole surface 211 opposite to the inner midsole surface 209. It is envisioned that the midsole 206 may be attached to the outsole 204 and exposed on the outside of the sole structure 200. As a non-limiting example, adhesives, stitching, and / or thermal bonding can be used to secure the sole interlayer 206 to the outsole 204.

[0048] The sole structure 200 may further include a strobel (midsole fabric) panel 220 disposed on the sole interlayer 206. The strobel panel 220 may include a bottom surface / ground-facing surface 222 and an opposite top surface / footbed surface 224. The strobel panel 220 may be at least partially secured to the upper 100 by stitching and / or adhesives. In some embodiments, at least a portion of the upper 100 (e.g., a fabric continuous with the sidewalls of the upper 100) may extend around the strobel panel 220 such that this at least portion of the upper 100 is located between the strobel panel 220 and the outsole 204.

[0049] The sole structure 200 may also include a footwear plate 300 directly connected to the sole interlayer 206 to provide energy return properties to the sole structure 200. By directly connecting the footwear plate 300 to the sole interlayer 206, energy can be easily transferred from the footwear plate 300 to the sole interlayer 206. For example, the footwear plate 300 may be in direct contact with the sole interlayer 206. Specifically, at least a portion of the footwear plate 300 may be disposed between the sole interlayer 206 and the Stellar panel 220. The footwear plate 300 may be partially or entirely made of composite materials (such as carbon fiber composites) to enhance the stiffness of the footwear article 10. For this reason, the footwear plate 300 may be referred to as a composite material plate. As used herein, the term "composite material" means a material made of two or more constituent materials having significantly different physical or chemical properties, which, when combined, produce a material with properties different from those of the individual components, while the individual components remain separate and independent in the finished structure, thus distinguishing composite materials from mixtures and solid solutions. The footwear plate 300 may be made wholly or partially of a plate material (such as carbon fiber reinforced polymer) that is stiffer than the upper material forming the upper 100, the midsole material forming the midsole layer 206, and the outsole material forming the outsole 204, to enhance the stability of the sole structure 200. In other words, the stiffness of the plate material is greater than that of the upper material of the upper 100, the midsole material forming the midsole layer 206, and the outsole material forming the outsole 204, to enhance the stability of the sole structure 200 while providing energy return properties to the sole structure 200. The footwear plate 300 is part of the sole structure 200 to reduce energy loss at the MTP joint during running and to enhance foot rolling when the footwear 10 rolls to engage with the ground surface. The footwear 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 to enhance the structural integrity of the sole structure 200. The footwear plate 300 is oriented along a longitudinal axis L that extends longitudinally between the front end 13 of the forefoot region 12 and the rear end 15 of the heel region 16. In other examples, the length of the plate 300 extends through the forefoot region 12 and the midfoot region 14, and does not appear in the heel region 16. The footwear plate 300 can serve as both an innersole and a chassis. The footwear plate 300 can have a thickness extending along a vertical direction V and a width extending between the outer and inner surfaces of the sole structure 200.

[0050] The footwear plate 300 may include a forefoot or first plate portion 302, a midfoot or second plate portion 304 directly connected to the first plate portion 302, and a heel or third plate portion 306 directly connected to the second plate portion 304. The first plate portion 302 may be entirely disposed within the forefoot region 12 of the sole structure 200. The second plate portion 304 may be entirely disposed within the midfoot region 14 of the sole structure 200. The third plate portion 306 may be entirely disposed within the heel region 16 of the sole structure 200. The third plate portion 306 is entirely disposed within an internal cavity 102 in the heel region 12 of the sole structure 200 to reduce impact on the wearer's foot during heel impact. The first plate portion 302 and the second plate portion 304 may be exposed, making the footwear plate 300 at least partially visible. The second plate portion 304 may be angled relative to the first plate portion 302 and the third plate portion 304. Therefore, the first plate portion 302 is spaced apart from the third plate portion 306 along the vertical direction V (i.e., the first direction) to enhance the stability of the sole structure 200 while minimizing energy loss when the footwear comes into contact with the ground surface GS.

[0051] The midsole 206 defines a through-hole 216 (such as a slit) that is fully disposed in the midfoot region 14 to receive a second plate portion 304 of the footwear plate 300. Thus, the through-hole 216 extends from the inner midsole surface 209 of the midsole body 208 to the outer midsole surface 211 of the midsole body 208. The second plate portion 304 may be fully disposed within the through-hole 216 of the midsole 206. To receive the second plate portion 304, the through-hole 216 may be angled relative to the inner midsole surface 209 and the outer midsole surface 211. A third plate portion 306 is disposed on top of the midsole 206 in the heel region 16 to minimize energy loss during heel impact. The second plate portion 304 is disposed between the inner midsole surface 209 and the outer midsole surface 211.

[0052] The midsole 206 defines a longitudinal recess 218 communicating with the midsole through-hole 216. The longitudinal recess 218 is adjacent to the outsole 204 and extends along the longitudinal direction LG (i.e., the second direction). The longitudinal recess 218 may be provided only in the forefoot region 12 of the sole structure 200 to maximize energy return during toe-off. A first plate portion 302 is at least partially provided in the longitudinal recess 218 to maximize energy return during toe-off. The outsole 204 has an inner outsole surface 226 facing the upper 100 and an outer outsole surface 228 facing away from the upper 100. The first plate portion 302 may directly contact the inner outsole surface 226 of the outsole 204 to maximize energy return during toe-off.

[0053] Figure 2 Footwear article 10 is shown, which, apart from the features described below, is similar to the footwear article mentioned above. Figure 1 The footwear article 10 described is generally the same. Instead of the through-hole 216, the midsole 206 defines a midsole opening 207 extending from the inner midsole surface 209 toward (but not through) the outer midsole surface 211. In other words, the midsole opening 207 does not extend through the entire thickness of the midsole 206. A second plate portion 304 is disposed within the midsole opening 207. A third plate portion 306 is disposed on top of the inner midsole surface 209 to absorb energy during heel impact. As discussed above, a first plate portion 302 is disposed in the forefoot region 12 of the sole structure 200. The first plate portion 302 may be disposed entirely within the midsole 206 and may be closer to the inner midsole surface 209 of the midsole 206 than to the outer midsole surface 211 of the midsole 206 to absorb energy during toe-off.

[0054] Figure 3 Footwear article 10 is shown, which, apart from the features described below, is similar to the footwear article mentioned above. Figure 1 The footwear article 10 described is generally the same. The sole interlayer 206 is configured as an embedded sole interlayer. Therefore, the sole interlayer 206 is entirely disposed within the internal cavity 102. Furthermore, the sole interlayer 206 is disposed only in the heel region 16 of the sole structure 200. The third plate portion 306 may be entirely disposed within the sole interlayer 206, and the first plate portion 302 may be entirely disposed within the outsole 204. The configuration of the sole structure 200 as described above facilitates energy absorption in the heel region 16 during heel impact and maximizes energy return during toe-off, while minimizing the number of components in the sole structure 200.

[0055] Figure 4 Footwear article 10 is shown, which, apart from the features described below, is similar to the footwear article mentioned above. Figure 3 The footwear article 10 described is generally the same. The midsole 206 is configured as an embedded midsole. Therefore, the midsole 206 is completely disposed within the internal cavity 102. Furthermore, the midsole 206 extends continuously through the heel region 16, the midfoot region 14, and then through the forefoot region 12 of the sole structure 200. A third plate portion 306 may be completely disposed within the midsole 206, and a first plate portion 302 may be completely disposed within the outsole 204. The configuration of the sole structure 200 as described above facilitates energy absorption in the heel region 16 during heel impact and maximizes energy return in the forefoot region 12 during toe-off, while providing cushioning along the entire length of the sole structure 200.

[0056] Figure 5 Footwear article 10 is shown, which, apart from the features described below, is similar to the footwear article mentioned above. Figure 3 The footwear article 10 described is generally the same. The sole interlayer 206 is constructed as an embedded sole interlayer. Therefore, the sole interlayer 206 is completely disposed within the internal cavity 102. However, the sole interlayer 206 includes two separate parts ( Right now, A first sole interlayer portion 206a and a second sole interlayer portion 206b. The first sole interlayer portion 206a and the second sole interlayer portion 206b are spaced apart from each other along a longitudinal axis L to define a gap G between the first sole interlayer portion 206a and the second sole interlayer portion 206b. The gap G is located in the midfoot region 14 of the sole structure 200 to receive a second plate portion 304. The first sole interlayer portion 206a extends along the entire heel region 16, and the second sole interlayer portion 206b extends along the entire forefoot region 12. A third plate portion 306 may be completely disposed within the sole interlayer 206, and a first plate portion 302 may be completely disposed within the outsole 204. The configuration of the sole structure 200 described above helps to absorb energy in the heel region 16 during heel impact and maximizes energy return in the forefoot region 12 during toe-off, while providing cushioning in the heel region 16 and forefoot region 12 of the sole structure 200.

[0057] Figure 6 Footwear article 10 is shown, which, apart from the features described below, is similar to the footwear article mentioned above. Figure 3 The footwear article 10 described is generally the same. The sole interlayer 206 is configured as an embedded sole interlayer. Therefore, the sole interlayer 206 is entirely disposed within the internal cavity 102. Furthermore, the sole interlayer 206 is disposed only in the forefoot region 12 of the sole structure 200. The first plate portion 302 can be entirely disposed within the sole interlayer 206, and the third plate portion 306 can be entirely disposed within the outsole 204. The configuration of the sole structure 200 as described above facilitates energy absorption in the forefoot region 12 during toe-off and maximizes energy return during heel impact, while minimizing the number of components in the sole structure 200.

[0058] Figure 7A flowchart illustrating a method 400 for manufacturing footwear article 10 is shown. Method 400 begins at frame 402. At frame 402, a footwear plate 300 is inserted through an opening (e.g., through-hole 216 or footwear plate opening 207) in a sole interlayer 206. This opening may extend through a portion or the entire thickness of the sole interlayer 206. This opening is located in the midfoot region 14 of the sole interlayer 206. It is envisioned that the upper 100 may wrap around the footwear plate 300. After frame 402, method 400 continues to frame 404. At frame 404, the sole interlayer 206 is attached to the outsole 204. As discussed above, the outsole 204 extends along a longitudinal axis LG or a second direction LG. For this purpose, the sole interlayer 206 may be sewn, glued, and / or heat-bonded to the outsole 204. Alternatively, the sole interlayer 206 may be an embedded sole interlayer. In this configuration, the midsole 206 is simply placed on top of the outsole 204 (but not fixed to it). At frame 404, the Stellar panel 204 can be positioned on top of the midsole 206. Method 400 then continues to frame 406. At frame 406, the upper 100 is attached to the sole structure 200. For this purpose, the upper 100 can be sewn, glued, and / or heat-bonded to the sole structure 200.

[0059] To aid in and clarify the description of the various embodiments, various terms are defined herein. Unless otherwise indicated, the following definitions apply throughout this specification (including the claims). Furthermore, all references mentioned are incorporated herein in their entirety.

[0060] "Footwear articles," "footwear products," and "footwear" can be considered as both machines and manufactured goods. Assembled, wearable footwear articles (such as shoes, sandals, boots, etc.) and their individual components (such as insoles, outsoles, uppers, etc.) are considered, in the singular or plural, and can be alternatively referred to as "footwear articles" or "footwear" before being finally assembled into wearable footwear articles.

[0061] The terms “a,” “an,” “the,” “at least one,” and “one or more” are used interchangeably to indicate at least one of the items present. Multiple such items may exist unless the context clearly indicates otherwise. Unless the context explicitly or clearly indicates otherwise, all numerical values ​​of parameters (e.g., quantities or conditions) in this specification (including the appended claims) should be understood to be modified in all cases by the term “about,” regardless of whether “about” actually precedes the numerical value. “About” indicates that the stated numerical value allows for some slight imprecision (somewhat close to the accuracy of the value; approximately or moderately close to the value; almost). If the imprecision provided by “about” is not otherwise understood in the art in this ordinary sense, then “about,” as used herein, at least indicates the variation that may arise from common methods of measuring and using these parameters. As used in the specification and appended claims, unless otherwise stated, a value is considered “approximately” equal to the stated value if it is neither more than 5% greater than the stated value nor less than 5% less than the stated value. Furthermore, the disclosure of a range should be understood as specifically disclosing all values ​​within that range and further subdivisions of the range.

[0062] The terms “comprising,” “including,” and “having” are inclusive and therefore specify the presence of the stated features, steps, operations, elements, or components, but do not exclude the presence or addition of one or more other features, steps, operations, elements, or components. The order of steps, processes, and operations may be changed where possible, and alternative or optional steps may be used. As used in this specification, the term “or” includes any and all combinations of the associated listed items. The term “any” is understood to include any possible combination of the referenced items, including “any one” of the referenced items. The term “any” is understood to include any possible combination of the referenced claims in the appended claims, including “any one” of the referenced claims.

[0063] For consistency and convenience, directional adjectives may be used throughout this detailed description corresponding to the illustrated embodiments. Those skilled in the art will recognize that terms such as “above,” “below,” “upward,” “downward,” “top,” “bottom,” etc., may be used descriptively with respect to the drawings and are not intended to limit the scope of the invention as defined by the claims.

[0064] The term "longitudinal" refers to the direction extending along the length of a component. For example, the longitudinal direction of a footwear article extends between the forefoot and heel areas. The terms "forward" or "anterior" are used to refer to the general direction from the heel area toward the forefoot area, and the terms "rearward" or "posterior" are used to refer to the opposite direction, i.e., from the forefoot area toward the heel area. In some cases, a component can be identified by a longitudinal axis and the forward and rearward longitudinal directions along that axis. The longitudinal direction or longitudinal axis can also be referred to as the front-rear direction or front-rear axis.

[0065] The term "transverse" refers to the direction that extends along the width of a component. For example, the transverse direction of footwear extends between the outer and inner surfaces of the footwear. The transverse direction or transverse axis can also be referred to as the lateral direction or lateral axis, or the mid-lateral direction or mid-lateral axis.

[0066] The term "vertical" refers to a direction that is generally perpendicular to both the lateral and longitudinal directions. For example, in the case of a sole structure being placed flat on a ground surface, the vertical direction can extend upwards from the ground surface. It will be understood that each of these directional adjectives can be applied to a single component of the sole structure. The term "upward" or "upwards" refers to a vertical direction pointing towards the top of a component, which may include the instep, fastening area, and / or throat of the upper. The term "downward" or "downwards" refers to a vertical direction opposite to the upward direction, pointing towards the bottom of the component and generally towards the bottom of the sole structure of the footwear article.

[0067] The “interior” of footwear (such as a shoe) refers to the portion of the space occupied by the wearer’s foot when the footwear is worn. The “inner side” of a component refers to the side or surface of the component in an assembled footwear that is oriented toward (or will be oriented toward) the interior of the component or footwear. The “outer side” or “exterior” of a component refers to the side or surface of the component in an assembled footwear that is oriented away from (or will be oriented away from) the interior of the footwear. In some cases, other components may be located between the inner side of a component and the interior of the assembled footwear. Similarly, other components may be located between the outer side of a component and the space outside the assembled footwear. Furthermore, the terms “inward” and “inner” refer to a direction toward the interior of a component or footwear (e.g., a shoe), and the terms “outward” and “outer” refer to a direction toward the exterior of a component or footwear (e.g., a shoe). Furthermore, the term "proximal" refers to the direction closer to the center of the footwear component or closer to the foot when the foot is inserted into the footwear. Similarly, the term "distal" refers to the relative position further away from the center of the footwear component or further away from the foot when the foot is inserted into the footwear. Therefore, the terms proximal and distal can be understood as providing largely opposite terms to describe relative spatial positions.

[0068] While several embodiments have been described, this description is intended to be exemplary and not restrictive, and it will be apparent to those skilled in the art that further embodiments and implementations are possible within the scope of these embodiments. Any feature of any embodiment may be used in combination with or in lieu of any other feature or element in any other embodiment, unless specifically limited thereto. Therefore, the embodiments are not limited except as provided in the appended claims and their equivalents. Moreover, various modifications and variations may be made within the scope of the appended claims.

[0069] While several modes of implementing many aspects of this teaching have been described in detail, those skilled in the art to which this teaching relates will recognize a variety of alternative aspects of implementing this teaching within the scope of the appended claims. It is intended that all content contained in the foregoing description or shown in the accompanying drawings be construed as an illustration and example of the overall scope of alternative embodiments that will be recognized by those of ordinary skill, such alternative implementations being implied by, structurally and / or functionally equivalent to, or otherwise apparent based on the contained content, and not limited to those embodiments explicitly depicted and / or described.

Claims

1. A shoe sole structure, comprising: The outsole defines an inner outsole surface and an outer outsole surface opposite to the inner outsole surface, and the inner outsole surface is spaced apart from the outer outsole surface along a first direction; A midsole layer, wherein the midsole layer is disposed on the outsole; The footwear plate is directly connected to the sole interlayer, wherein the footwear plate comprises a composite material and includes a first plate portion, a second plate portion connected to the first plate portion, and a third plate portion connected to the second plate portion, and the second plate portion is connected between the first plate portion and the third plate portion; and The second plate portion is inclined at an angle relative to the first plate portion and the third plate portion, such that the first plate portion is spaced apart from the third plate portion along the first direction, thereby enhancing the stability of the sole structure and minimizing energy loss when the sole structure contacts the ground surface. Wherein, the midsole defines an inner midsole surface and an outer midsole surface opposite to the inner midsole surface, and the midsole defines a midsole through-hole extending from the inner midsole surface of the midsole to the outer midsole surface of the midsole; and The sole interlayer defines a longitudinal recess in the sole interlayer that communicates with the through-hole of the sole interlayer. The longitudinal recess in the sole interlayer is adjacent to the outsole of the shoe. The longitudinal recess in the sole interlayer is disposed in the forefoot region of the sole structure. The first plate portion is at least partially disposed in the longitudinal recess in the sole interlayer to maximize energy return during toe-off.

2. The sole structure according to claim 1, wherein, The sole interlayer includes a sole interlayer material, the composite material having a first stiffness, the sole interlayer material having a second stiffness, and the first stiffness being greater than the second stiffness.

3. The sole structure according to claim 1 or 2, wherein the second plate portion is disposed within the sole interlayer through-hole of the sole interlayer, the first plate portion is disposed in the forefoot region of the sole structure, the third plate portion is disposed in the heel region of the sole structure, and the second plate portion is disposed in the midfoot region of the sole structure, the third plate portion is disposed on the top of the sole interlayer, the second plate portion is disposed between the inner sole interlayer surface and the outer sole interlayer surface of the sole interlayer, and the sole interlayer through-hole is inclined at an angle relative to the inner sole interlayer surface and the outer sole interlayer surface, the first plate portion is spaced apart from the second plate portion along a second direction, the second direction being perpendicular to the first direction, and the outsole extends along the second direction.

4. The sole structure according to claim 3, wherein, The third plate portion is in direct contact with the inner outsole surface of the outsole, and the longitudinal recess of the outsole extends along the second direction, which is perpendicular to the first direction.

5. The sole structure according to any one of claims 1-2 and 4, wherein, The sole interlayer extends through the heel area, midfoot area, and forefoot area of ​​the sole structure.

6. The sole structure according to claim 3, wherein, The sole interlayer extends through the heel area, midfoot area, and forefoot area of ​​the sole structure.

7. A shoe sole structure, comprising: The outsole defines an inner outsole surface and an outer outsole surface opposite to the inner outsole surface, and the inner outsole surface is spaced apart from the outer outsole surface along a first direction; A midsole layer, wherein the midsole layer is disposed on the outsole; The footwear plate is directly connected to the sole interlayer, wherein the footwear plate comprises a composite material and includes a first plate portion, a second plate portion connected to the first plate portion, and a third plate portion connected to the second plate portion, and the second plate portion is connected between the first plate portion and the third plate portion; and The second plate portion is inclined at an angle relative to the first plate portion and the third plate portion, such that the first plate portion is spaced apart from the third plate portion along the first direction, thereby enhancing the stability of the sole structure and minimizing energy loss when the sole structure contacts the ground surface. The sole interlayer defines an inner sole interlayer surface and an outer sole interlayer surface opposite to the inner sole interlayer surface. The sole interlayer defines a sole interlayer opening extending from the inner sole interlayer surface into the sole interlayer. The sole interlayer opening does not extend through the entire thickness of the sole interlayer. The second plate is partially disposed within the sole interlayer opening of the sole interlayer. The third plate is partially disposed on top of the inner sole interlayer surface at the heel region of the sole structure.

8. The sole structure according to claim 7, wherein, The sole interlayer includes a sole interlayer material, the composite material having a first stiffness, the sole interlayer material having a second stiffness, and the first stiffness being greater than the second stiffness.

9. The sole structure according to any one of claims 7-8, wherein, The first plate portion is disposed in the forefoot region of the sole structure, the first plate portion is disposed within the sole interlayer, and the first plate portion is closer to the inner sole interlayer surface of the sole interlayer than the outer sole interlayer surface that is closer to the sole interlayer.

10. The sole structure according to any one of claims 7-8, in, The sole interlayer is only located in the heel area of ​​the sole structure.

11. The sole structure according to any one of claims 7-8, wherein, The sole interlayer extends through the heel area, midfoot area, and forefoot area of ​​the sole structure.

12. The sole structure according to claim 9, wherein, The sole interlayer extends through the heel area, midfoot area, and forefoot area of ​​the sole structure.

13. A type of footwear, comprising: The upper defines an internal cavity and an ankle opening communicating with the internal cavity; A sole structure connected to the upper, wherein the sole structure includes a forefoot region, a midfoot region, and a heel region, the midfoot region being disposed between the forefoot region and the heel region, and the sole structure comprising: The outsole defines an inner outsole surface and an outer outsole surface opposite to the inner outsole surface, and the inner outsole surface is spaced apart from the outer outsole surface along a first direction; A midsole layer, wherein the midsole layer is disposed on the outsole; A footwear plate is attached to the sole interlayer, wherein the footwear plate comprises a composite material and includes a first plate portion, a second plate portion directly connected to the first plate portion, and a third plate portion directly connected to the second plate portion, and the second plate portion is connected between the first plate portion and the third plate portion; and The second plate portion is inclined at an angle relative to the first plate portion and the third plate portion, such that the first plate portion is spaced apart from the third plate portion along the first direction, thereby enhancing the stability of the sole structure and minimizing the energy loss of the sole structure when the footwear comes into contact with the ground surface. The sole interlayer defines an inner sole interlayer surface and an outer sole interlayer surface opposite to the inner sole interlayer surface. The inner sole interlayer surface faces the upper, and the outer sole interlayer surface faces away from the upper. The sole interlayer defines a sole interlayer through-hole extending from the inner sole interlayer surface to the outer sole interlayer surface. A second plate is partially disposed within the sole interlayer through-hole. A first plate is partially disposed in the forefoot region of the sole structure. A third plate is partially disposed in the heel region of the sole structure. The second plate is partially disposed in the midfoot region of the sole structure.

14. The footwear article according to claim 13, wherein, The third plate is disposed on the top of the sole interlayer, the second plate is disposed between the inner sole interlayer surface and the outer sole interlayer surface of the sole interlayer, and the through hole of the sole interlayer is inclined at an angle relative to the inner sole interlayer surface and the outer sole interlayer surface.

15. The footwear article according to claim 13, wherein, The sole interlayer defines a longitudinal recess in communication with a through-hole in the sole interlayer, the longitudinal recess in the sole interlayer being adjacent to the outsole, the longitudinal recess in the sole interlayer being disposed in the forefoot region of the sole structure, and the first plate portion being at least partially disposed in the longitudinal recess in the sole interlayer to maximize energy return during toe-off.

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

17. The footwear article according to claim 13, wherein, The sole interlayer is configured as an embedded sole interlayer, the sole interlayer is completely disposed within the internal cavity of the upper, the third plate is partially disposed within the sole interlayer, and the first plate is partially disposed within the outsole.

18. Footwear according to any one of claims 13-17, wherein, The sole interlayer extends through the heel area, the midfoot area, and the forefoot area.

19. A footwear item comprising: The upper defines an internal cavity and an ankle opening communicating with the internal cavity; A sole structure connected to the upper, wherein the sole structure includes a forefoot region, a midfoot region, and a heel region, the midfoot region being disposed between the forefoot region and the heel region, and the sole structure comprising: The outsole defines an inner outsole surface and an outer outsole surface opposite to the inner outsole surface, and the inner outsole surface is spaced apart from the outer outsole surface along a first direction; A midsole layer, wherein the midsole layer is disposed on the outsole; A footwear plate is attached to the sole interlayer, wherein the footwear plate comprises a composite material and includes a first plate portion, a second plate portion directly connected to the first plate portion, and a third plate portion directly connected to the second plate portion, and the second plate portion is connected between the first plate portion and the third plate portion; and The second plate portion is inclined at an angle relative to the first plate portion and the third plate portion, such that the first plate portion is spaced apart from the third plate portion along the first direction, thereby enhancing the stability of the sole structure and minimizing the energy loss of the sole structure when the footwear comes into contact with the ground surface. The sole interlayer defines an inner sole interlayer surface and an outer sole interlayer surface opposite to the inner sole interlayer surface. The inner sole interlayer surface faces the upper, and the outer sole interlayer surface faces away from the upper. The sole interlayer defines a sole interlayer opening extending from the inner sole interlayer surface into the sole interlayer. The sole interlayer opening does not extend through the entire thickness of the sole interlayer. A second plate is partially disposed within the sole interlayer opening of the sole interlayer, and a third plate is partially disposed on top of the inner sole interlayer surface at the heel region of the sole structure.

20. The footwear article according to claim 19, wherein, The first plate portion is disposed in the forefoot region of the sole structure, the first plate portion is disposed within the sole interlayer, and the first plate portion is closer to the inner sole interlayer surface of the sole interlayer than the outer sole interlayer surface that is closer to the sole interlayer.

21. The footwear article according to claim 19, wherein, The sole interlayer is only located in the heel area of ​​the sole structure.

22. The footwear article according to any one of claims 19-20, wherein, The sole interlayer extends through the heel area, the midfoot area, and the forefoot area.

23. A method for manufacturing footwear, comprising: A footwear plate is inserted through an opening in the sole interlayer to directly attach the footwear plate to the sole interlayer, wherein the footwear plate comprises a composite material, the footwear plate includes a first plate portion, a second plate portion connected to the first plate portion, and a third plate portion connected to the second plate portion, and the second plate portion is connected between the first plate portion and the third plate portion, and the second plate portion is inclined at an angle relative to the first plate portion and the third plate portion, such that the first plate portion is spaced apart from the third plate portion along a first direction; The insole interlayer is attached to the outsole, wherein the outsole extends along a longitudinal axis, the first direction being perpendicular to the longitudinal axis, the insole structure including the insole interlayer and the outsole, the insole structure having a forefoot region, a heel region and a midfoot region located between the forefoot region and the heel region, and the opening of the insole interlayer is provided at the midfoot region; as well as Attach the upper to the sole structure; Wherein, the opening of the sole interlayer is a through hole extending along the entire thickness of the sole interlayer, the sole interlayer defines a longitudinal recess of the sole interlayer communicating with the through hole of the sole interlayer, the longitudinal recess of the sole interlayer being adjacent to the outsole and disposed in the forefoot region of the sole structure, and the first plate portion is at least partially disposed in the longitudinal recess of the sole interlayer to maximize energy return during toe-off.

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