Sole plate comprising a metal plate and method for manufacturing the same

Abstract

A sole plate for an article of footwear includes a one-piece, unitary metal plate including a top surface, a bottom surface, and a plate thickness measured from the top surface to the bottom surface. The sole plate can include a protrusion formed in the metal plate and a corresponding nub on the bottom surface of the metal plate. The protrusion can include a cavity surface defined by the top surface of the metal plate, a projection surface defined by the bottom surface of the metal plate, and a wall thickness measured from the cavity surface to the projection surface. The plate thickness and the wall thickness can be greater than or equal to 0.01 mm and less than or equal to 0.5 mm. The metal plate can be formed by a method including stamping, deep draw, progressive sheet forming, or a combination thereof.

Description

Technical Field

[0001] The described embodiments generally relate to footwear articles and methods of manufacturing footwear articles. In particular, the described embodiments relate to sole plates for footwear articles comprising a metal plate, and methods of manufacturing sole plates comprising a metal plate. Background Technology

[0002] Footwear can be manufactured from a wide range of materials using a broad range of technologies. The durability, comfort, and / or performance characteristics of footwear are generally of concern, for both athletic and non-athletic activities. Footwear for athletic activities must meet higher performance standards than footwear for non-athletic activities. For example, many sports require a high degree of agility. This necessitates that footwear be lightweight or bulky, as weight reduces an athlete's agility and speed. Therefore, there is a continuous need for innovation in footwear and its manufacturing methods to reduce weight while providing necessary support. Summary of the Invention

[0003] The first embodiment (1) of this application relates to a sole plate for footwear articles, the sole plate comprising: a single, integrally formed metal plate including a top surface, a bottom surface and a plate thickness measured from the top surface to the bottom surface; and a protrusion formed in the metal plate, the protrusion defining a cavity on the top surface of the metal plate and defining a bump on the bottom surface of the metal plate, the protrusion including a cavity surface defined by the top surface of the metal plate, a protruding surface defined by the bottom surface of the metal plate and a wall thickness measured from the cavity surface to the protruding surface, wherein the plate thickness is greater than or equal to 0.01 mm and less than or equal to 0.5 mm, and wherein the wall thickness is greater than or equal to 0.01 mm and less than or equal to 0.5 mm.

[0004] In the second embodiment (2), the cavity according to the first embodiment (1) includes a maximum depth of 0.5 mm or more and 22 mm or less.

[0005] In the third embodiment (3), the plate thickness deviation according to any one of embodiments (1)-(2) is ±200 micrometers over 50% or more of the area of ​​the metal plate.

[0006] In the fourth embodiment (4), the wall thickness deviation of the protrusion according to any one of embodiments (1)-(3) is ±100 micrometers over 50% or more of the area of ​​the protrusion.

[0007] In the fifth embodiment (5), the wall thickness according to any one of embodiments (1)–(4) in the region adjacent to the protrusion is substantially equal to the plate thickness according to any one of embodiments (1)–(4).

[0008] In the sixth embodiment (6), the protrusion according to any one of embodiments (1)-(5) is included by the anti-slip nail.

[0009] In the seventh embodiment (7), the sole plate according to any one of embodiments (1)–(6) includes a plurality of additional protrusions; each additional protrusion is formed in the metal plate, defining a cavity on the top surface of the metal plate and a protrusion on the bottom surface of the metal plate, and includes a cavity surface defined by the top surface of the metal plate, a protruding surface defined by the bottom surface of the metal plate, and a wall thickness greater than or equal to 0.01 mm and less than or equal to 0.5 mm measured from the cavity surface to the protruding surface; and each additional protrusion is included by anti-slip studs.

[0010] In the eighth embodiment (8), the protrusion according to any one of embodiments (1)–(5) and (7) is a ridge.

[0011] In the ninth embodiment (9), the maximum width of the ridge according to the eighth embodiment (8) is greater than or equal to 0.5 mm and less than or equal to 4 mm. This maximum width is measured between the edges of the protrusions on the bottom surface, perpendicular to the longitudinal axis of the ridge.

[0012] In the tenth embodiment (10), the ratio of the maximum depth of the cavity to the maximum width of the ridge according to any one of embodiments (8)-(9) is greater than or equal to 1:2 and less than or equal to 10:1.

[0013] In the eleventh embodiment (11), the sole plate according to any one of embodiments (1)–(10) includes a plurality of additional protrusions; each additional protrusion is formed in the metal plate, defining a cavity on the top surface of the metal plate and a protrusion on the bottom surface of the metal plate, and includes a cavity surface defined by the top surface of the metal plate, a protruding surface defined by the bottom surface of the metal plate, and a wall thickness greater than or equal to 0.01 mm and less than or equal to 0.5 mm measured from the cavity surface to the protruding surface; and each additional protrusion is an additional ridge in a series of corrugated ridges.

[0014] In the twelfth embodiment (12), the distance between the peaks of adjacent ridges in the series of corrugated ridges according to the eleventh embodiment (11) is greater than or equal to 0.5 mm and less than or equal to 6 mm.

[0015] In the thirteenth embodiment (13), the ridges of the series of corrugated ridges according to any one of embodiments (11)-(12) are arranged substantially parallel to the longitudinal axis of the metal plate.

[0016] In the fourteenth embodiment (14), the metal plate according to any one of embodiments (1)–(13) is made of at least one metal selected from steel, titanium alloy, aluminum and brass.

[0017] In the fifteenth embodiment (15), the metal plate according to any one of embodiments (1)–(14) is made of a metal with a density greater than or equal to 4 g / cc and less than or equal to 8 g / cc.

[0018] In the sixteenth embodiment (16), the size of the metal plate according to any one of embodiments (1)-(15) is set to extend from the forefoot end of the footwear to the heel end and includes a mass greater than or equal to 30 grams and less than or equal to 80 grams.

[0019] In the seventeenth embodiment (17), the sole plate according to any one of embodiments (1)-(16) includes a body wing extending from the body side of the metal plate and a mid-wing extending from the mid-side of the metal plate, the body wing and the mid-wing being integrally formed with the metal plate.

[0020] In the eighteenth embodiment (18), the body side wing of the seventeenth embodiment (17) is bent in the direction above the top surface of the metal plate, and the near-center wing of the seventeenth embodiment (17) is bent in the direction above the top surface of the metal plate.

[0021] The nineteenth embodiment (19) of this application relates to a footwear article comprising: an upper; and a sole plate according to any one of embodiments (1)–(18), the sole plate being coupled to the upper.

[0022] The twentieth embodiment (20) of this application relates to a method of manufacturing a sole plate for footwear articles, the method comprising: forming a protrusion in a metal plate, the metal plate including a top surface, a bottom surface and a plate thickness greater than or equal to 0.01 mm and less than or equal to 0.5 mm measured from the top surface to the bottom surface, wherein the protrusion defines a cavity on the top surface of the metal plate and a protrusion on the bottom surface of the metal plate, and includes a cavity surface defined by the top surface of the metal plate, a protruding surface defined by the bottom surface of the metal plate and a wall thickness greater than or equal to 0.01 mm and less than or equal to 0.5 mm measured from the cavity surface to the protruding surface, and wherein the forming comprises a process selected from stamping, deep drawing and progressive sheet forming (ISF).

[0023] In the twenty-first embodiment (21), the method according to the twenty-tenth embodiment (20) further includes: forming the metal plate while forming the protrusion.

[0024] In the twenty-second embodiment (22), forming the metal plate according to any one of embodiments (20)-(21) includes forming a concave curvature in the periphery region of the top surface of the metal plate.

[0025] In the twenty-third embodiment (23), the sole plate according to any one of embodiments (20)-(22) includes a body wing extending from the body side of the metal plate and a mid-wing extending from the mid-side of the metal plate, the body wing and the mid-wing being integrally formed with the metal plate, and the method according to any one of embodiments (20)-(22) further includes: bending the body wing in a direction above the top surface of the metal plate and bending the mid-wing in a direction above the top surface of the metal plate.

[0026] In the twenty-fourth embodiment (24), the protrusion according to any one of embodiments (20)-(23) is included by anti-slip studs.

[0027] In the twenty-fifth embodiment (25), the method according to any one of embodiments (20)-(24) further includes: forming a variable plate thickness in the metal plate: forming a variable plate thickness includes: selectively thinning a region of the metal plate adjacent to a region selected for forming the protrusion. Attached Figure Description

[0028] Figure 1 A shoe sole plate comprising a metal plate is shown according to some embodiments.

[0029] Figure 2 It shows some embodiments Figure 1 The cross-sectional view of the sole plate taken along line 2'-2'.

[0030] Figure 3 It shows some embodiments Figure 1 The cross-sectional view of the sole plate along line 3'-3'.

[0031] Figure 4 It shows some embodiments Figure 1 A sectional view of the sole plate taken along line 4'-4'.

[0032] Figure 5 It shows some embodiments Figure 1 The sole of the shoe.

[0033] Figure 6 It shows some embodiments Figure 5 A sectional view of the sole plate taken along line 6'-6'.

[0034] Figure 7 It shows some embodiments Figure 1 The sole of the shoe.

[0035] Figure 8 It shows some embodiments Figure 7 A sectional view of the sole plate taken along line 8'-8'.

[0036] Figure 9 Footwear products according to some embodiments are shown.

[0037] Figure 10 Footwear products according to some embodiments are shown.

[0038] Figure 11A-11B A shoe sole plate according to some embodiments is shown.

[0039] Figure 12 This is an exemplary flowchart of a method according to some embodiments.

[0040] Figures 13A-13C A mold for forming a metal sheet is shown according to some embodiments.

[0041] Figure 14 A sheet material comprising a metal plate is shown according to some embodiments.

[0042] Figure 15 Various surface configurations of metal plates according to some embodiments are shown.

[0043] Figure 16 Metal plates with different surface configurations and / or orientations in different regions are shown according to some embodiments.

[0044] Figures 17A-17B A shoe sole plate comprising a metal plate and polymer segments is shown according to some embodiments.

[0045] Figure 18 Various configurations for coupling polymer segments to a metal plate, according to some embodiments, are shown.

[0046] Figures 19A-19C A protrusion comprising polymer segments is shown according to some embodiments.

[0047] Figure 20 A shoe sole plate including a second metal plate is shown according to some embodiments.

[0048] Figure 21 It shows some embodiments Figure 20 The cross-sectional view of the sole plate taken along line 21'-21'.

[0049] Figure 22 It shows some embodiments Figure 20 A sectional view of the sole plate taken along line 22'-22'.

[0050] Figure 23 A shoe sole plate comprising a metal plate and metal segments is shown according to some embodiments.

[0051] Figure 24It shows some embodiments Figure 23 A sectional view of the sole plate taken along line 24'-24'.

[0052] Figure 25 Metal segments of a coupled metal plate according to some embodiments are shown.

[0053] Figure 26 A draping simulation based on some embodiments is shown.

[0054] Figures 27A-27B The following are examples based on some embodiments. Figure 26 The metal sheet is formed by cladding.

[0055] Figure 28 This is an exemplary flowchart of a method according to some embodiments. Detailed Implementation

[0056] The present invention will now be described in detail with reference to embodiments illustrated in the accompanying drawings. References to "some embodiments," "one embodiment," "embodiment," "exemplary embodiment," etc., indicate that the described embodiments may include specific features, structures, or characteristics, but each embodiment may not necessarily include that specific feature, structure, or characteristic. Furthermore, these phrases do not necessarily refer to the same embodiment. Further, when a specific feature, structure, or characteristic is described in connection with an embodiment, it is believed that in conjunction with other embodiments (whether explicitly described or not) influencing those features, structures, or characteristics is within the knowledge of those skilled in the art.

[0057] The indefinite articles “a / an” and “the” include multiple referents unless explicitly contradicted or otherwise specified by the context.

[0058] The term "includes / contains" is an open-ended transitional phrase. The list of elements following the transitional phrase "includes / contains" is a non-exclusive list, allowing elements other than those specifically described in the list to exist.

[0059] As used herein, unless otherwise specified, references to "first," "second," "third," "fourth," etc., are not intended to indicate order, nor do they imply that a later-numbered feature requires a earlier-numbered feature. Furthermore, unless otherwise specified, the use of "first," "second," "third," "fourth," etc., does not necessarily imply that features such as "first," "second," "third," "fourth," etc., have different characteristics or values.

[0060] As used herein, the term “and / or” when used in a list of two or more items means that any one of the listed items may be used alone, or any combination of two or more of the listed items may be used. For example, if a composition is described as containing components A, B, and / or C, the composition may contain: A alone; B alone; C alone; a combination of A and B; a combination of A and C; a combination of B and C; or a combination of A, B, and C, unless it is obvious from the context that a single listed item or a combination thereof is not possible on its own.

[0061] Footwear serves a variety of purposes. Among other things, footwear can provide a unique aesthetic appearance, offer warmth or coolness, provide support for certain parts of the foot or ankle, and provide other performance characteristics such as breathability, moisture-wicking properties, compression properties, energy return properties, and weight characteristics. Each of these purposes, individually or in combination, provides footwear suitable for use in competitive sports. Characteristics of footwear products (e.g., the materials and components used to manufacture the footwear, and how these materials / components are manufactured) can be altered to produce desired properties such as durability, stiffness, weight, tackiness, texture, feel, and / or breathability.

[0062] Weight is a crucial consideration in athletic footwear. For every ounce of weight added to an athletic footwear product, the athlete must expend more energy to lift and move it. This can deplete an athlete's energy reserves, which are best used for performing desired movements such as sprinting, changing direction, or kicking a ball. The ability to manufacture lightweight components for footwear can enhance an athlete's speed, agility, and dexterity. At the same time, depending on the component, it must maintain a certain level of stiffness, which is necessary for providing durability, energy return, and / or support. However, as long as a component achieves the required level of stiffness, making that component lighter is generally beneficial.

[0063] In some cases, certain materials and manufacturing processes limit the extent to which lightweight components can be manufactured; for example, they limit how thin a component can be made. Typically, soles used in footwear are made from polyamide (nylon) or other thermoplastic polymers using injection molding. When injection molding thermoplastic polymers such as nylon, it is difficult to obtain components with a thickness of less than about 0.9 mm, for example. This is because it is difficult to allow the thermoplastic polymer to flow through portions spaced less than about 0.9 mm in the mold. Therefore, there are limitations on how thin and, consequently how lightweight, soles or other components made of thermoplastic polymers can be manufactured. Other problems also exist, including the susceptibility of plastic components thinner than a certain thickness to cracking, breaking, or stretching during competitive sports.

[0064] To address these issues, and according to embodiments of this disclosure, metallic materials can be used, employing manufacturing processes including stamping, deep drawing, incremental sheet forming (ISF) (e.g., single-point ISF), and / or other sheet metal forming processes. The metallic components described herein (e.g., for shoe soles) can be lighter than polymeric components performing the same function, and in some cases, improve that function. Compared to thermoplastic polymers, various metals possess at least the following characteristics that enable the manufacture of functional metallic sheets for shoe soles that are lighter than similar polymeric soles, according to embodiments of this disclosure.

[0065] The density of steel (approximately 7.85 g / cc) is about 8 times that of nylon (approximately 1.01 g / cc). The density of titanium (approximately 4.5 g / cc) is about 4.5 times that of nylon. Therefore, to be lighter than a theoretically thin nylon sole with constant thickness, a steel sole needs to be at least 8 times thinner than a nylon sole. A titanium sole needs to be at least 4.5 times thinner than a nylon sole. Using manufacturing processes such as stamping, deep drawing, and / or ISF (In-Form Factor), metals like steel and titanium can be formed into functional components with thicknesses as small as 0.01 mm. Thus, a steel sole with an average thickness of 0.1 mm can be formed, which is 9 times thinner on average than a nylon sole with a thickness of 0.9 mm (potentially the minimum feasible thickness for nylon), and therefore lighter. Similarly, a titanium sole with an average thickness of 0.15 mm can be formed, which is 6 times thinner on average than a nylon sole with a thickness of 0.9 mm, and therefore significantly lighter.

[0066] The following factors, individually or in combination, amplify these weight reductions: 1. The constant 0.9 mm thickness of nylon or other thermoplastic polymer sole plates represents the theoretical lower limit for thickness and weight. In practice, nylon or other thermoplastic polymer sole plates will have portions thicker than 0.9 mm, thus increasing weight—compared to the sole plates described herein.

[0067] 2. Typically, nylon or other thermoplastic polymer soles contain solid thermoplastic polyurethane (TPU) anti-slip studs. TPU has a higher density than nylon, thus adding weight compared to the soles described herein.

[0068] 3. Structural features on typical nylon or other thermoplastic polymer soles are usually solid to provide the necessary rigidity. In contrast, sheet metal can be shaped using stamping, deep drawing, and / or progressive sheet forming to incorporate hollow yet still rigid and supportive structural features (e.g., anti-slip studs or ridges).

[0069] The sole plate described herein may include a single, integrally formed metal plate comprising: a top surface configured to face other parts of the footwear article, a bottom surface configured to face and / or interact with the ground, and a plate thickness measured from the top surface to the bottom surface. In some embodiments, the metal plate may be configured to substantially span the entire area of ​​the sole of the footwear article. The construction, dimensional, and manufacturing method of the sole plate according to embodiments of this disclosure overcomes, in whole or in part, the aforementioned problems.

[0070] Figure 1 A sole plate 100 according to some embodiments is shown. In some embodiments, the sole plate 100 may be configured for a specific side of a shoe. For example, Figure 1 The image shows a sole plate 100 configured for a left-foot footwear product. However, the sole plate 100 can also be configured for a right-foot footwear product and can include—with the same design as for—a left-foot footwear product. Figure 1 The sole plate 100 shown has the same features as described, but is a mirror image.

[0071] The sole plate 100 includes a metal plate 101. In some embodiments, the sole plate 100 may include additional components other than the metal plate 101, such as polymer components coupled to the metal plate 101. In some embodiments, the sole plate 100 may include only the metal plate 101 and other metal elements integrally formed with the metal plate 101.

[0072] In some embodiments, the metal sheet 101 may be a single, integrally formed sheet. That is, apart from surface treatments (as described herein) included within the thickness of the metal sheet 101, no other components of the metal sheet 101 are formed and then coupled to the metal sheet 101. In some embodiments, the metal sheet 101 may include steel (e.g., maraging steel), titanium, titanium alloys, aluminum, aluminum alloys, brass, INCONEL®, Nitinol, WASPALOY®, and / or similar lightweight metals.

[0073] In some embodiments, the metal plate 101 may contain a metal with a density greater than or equal to 4 g / cc and less than or equal to 8 g / cc. More specifically, in some embodiments, the metal plate 101 may contain a metal with the following densities: greater than or equal to 4 g / cc and less than or equal to 7 g / cc, greater than or equal to 4 g / cc and less than or equal to 6 g / cc, greater than or equal to 4 g / cc and less than or equal to 5 g / cc, greater than or equal to 5 g / cc and less than or equal to 8 g / cc, greater than or equal to 6 g / cc and less than or equal to 8 g / cc, or greater than or equal to 7 g / cc and less than or equal to 8 g / cc.

[0074] In some embodiments, the size of the metal plate 101 may be set to be such that it forms part of the footwear article (e.g., Figure 9 The footwear article 900 shown extends from the forefoot end (e.g., forefoot end 902) to the heel end (e.g., heel end 904). Additionally or alternatively, in some embodiments, the metal plate 101 may be sized to extend from the side of the footwear article (e.g., side of the body 910) that forms part of the footwear article (e.g., footwear article 900) to the midline. In some embodiments, the metal plate 101 may be sized to extend along the entire length of the footwear article from the side of the footwear article to the midline.

[0075] In some embodiments, the size of the metal plate 101 may be set to cover more than 50% of the sole area of ​​the footwear product. More specifically, the size of the metal plate 101 may be set to cover more than 60%, 70%, 80%, 90%, 95%, or all of the sole area of ​​the footwear product.

[0076] In some embodiments, the metal plate 101 may include a mass greater than or equal to 30 grams and less than or equal to 80 grams. More specifically, in some embodiments, the metal plate 101 may include the following masses: greater than or equal to 30 grams and less than or equal to 70 grams, greater than or equal to 30 grams and less than or equal to 60 grams, greater than or equal to 30 grams and less than or equal to 50 grams, or greater than or equal to 30 grams and less than or equal to 40 grams.

[0077] Metal plate 101 may include a top surface 102. Top surface 102 may be configured to face and couple to other components of the footwear article, such as the midsole and upper. As used herein, describing two components as coupled to each other means that the first and second components are either directly coupled to each other or indirectly coupled through another component, adhesive, etc., unless otherwise specified as direct or indirect coupling.

[0078] The metal plate 101 may include a bottom surface 104. The bottom surface 104 may be configured to face the ground and / or interact with the ground, such as a field, artificial turf, running track, loose soil, mud, etc.

[0079] The metal plate 101 may include a perimeter edge 105, i.e., where the top surface 102 transitions to the bottom surface 104.

[0080] The raised sole plate 100 may include one or more protrusions 106. In some embodiments, the protrusions 106 may be formed in the metal plate 101 by stamping, deep drawing, and / or ISF. Therefore, in some embodiments, the metal plate 101 may include the one or more protrusions 106.

[0081] The protrusion 106 may include various types of protrusions. For example, the protrusion 106 may include one or more anti-slip studs 106a and / or one or more ridges 106b. In some embodiments, the anti-slip studs 106a may be configured to interact with the ground to provide traction friction with the ground. In some embodiments, the ridges 106b may be configured, depending on their orientation, to provide additional stiffness and / or flexibility to the metal plate 101. However, the ridges 106b may also be configured to interact with the ground to provide traction friction with the ground, for example, if the ground is soft (e.g., muddy).

[0082] like Figure 1 As shown, the metal plate 101 may include a side panel 110. The side panel 110 may be configured to face the outside of the wearer's foot in the wearing position. For example, if the footwear article including the metal plate 101 is a left-foot footwear article, the side panel 110 will face the wearer's left side.

[0083] Similarly, the metal plate 101 may include a mesial side 120. The mesial side 120 may be configured to face the inside of the wearer's foot in the wearing position. For example, if the footwear containing the metal plate 101 is a left-foot footwear, the mesial side 120 will face the space between the wearer's feet and the wearer's right side.

[0084] In some embodiments, the metal plate 101 may include a forefoot portion 130. In such embodiments, the forefoot portion 130 may be configured to occupy—the part comprising the metal plate 101—of a footwear article (e.g., Figure 9 The front half of the footwear product shown (900). The front half of the footwear product includes the portion approximately 50% of the length of the footwear product from its forefoot tip.

[0085] In some embodiments, the metal plate 101 may include a rearfoot portion 140. In such embodiments, the rearfoot portion 140 may be configured to occupy—the part comprising the metal plate 101—of a footwear article (e.g., Figure 9 The rear half of the footwear product shown (900). The rear half of the footwear product includes the portion extending more than 50% of the length of the footwear product from its forefoot.

[0086] The forefoot portion 130 and the rearfoot portion 140 do not necessarily occupy the entire front and rear halves of the footwear, respectively.

[0087] Metal plate 101 may have a longitudinal axis L extending along the longest dimension of metal plate 101. P When viewing the metal plate 101 from the front side of the top surface 102 or the bottom surface 104, the longitudinal axis L P It is a straight line connecting the two farthest points on the perimeter edge 105, such as Figure 5As shown. However, the longitudinal axis L P The curvature of the metal plate 101 in the vertical direction V (except for the protrusion 106) can be along the overall curvature of the metal plate 101 in the vertical direction V, such as Figure 1 As shown.

[0088] Figure 1 A non-slip stud 106a with a generally circular horizontal cross-section is shown. In some embodiments, this may be obtained from stamping, deep drawing, or ISF processes, although deep drawing naturally produces such a circular horizontal cross-section. However, in some embodiments, the non-slip stud 106a does not necessarily have a generally circular horizontal cross-section. For example, the non-slip stud 106a may be as follows: Figure 5 The irregular shape is shown. Additionally, the anti-slip stud 106a can define flat protrusions, such as... Figure 1 As shown, or pointed, rounded, and / or textured bumps.

[0089] Similarly, ridge 106b can have the same Figure 1 Different shapes are shown. For example, ridge 106b can define a rounded protrusion, such as... Figure 3 As shown, flat bumps, such as Figure 4 As shown, or a pointed protrusion. Figure 1 , 3 The shape shown in Figure 4 should not be interpreted as limiting the shape of ridge 106b. As used herein, the term "ridge" refers to a protrusion 106 whose length (measured along a direction parallel to the portion surrounding the bottom surface 104) is more than twice its maximum width, the maximum width being as per the description of the protrusion. Figure 3 Defined. In some embodiments, ridge 106b may be adjacent to anti-slip stud 106a.

[0090] Although Figure 1 The metal plate 101 shows 20 anti-slip studs 106a and four ridges 106b, but the metal plate 101 may contain any number of anti-slip studs 106a and any number of ridges 106b, arranged in any configuration. In some embodiments, the metal plate 101 may not contain anti-slip studs 106a. In some embodiments, the metal plate 101 may not contain ridges 106b.

[0091] In addition, although Figure 1 The metal plate 101 is shown to have a solid structure without gaps, but in some embodiments, slits, holes and / or other gaps may be formed in the metal plate 101.

[0092] Figure 2 It shows some embodiments Figure 1 The cross-section of the metal plate 101 shown is taken along line 2'-2' and viewed from the front foot end of the metal plate 101.

[0093] like Figure 2 As shown, the metal plate 101 includes a plate thickness t measured from the top surface 102 to the bottom surface 104. P Plate thickness t P The measurement can be applied to the portion of metal plate 101 that includes the protrusion 106. In some embodiments, the plate thickness t P It can be greater than or equal to 0.01 mm and less than or equal to 0.5 mm. More specifically, the plate thickness t P The thickness t within this range can be greater than or equal to 0.01 mm and less than or equal to 0.4 mm, greater than or equal to 0.01 mm and less than or equal to 0.35 mm, greater than or equal to 0.01 mm and less than or equal to 0.3 mm, greater than or equal to 0.01 mm and less than or equal to 0.25 mm, greater than or equal to 0.01 mm and less than or equal to 0.20 mm, greater than or equal to 0.01 mm and less than or equal to 0.15 mm, or greater than or equal to 0.01 mm and less than or equal to 0.1 mm. P The metal plate 101 may have an average thickness that is kept below an upper limit for the metal plate 101—which is lighter than the corresponding polymer sole component. In some embodiments, the metal plate 101 may include a minimum plate thickness of 0.01 mm or more and 0.15 mm or less, for example, 0.01 mm or more and 0.12 mm or more, 0.01 mm or more and 0.10 mm or more, 0.01 mm or more and 0.8 mm or more, or 0.01 mm or more and 0.5 mm or more.

[0094] In some embodiments, the plate thickness t P The deviation can be ±300 micrometers. More specifically, the plate thickness t P The deviation can be ±250 μm, ±225 μm, ±200 μm, ±175 μm, ±150 μm, ±125 μm, ±100 μm, ±75 μm, ±50 μm, ±25 μm, ±10 μm, or ±5 μm. Plate thickness t P The deviation is ±5 micrometers. For example, this means that the metal plate 101 is no more than 5 micrometers thicker than its average thickness at its maximum thickness and no more than 5 micrometers thinner than its average thickness at its minimum thickness. The average thickness is calculated as the average of the thickest and thinnest thicknesses. It should be noted that wrinkles in the metal plate 101 cause localized double-layer formation, which is not considered part of the plate thickness t. P The change in plate thickness t at the fold. P It refers to the thickness of a single layer of pleats.

[0095] In some embodiments, the plate thickness t PThe deviation can be any of the values ​​mentioned above, spanning at least a minimum area percentage of the metal plate 101. In some embodiments, the plate thickness t P The deviation can be any of the values ​​mentioned above, spanning 30% or more of the area of ​​metal plate 101. More specifically, the plate thickness t P The deviation can be any of the values ​​mentioned above, spanning 40% or more, 50% or more, 60% or more, 70% or more, 80% or more, 90% or more, or 95% or more of the area of ​​the metal plate 101. In this context, the area of ​​the metal plate 101 can be approximated by determining the volume of the metal plate 101 using an immersion method, determining its total surface area by considering its density (e.g., based on the metal type), and then dividing that value by 2.

[0096] In some embodiments, the plate thickness t P The deviation can be any of the values ​​mentioned above, spanning any percentage range of the area mentioned above, excluding the wall thickness and the area of ​​protrusions 106 during the calculation. Excluding the area of ​​protrusions 106 can include subtracting the surface area of ​​their protruding surfaces from the above approximation.

[0097] In some embodiments, the plate thickness t P The deviation can be any of the values ​​mentioned above, spanning a specific region, and the wall thickness of protrusion 106 may be included or excluded during the calculation. For example, in some embodiments, the plate thickness t P The deviation can be any of the values ​​mentioned above, spanning the foreleg portion 130, and the calculation may include or exclude the protrusions 106 in the foreleg portion 130. In some embodiments, the plate thickness t P The deviation can be any of the values ​​mentioned above, spanning the hind foot portion 140, and the calculation may include or exclude the protrusions 106 in the hind foot portion 140. In some embodiments, the plate thickness t P The deviation can be any of the above values, spanning a region of 150 ( Figure 1 An example is shown in the figure, which covers two protrusions 106, and these two protrusions 106 are included or excluded in the calculation. In some embodiments, the plate thickness t P The deviation can be any of the values ​​mentioned above, spanning region 150, which encompasses a set of protrusions 106, such as three protrusions 106, four protrusions 106, all protrusions 106 in the forefoot portion 130, or all protrusions 106 in the hindfoot portion 140, including or excluding this set of protrusions 106 in the calculation.

[0098] In some embodiments, the metal plate 101 may be configured to have a variable plate thickness t. PFor example, in some embodiments, the metal sheet 101 may be formed prior to forming the protrusion 106, giving it regions containing a smaller thickness and regions containing a larger thickness. In such embodiments, forming the metal sheet 101 with a variable thickness may include rolling, stamping, laser ablation, or forging a metal sheet with a variable thickness.

[0099] In some embodiments, the hind foot portion 140 of the metal plate 101 may have a greater plate thickness than the forefoot portion 130. This can provide increased stiffness in the hind foot portion 140—particularly near the heel. In some embodiments, the hind foot portion 140 may contain a plate thickness at least 0.1 mm greater than the plate thickness contained in the forefoot portion 130. More specifically, in some embodiments, the hind foot portion 140 may contain a plate thickness at least 0.2 mm, at least 0.3 mm, at least 0.4 mm, or at least 0.5 mm greater than the plate thickness contained in the forefoot portion 130.

[0100] In some embodiments, the portion of the hind foot portion 140 excluding the protrusion 106 may have a plate thickness greater than or equal to 0.3 mm and less than or equal to 0.5 mm; while the portion of the forefoot portion 130 excluding the protrusion 106 may have a plate thickness greater than or equal to 0.01 mm and less than or equal to 0.3 mm. In some embodiments, the portion of the hind foot portion 140 excluding the protrusion 106 may have a plate thickness greater than or equal to 0.2 mm and less than or equal to 0.5 mm; while the portion of the forefoot portion 130 excluding the protrusion 106 may have a plate thickness greater than or equal to 0.01 mm and less than or equal to 0.2 mm. In some embodiments, the portion of the hind foot portion 140 excluding the protrusion 106 may have a plate thickness greater than or equal to 0.4 mm and less than or equal to 0.5 mm; while the portion of the forefoot portion 130 excluding the protrusion 106 may have a plate thickness greater than or equal to 0.01 mm and less than or equal to 0.4 mm.

[0101] In some embodiments, the foreleg portion 130 of the metal plate 101 may have a greater plate thickness than the rear leg portion 140. In some embodiments, the foreleg portion 130 may contain a plate thickness at least 0.1 mm greater than the plate thickness contained in the rear leg portion 140. More specifically, in some embodiments, the foreleg portion 130 may contain a plate thickness at least 0.2 mm, at least 0.3 mm, at least 0.4 mm, or at least 0.5 mm greater than the plate thickness contained in the rear leg portion 140.

[0102] In some embodiments, a surface finish may be applied to the metal plate 101. In some embodiments, the surface finish may be applied via electrochemical processes, such as electroplating, anodizing, or electroless plating. In some embodiments, the surface finish may be applied via chemical conversion coating processes, such as black oxide conversion coating or phosphate conversion coating. In some embodiments, the surface finish may be applied via mechanical coating processes, such as shot peening or mechanical plating. In some embodiments, the surface finish may be applied via thermal spraying, vapor deposition, zinc plating, coating and lamination, or enamel coating. In some embodiments, the surface finish may be applied via a dip-coating process, such as immersion in liquid TPU. In some embodiments, the surface finish may include paint and / or organic coatings, such as post-drying liquid paints, powder coatings, polymer coatings, or ceramic coatings.

[0103] For any thickness and its deviation disclosed herein (e.g., of metal plate 101 or protrusion 106), in embodiments where metal plate 101 includes a surface treatment, the measurement of thickness and deviation includes the surface treatment. That is, for a surface-treated metal plate 101, the top surface 102 and bottom surface 104 are considered to include a surface treatment unless the surface treatment is a clearly distinguishable material (e.g., TPU or paint) and that material can be removed so that the boundary between the material and metal plate 101 is clearly visible to the naked eye.

[0104] Figure 2 The cross-section of the two protrusions 106 formed in the metal plate 101 is shown. Figure 2 The protrusion 106 shown is the anti-slip stud 106a; however, regarding Figure 2 The disclosed content may apply to any protrusion 106 unless specifically noted that a feature belongs to anti-slip stud 106a.

[0105] The protrusion 106 may define a cavity 210 on the top surface 102. The cavity 210 may have a top perimeter 230, i.e., the point where the top surface 102 begins to transition into the cavity 210. Therefore, the top perimeter 230 may be defined by an edge 232 on the top surface 102, i.e., where the top surface 102 transitions into the cavity 210. In some embodiments, the edge 232 may be rounded. In such an embodiment, the edge 232 may include a radius of curvature r. E In some embodiments, the radius of curvature r E It can be greater than or equal to 0.1 mm and less than or equal to 5 mm. More specifically, the radius of curvature r EIt can be greater than or equal to 0.1mm and less than or equal to 3mm, greater than or equal to 0.1mm and less than or equal to 1.5mm, greater than or equal to 0.1mm and less than or equal to 1mm, greater than or equal to 0.1mm and less than or equal to 0.5mm, or greater than or equal to 0.1mm and less than or equal to 0.3mm.

[0106] The protrusion 106 may define a protrusion 220 on the bottom surface 104, the position of which corresponds to the cavity 210 on the top surface 102.

[0107] The protrusion 106 may include a cavity surface 212 defined by the top surface 102 of the metal plate 101—within the region of the protrusion 106. Similarly, the protrusion 106 may include a protruding surface 222 defined by the bottom surface 104 of the metal plate 101—within the region of the protrusion 106. The protrusion 106 may include a wall thickness t measured from the cavity surface 212 to the protruding surface 222. W .

[0108] The protrusion 106 forms part of the metal plate 101. Therefore, the wall thickness t W The plate thickness t can be as described above. P Any value described. Additionally, the wall thickness t. W The deviation can be the plate thickness t mentioned above. P Any value describing the deviation either spans the entirety of protrusion 106 or spans at least a minimum area percentage of protrusion 106, as described above for metal plate 101. In this context, the area of ​​a protrusion is the surface area of ​​its protruding surface 222.

[0109] In some embodiments, the wall thickness t of the protrusion 106 W It can be less than the plate thickness t P This applies both globally and in areas adjacent to the protrusion 106. In some embodiments, this may be due to stamping, deep drawing, or ISF processes, which thin the metal sheet 101 as it is stretched to form the protrusion 106. For example, in some embodiments, such as the ISF embodiment, the wall thickness t of the protrusion 106 is... W It can be compared to the plate thickness t in the adjacent protrusion 106 region. P It is reduced by up to 50%. In some embodiments, such as the stamping embodiment, the wall thickness t of the protrusion 106 is... W It can be compared to the plate thickness t in the adjacent protrusion 106 region. P It's as small as 40%.

[0110] In some embodiments, the wall thickness t of the protrusion 106 W It can be approximately equal to (e.g., with a difference of less than or equal to 10%) the plate thickness t PThis applies both globally and in regions adjacent to the protrusions 106. In some embodiments, this can be achieved by selectively thinning regions of the metal plate 101, other than (e.g., adjacent to) the regions selected for forming the one or more protrusions 106, prior to their formation. In such embodiments, the thinning of the metal plate 101 during the formation of the one or more protrusions 106 can subsequently roughly equalize the thickness of these regions. Figure 1 An example of region 160 is shown, which is adjacent to the region selected to form protrusion 106.

[0111] The cavity 210 of the protrusion 106 may include a maximum depth d MAX This depth is measured in a direction perpendicular to the plane P defined by the top perimeter 230 of the cavity 210, from a point on the plane P to a point on the cavity surface 212. For any protrusion 106, in some embodiments, d MAX It can be greater than or equal to 0.5 mm and less than or equal to 22 mm. More specifically, in some embodiments, d MAX It can be greater than or equal to 2mm and less than or equal to 15mm, greater than or equal to 5mm and less than or equal to 12mm, or greater than or equal to 7mm and less than or equal to 10mm.

[0112] Specifically, for anti-slip studs 106a, in some embodiments, d MAX It can be greater than or equal to 5mm and less than or equal to 22mm. More specifically, for anti-slip studs 106a, in some embodiments, d MAX It can be greater than or equal to 7mm and less than or equal to 15mm, greater than or equal to 10mm and less than or equal to 15mm, or greater than or equal to 12mm and less than or equal to 15mm. For anti-slip stud 106a, in some embodiments, d MAX It can be greater than or equal to 12mm and less than or equal to 21mm, greater than or equal to 15mm and less than or equal to 21mm, or greater than or equal to 18mm and less than or equal to 21mm.

[0113] like Figure 2 As shown, cavity 210 can define a drawing angle Θ. The drawing angle Θ is measured as the angle between the sidewall portion 214 of cavity surface 212 and a straight line l, wherein the straight line l extends perpendicularly into cavity 210 into plane P. In some embodiments, the drawing angle Θ can be substantially constant over the entire sidewall portion 214 (i.e., the sidewall portion 214 along...). Figure 2The vertical cross-section shown is substantially linear. In some embodiments, the drawing angle Θ may vary along the sidewall portion 214, for example, by more than ±10 degrees, more than ±20 degrees, or more than ±30 degrees. In some embodiments, the sidewall portion 214 may be convex or curved inward into the cavity 210. In some embodiments, the sidewall portion 214 may be recessed.

[0114] For any protrusion 106, in some embodiments, the drawing angle Θ can be greater than or equal to 0 degrees and less than or equal to 20 degrees. More specifically, in some embodiments, the drawing angle Θ can be greater than or equal to 0 degrees and less than or equal to 15 degrees, greater than or equal to 0 degrees and less than or equal to 10 degrees, greater than or equal to 0 degrees and less than or equal to 7 degrees, greater than or equal to 0 degrees and less than or equal to 5 degrees, or greater than or equal to 0 degrees and less than or equal to 2 degrees.

[0115] Figure 2 Two protrusions 106 are shown. However, in some embodiments, in addition to the specific type of protrusion 106, the sole plate 100 may include additional protrusions of that specific type 106. For example, in some embodiments, the sole plate 100 may include one anti-slip stud 106a and multiple additional anti-slip studs 106a, such as... Figure 1 As shown. Similarly, in some embodiments, the sole plate 100 may include a ridge 106b and a plurality of additional ridges 106b, such as Figure 1 As shown. In some embodiments, the plurality of additional ridges 106b may be part of a series of corrugated ridges, as per [reference to...]. Figure 4 The additional protrusions 106 of this particular type may contain the same or similar features as one or more protrusions 106 of the corresponding type described herein.

[0116] like Figure 2 As shown, the top surface 102 of the metal plate 101 may include a perimeter region 240. In some embodiments, the perimeter region 240 may include a concave curvature. This concave curvature may facilitate attachment to the bottom of the footwear article and / or provide a smooth transition between the metal plate 101 and the rest of the footwear article. In some embodiments, a particular portion of the top surface 102 may include a recessed region. For example, in some embodiments, the top surface 102 of the metal plate 101 in the rearfoot portion 140 may include a recessed region to accommodate the wearer's heel. Alternatively or additionally, in some embodiments, the top surface 102 of the metal plate 101 in the forefoot portion 130 may include a recessed region to accommodate the wearer's forefoot.

[0117] Figure 3 It shows some embodiments Figure 1 The cross-section of the metal plate 101 shown is taken along line 3'-3' and viewed from the foreleg end of the metal plate 101. Specifically, Figure 3 The cross-section of two protrusions 106 formed in a metal plate 101 according to some embodiments is shown. Figure 3 The protrusion 106 shown is ridge 106b; however, regarding Figure 3 The disclosed information may be applied to any protrusion 106 unless otherwise specified that a feature belongs to ridge 106b.

[0118] Protrusion 106 may include longitudinal axis L R ,exist Figure 3 The image shows the extension into the paper surface. The longitudinal axis L... R Extend along the longest dimension of protrusion 106. For example... Figure 3 As shown, protrusion 106 may include a maximum width w MAX w MAX It is between the edges 302 of the protrusion 220, perpendicular to the longitudinal axis L of the protrusion 106. R The measured edge is defined by a protrusion 106 on the bottom surface 104. In some embodiments, the edge 302 of the protrusion 220 may be defined by a point where the bottom surface 104 transitions from a portion adjacent to the protrusion 106 to the protrusion 220 and the protruding surface 222, i.e., where the bottom surface 104 begins to curve into the protrusion 220 defined by the protrusion 106.

[0119] For any protrusion 106, in some embodiments, w MAX It can be greater than or equal to 1 mm and less than or equal to 30 mm. More specifically, in some embodiments, w MAX It can be greater than or equal to 3mm and less than or equal to 20mm, greater than or equal to 5mm and less than or equal to 20mm, greater than or equal to 10mm and less than or equal to 20mm, or greater than or equal to 10mm and less than or equal to 15mm.

[0120] Specifically, for spine 106b, in some embodiments, w MAX It can be greater than or equal to 0.5 mm and less than or equal to 10 mm. More specifically, for ridge 106b, in some embodiments, w MAX It can be greater than or equal to 0.5mm and less than or equal to 8mm, greater than or equal to 0.5mm and less than or equal to 6mm, greater than or equal to 0.5mm and less than or equal to 4mm, greater than or equal to 0.5mm and less than or equal to 2.5mm, or greater than or equal to 0.5mm and less than or equal to 1mm.

[0121] Specifically, for spine 106b, in some embodiments, d MAX It can be greater than or equal to 0.5 mm and less than or equal to 15 mm. More specifically, for ridge 106b, in some embodiments, d MAXIt can be greater than or equal to 0.5mm and less than or equal to 12mm, greater than or equal to 0.5mm and less than or equal to 10mm, greater than or equal to 0.5mm and less than or equal to 7mm, greater than or equal to 0.5mm and less than or equal to 5mm, or greater than or equal to 0.5mm and less than or equal to 2mm.

[0122] Specifically, for ridge 106b, in some embodiments, the maximum depth d of ridge 106b is... MAX The maximum width w of ridge 106b MAX The ratio can be greater than or equal to 1:10 and less than or equal to 10:1. More specifically, for spine 106b, in some embodiments, the ratio can be greater than or equal to 1:2 and less than or equal to 10:1, greater than or equal to 1:1 and less than or equal to 10:1, greater than or equal to 2:1 and less than or equal to 10:1, greater than or equal to 5:1 and less than or equal to 10:1, greater than or equal to 1:10 and less than or equal to 2:1, greater than or equal to 1:10 and less than or equal to 1:1, greater than or equal to 1:10 and less than or equal to 1:2, greater than or equal to 1:10 and less than or equal to 1:5, greater than or equal to 1:5 and less than or equal to 5:1, greater than or equal to 1:2 and less than or equal to 2:1, or approximately 1:1.

[0123] Figure 3 Two ridges, 106b, are shown. But besides... Figure 3 In addition to the ridge 106b shown, in some embodiments, the sole plate 100 may include additional ridges 106b. In some embodiments, the plurality of additional ridges 106b may be part of a series of corrugated ridges.

[0124] Figure 4 A series 410 of ridges 106b according to some embodiments is shown. In some embodiments, series 410 may include a series of corrugated ridges 106b spaced apart by grooves 414. In some embodiments, grooves 414 may be defined by a bottom surface 104.

[0125] like Figure 4 As shown, each ridge 106b may include a peak 412. The peak 412 of a ridge 106b may represent a point on the convex surface 222 of the ridge 106b that is farthest from the plane defined by the corresponding edge 302—measured in a direction perpendicular to that plane. When a ridge 106b has multiple points on its convex surface 222 that are farthest from and equidistant from the plane defined by the edge 302, its peak 412 is the geometric center of these points.

[0126] In some embodiments, series 410 may include the distance d between peaks 412 of adjacent ridges 106b. P In some embodiments, d PIt can be greater than or equal to 0.5 mm and less than or equal to 20 mm. More specifically, in some embodiments, d P The diameter can be greater than or equal to 0.5 mm and less than or equal to 15 mm, greater than or equal to 0.5 mm and less than or equal to 10 mm, greater than or equal to 0.5 mm and less than or equal to 8 mm, greater than or equal to 0.5 mm and less than or equal to 6 mm, greater than or equal to 0.5 mm and less than or equal to 4 mm, greater than or equal to 0.5 mm and less than or equal to 2.5 mm, or greater than or equal to 0.5 mm and less than or equal to 1 mm. Any of the above d... P The range can be applied to adjacent ridges 106b of one, some, or all pairs in series 410.

[0127] In this paper, the term "series of wavy ridges" refers to a group of ridges 106b, in which each pair of adjacent ridges 106b satisfies the following conditions: 1) the ridges 106b in the pair are substantially parallel to each other and at least partially side by side, and 2) the distance d between the peaks 412 of the pair of ridges. P The width w of the widest ridge in the pair is less than or equal to the maximum width of 106b. MAX Three times that. This group of ridges 106b can consist of two or more ridges 106b.

[0128] In some embodiments, the series 410 may be located within the hind foot portion 140. In some embodiments, the series 410 may be located within the forefoot portion 130. In some embodiments, the series 410 may span the boundary between the hind foot portion 140 and the forefoot portion 130.

[0129] In some embodiments, one or more ridges 106b of series 410 may be substantially parallel to the longitudinal axis L of metal plate 101. P Arrangement, in Figure 4 Longitudinal axis L P It is shown as extending into the paper. In such an embodiment, the lengthwise axis L of one or more ridges 106b R The longitudinal axis L is substantially parallel to the metal plate 101. P Therefore, in some embodiments, when the metal plate 101 is included in footwear, the longitudinal axis L of one or more ridges 106b is extended. R It can basically follow the pattern from footwear products (e.g., Figure 9 The footwear article 900 shown extends in the direction from the forefoot end (e.g., forefoot end 902) to the heel end (e.g., heel end 904).

[0130] In some embodiments, as described herein, the size and shape of the metal plate 101 may be configured to span only a portion of the area of ​​the sole. In some such embodiments, the longitudinal axis L of the metal plate 101... P (It extends along the longest dimension of the metal plate 101), possibly extending from the body-side 110 to the proximal side 120 of the metal plate 101. In such an embodiment, the longitudinal axis L of one or more ridges 106b of the series 410 R It can be basically perpendicular to the longitudinal axis L P The extension extends substantially in the direction from the forefoot end to the heel end of the footwear article when the metal plate 101 is included in the footwear article.

[0131] In some embodiments, when the metal plate 101 is included in the footwear article, the series 410 or any single ridge 106b arranged in this way can provide additional stiffness to the footwear article in the direction from the forefoot end to the heel end.

[0132] In this document, "substantially parallel" to another component or axis, or "substantially in one direction" means that the component or axis extends at an angle of less than or equal to 10 degrees relative to the other component, another axis, or that direction. "Substantially perpendicular" to another component or axis means that the component or axis extends at an angle of greater than or equal to 80 degrees and less than or equal to 100 degrees relative to the other component or another axis.

[0133] Figure 5 Another series 540 of ridges 106b according to some embodiments is shown. In some embodiments, series 540 may include a series of corrugated ridges 106b spaced apart by grooves 542.

[0134] In some embodiments, the series 540 may be located within the forefoot portion 130. In some embodiments, the series 540 may be located within the hindfoot portion 140. In some embodiments, the series 540 may span the boundary between the hindfoot portion 140 and the forefoot portion 130.

[0135] like Figure 5 As shown, in some embodiments, one or more ridges 106b of series 540 may be substantially perpendicular to the longitudinal axis L of metal plate 101. P Arrangement. In such an embodiment, the longitudinal axis L of one or more ridges 106b R Basically perpendicular to the longitudinal axis L of the metal plate 101 P Therefore, in some embodiments, when the metal plate 101 is included in footwear, the longitudinal axis L of one or more ridges 106b is extended. R It can basically follow the pattern from footwear products (e.g., Figure 9 The footwear article 900 shown extends from the side of the body (e.g., side of the body 910) to the midline.

[0136] In some embodiments, as described herein, the size and shape of the metal plate 101 may be configured to span only a portion of the area of ​​the sole. In some such embodiments, the longitudinal axis L of the metal plate 101... P (It extends along the longest dimension of the metal plate 101), possibly extending from the body-side 110 to the proximal side 120 of the metal plate 101. In such an embodiment, the longitudinal axis L of one or more ridges 106b of the series 540 R It can be basically parallel to the longitudinal axis L P The extension extends substantially along the direction from the side of the footwear to the midline when the metal plate 101 is included in the footwear article.

[0137] In some embodiments, when the metal plate 101 is included in the footwear article, the series 540 or any single ridge 106b arranged in this way can provide flexibility to the footwear article in a direction from the forefoot end to the heel end.

[0138] In some embodiments, the sole plate 100 includes a series 410 in addition to a series 540. In some embodiments, the sole plate 100 includes only one of a series 410 or a series 540. In some embodiments, the sole plate 100 includes neither a series 410 nor a series 540.

[0139] Figure 4 The series 410 is shown to have a ridge 106b extending longitudinally within the rear foot portion 140 relative to the definition of the complete footwear article. Figure 5 Series 540 is shown having a latitudinal ridge 106b extending within the forefoot portion 130, defined relative to the complete footwear article. However, in some embodiments, the metal plate 101 may include one or more longitudinally extending ridges 106b within the forefoot portion 130, the rearfoot portion 140, or both. In some embodiments, one or more longitudinally extending ridges 106b may extend across the boundary between the forefoot portion 130 and the rearfoot portion 140. Similarly, in some embodiments, the metal plate 101 may include one or more latitudinal ridges 106b within the forefoot portion 130, the rearfoot portion 140, or both. In some embodiments, the latitudinal ridge 106b may be located on the boundary between the forefoot portion 130 and the rearfoot portion 140. In any of these embodiments, the ridge 106b may be isolated or part of a series of corrugated ridges, such as Series 410 or Series 540.

[0140] Although Figure 4-5Showing four ridges 106b in series 410 and 540, but series 410 and / or series 540 may contain any number of ridges 106b. In some embodiments, series 410 and / or series 540 may contain more than or equal to three ridges 106b and less than or equal to 50 ridges 106b. More specifically, in some embodiments, series 410 and / or series 540 may contain more than or equal to 4 and less than or equal to 30 ridges, more than or equal to 5 and less than or equal to 25 ridges, more than or equal to 6 and less than or equal to 20 ridges, more than or equal to 7 and less than or equal to 20 ridges, more than or equal to 8 and less than or equal to 20 ridges, more than or equal to 9 and less than or equal to 20 ridges, more than or equal to 10 and less than or equal to 20 ridges, more than or equal to 10 and less than or equal to 18 ridges, more than or equal to 12 and less than or equal to 16 ridges, or approximately 15 ridges.

[0141] Figure 6 A metal plate 101 according to some embodiments is shown along... Figure 5 A sectional view taken along line 6'-6'. Figure 6 An embodiment of series 540 is shown in more detail.

[0142] like Figure 6 As shown, in some embodiments, one or more ridges 106b of series 540 can be derived from a plane P defined by the portion of the bottom surface 104 surrounding series 540. S Indentation. In such an embodiment, the peak 412 of one or more ridges 106b intersects with the plane P. S There are gaps between them.

[0143] However, in some embodiments, one or more ridges 106b of series 540 do not necessarily originate from plane P. S It is concave, but can be in contact with plane P. S flush with or extending beyond plane P S .

[0144] Figure 7 A shoe sole 100 according to some embodiments is shown. Figure 7 The protrusion 106 is not shown in the image; however, the sole plate 100 may include, for example, protrusions 106 and 106. Figure 1-6 The protrusion 106 shown and described in the context.

[0145] like Figure 7As shown, in some embodiments, the sole plate 100 may include one or more side wings 710 extending from the side 110 of the metal plate 101. In some embodiments, the sole plate 100 may include a first side wing 710a extending from the side 110 on the forefoot portion 130. In some embodiments, the sole plate 100 may include a second side wing 710b extending from the side 110 on the rearfoot portion 140.

[0146] In some embodiments, the sole plate 100 may include one or more mesial wings 720 extending from the mesial side 120 of the metal plate 101. In some embodiments, the sole plate 100 may include a first mesial wing 720a extending from the mesial side 120 on the forefoot portion 130. In some embodiments, the sole plate 100 may include a second mesial wing 720b extending from the mesial side 120 on the rearfoot portion 140.

[0147] In some embodiments, one or more side wings 710 and / or one or more near-center wings 720 may be integrally formed with the metal plate 101. Thus, in some embodiments, they may be formed of the same material and may form part of the same sheet metal used to manufacture the metal plate 101.

[0148] In some embodiments, the gap may pass through wings 710 and 720. For example, in some embodiments, the gap 712 may pass through the second body side wing 710b and / or the second near-center wing 720b.

[0149] Although Figure 7 A total of four body-side and near-center wings 710, 720 extending from metal plate 101 are shown, but in some embodiments, additional body-side and / or near-center wings 710, 720 may extend from metal plate 101. In some embodiments, fewer body-side and / or near-center wings 710, 720, such as any subset of the four shown, may extend from metal plate 101.

[0150] In addition, although Figure 7 The side wings and mid-side wings 710 and 720 extend from the side and mid-side wings 110 and 120 of the metal plate 101, respectively. However, in some embodiments, the sole plate 100 may include wings extending from one or more other directions and from other portions of the metal plate 101, such as extending rearward from the heel portion of the metal plate 101 and / or forward from the toe portion of the metal plate 101.

[0151] Figure 8 A sole plate 100 according to some embodiments is shown—along Figure 7 A cross-sectional view taken along line 8'-8' and viewed from the forefoot end of metal plate 101. (See figure) Figure 8As shown, in some embodiments, the first body side wing 710a and the first near-center wing 720a can be bent in a direction above the top surface 102 of the metal plate 101. The second body side wing 710b and the second near-center wing 720b, or any wing extending from the metal plate 101, can also be bent in this way.

[0152] Figure 9-10 A footwear article 900 comprising a sole plate 100 is shown according to some embodiments. In some embodiments, the footwear article 900 may be an athletic footwear article. For example, in some embodiments, the footwear article 900 may be a soccer shoe, track and field shoe, or American football shoe. However, the footwear article 900 is not limited to these types of shoes.

[0153] Although Figure 9-10 The sole plate 100 shows one or more body wings 710 extending from the metal plate 101, but in some embodiments, the sole plate 100 included in the footwear article 900 may not include wings 710, 720, such as... Figure 1 As shown.

[0154] like Figure 9 As shown, footwear article 900 may include an upper 920. The upper 920 may be formed of any known material and may be configured to accommodate a wearer's foot. In some embodiments, a metal plate 101 may be coupled to the upper 920, for example, through the midsole, using adhesives, rivets, snap-fit ​​components, lacing, and / or stitching (e.g., using holes drilled through the metal plate 101). In some embodiments, the upper 920 may include metal wire or other components that can be welded to the metal plate 101. In some embodiments, depending on the materials contained therein, the upper 920 may be coupled to the metal plate 101 using any of the methods described herein for coupling polymeric or metal components to the metal plate 101.

[0155] In some embodiments, the side wings and / or mid-wings 710, 720 may be coupled to the upper 920 via adhesives, rivets, and / or stitching (e.g., using drilled holes in the wings). In some embodiments, the side wings and / or mid-wings 710, 720 may be configured to provide support to the upper 920. For example, the side wings and / or mid-wings 710, 720 may provide additional stiffness to the upper 920.

[0156] In some embodiments, the side wings and / or mid-wings 710, 720 may be configured to provide support to the sides of the upper 920, for example, the side wings 910 and / or mid-wings (opposite to the side wings 910, Figure 9-10(Not shown in the image). In some embodiments, the sole plate 100 may include only a lateral wing 710 that provides support to the lateral side 910 of the upper 920, without a midfoot wing 720. In some embodiments, the sole plate 100 may include more and / or larger lateral wings 710 than the midfoot wing 720, thereby providing more support to the lateral side 910 of the upper 920 than to the midfoot wing.

[0157] Additionally or alternatively, in some embodiments, the side wings and / or near-center wings 710, 720 may be configured as heel stabilizers. For example, Figure 10 The display body wing 710 provides support for the heel portion of the footwear 900 and acts as at least part of the heel stabilizer.

[0158] In some embodiments, the sole plate 100 may include a wing that extends rearward from the metal plate 101 as the sole plate 100 is formed and is configured as a complete heel stabilizer.

[0159] In some embodiments, the sole plate 100 may include a wing that extends forward from the metal plate 101 as the sole plate 100 is formed and is configured as a toe cap. When bent toward the top surface 102, the forward wing may reinforce the forefoot end 902 of the footwear article 900 and may protect the upper 920 and / or the wearer's foot from abrasion and / or impact.

[0160] In some embodiments, the sole plate 100 may conform to the shape of the upper 920 and / or the midsole. For example, in some embodiments, there is no empty space between the upper 920 and / or the midsole and the metal plate 101. Additionally or alternatively, in some embodiments, there is no empty space between the upper 920 and / or the midsole and the wings 710, 720.

[0161] Although Figure 9-10 The side 910 of the footwear article 900 is shown, but in some embodiments, Figure 9 The wing configuration shown can be implemented on the mid-side of the footwear article 900. Similarly, in some embodiments, Figure 10 The wing configuration shown can be implemented on the mid-side of the footwear article 900. In some embodiments, Figure 9 The wing configuration shown can be implemented on the side 910 of the footwear 900, while Figure 10 The wing configuration shown can be implemented on the mid-side of footwear 900, or vice versa.

[0162] Figure 11A A sole plate 1100 according to some embodiments is shown. In some embodiments, the sole plate 1100 may include a metal plate 1101 configured for a basketball shoe.

[0163] In some embodiments, the metal plate 1101 may include a base 1102 and forks 1104 extending from the base 1102. Forks 1104a-b configured to extend toward the forefoot end of the footwear article may define a gap 1108a between the forks 1104a-b. Forks 1104c-d configured to extend toward the heel end of the footwear article may define a gap 1108b between the forks 1104c-d.

[0164] Each fork tooth 1104 may include a distal end 1106. In some embodiments, the distance between the distal ends 1106a-b of the fork teeth 1104a-b may be shorter than the distance across it at the widest point of the gap 1108a. In some embodiments, the distance between the distal ends 1106c-d of the fork teeth 1104c-d may be shorter than the distance across it at the widest point of the gap 1108b.

[0165] Metal plate 1101 may contain any metal type and thickness described above for metal plate 101.

[0166] In some embodiments, metal plate 1101 may include ridge 106b as described above for metal plate 101.

[0167] In some embodiments, the sole plate 1100 may include wings extending from the metal plate 1101, which are the same as or similar to wings 710, 720.

[0168] Figure 11B A sole plate 1110 according to some embodiments is shown. In some embodiments, the sole plate 1110 may include a metal plate 1111 configured for a running shoe.

[0169] In some embodiments, the metal plate 1111 may include a base 1112 and forks 1114 extending from the base 1112. Forks 1114a-e configured to extend toward the forefoot end of the footwear article may define gaps 1118a-d between pairs of forks 1114a-e.

[0170] The fork teeth 1114a-e may each include distal ends 1116a-e. In some embodiments, the distance between the distal ends 1116 (e.g., distal ends 1116a-b) of a pair of adjacent fork teeth 1114 (e.g., fork teeth 1114a-b) may be shorter than the width spanning the widest point of a corresponding gap 1118 (e.g., gap 1118a) defined by the pair of adjacent fork teeth 1114.

[0171] Metal plate 1111 may contain any metal type and thickness described above for metal plate 101.

[0172] In some embodiments, metal plate 1111 may include ridge 106b as described above for metal plate 101.

[0173] In some embodiments, the sole plate 1110 may include wings extending from the metal plate 1111, which are the same as or similar to wings 710, 720.

[0174] Figure 12 A method 1200 is shown for manufacturing a sole plate (e.g., sole plate 100) for footwear articles (e.g., footwear article 900) according to some embodiments.

[0175] Unless otherwise stated, the steps of method 1200 do not need to be performed in the order set forth herein. Furthermore, unless otherwise specified, the steps of method 1200 do not need to be performed in a specific order. These steps may be performed in a different order or simultaneously. For example, step 1220 may be performed before, after, or simultaneously with step 1210. Moreover, method 1200 does not need to include... Figure 12 All the steps shown. For example, method 1200 may exclude step 1220, for example, if a substantially flat metal plate is used. Similarly, method 1200 may exclude step 1230, for example, if the sole plate does not include a mid-wing or side-wing.

[0176] Step 1210 includes forming a protrusion (e.g., protrusion 106) in a sheet metal (e.g., sheet metal 101). In some embodiments, the forming may include a process selected from stamping, deep drawing, and progressive sheet metal forming (ISF). For each of these processes, using sheet metal provides a smaller drawing angle compared to polymer materials, thereby enabling more extreme geometries. For example, a sole structure having the wall thickness, thickness deviation, and width described herein can be formed with functional anti-slip studs and ridges.

[0177] Step 1220 includes forming the metal sheet. In some embodiments, forming the metal sheet can be performed simultaneously with forming the protrusion in step 1210. In some embodiments, forming the metal sheet may include forming a concave curvature in a peripheral region (e.g., peripheral region 240) of the top surface (e.g., top surface 102) of the metal sheet.

[0178] In some embodiments, for example, if the sole plate includes a side wing (e.g., side wing 710) and / or a mid-wing (e.g., mid-wing 720), method 1200 may include step 1230: bending the side wing in a direction above the top surface of the metal plate, and / or bending the mid-wing in a direction above the top surface of the metal plate. In some embodiments, step 1230 may be performed sequentially (before or after) or simultaneously with step 1220.

[0179] In some embodiments, method 1200 may include the step of forming a variable plate thickness t in a metal plate. P In some embodiments, a variable plate thickness t is formed. P The steps may include processes selected from rolling, stamping, and laser ablation. In some embodiments, a variable plate thickness t is formed. P The steps may include: forging a metal plate into a shape containing a variable plate thickness t, either by the manufacturer of the sole plate described herein or by a third party. P In some embodiments, the step of forming a variable plate thickness may be performed before step 1210.

[0180] In some embodiments, a variable plate thickness t is formed P The steps may include selectively thinning a metal plate in the foreleg portion (e.g., foreleg portion 130). In some embodiments, a variable plate thickness t is formed. P The steps may include selectively thinning a metal plate in the hind foot portion (e.g., hind foot portion 140).

[0181] In some embodiments, a variable plate thickness t is formed P The steps may include selectively thinning the metal sheet in an area other than (e.g., adjacent to) the area selected for forming the protrusion 106. Figure 1 An example of region 160 is shown, which is adjacent to the region selected for forming the protrusion 106. In such an embodiment, the plate thickness t at the region selected for forming the protrusion 106 is... P It can be greater than the plate thickness t in the adjacent region. P Once the stamping, deep drawing, or ISF process used to create the protrusion 106 is completed, thereby thinning the metal sheet 101 in the selected region for forming the protrusion 106, earlier selective thinning of adjacent regions (e.g., region 160) can make the protrusion 106 include a wall thickness t. W The wall thickness is substantially equal to (e.g., the difference is less than or equal to 10%) the plate thickness t in the adjacent region. P In some embodiments, the wall thickness t W Plate thickness t in adjacent regions P The deviation can be ±50 micrometers, ±25 micrometers, ±15 micrometers, ±10 micrometers, or ±5 micrometers. Wall thickness t W With plate thickness t P The deviation between them is ±5 micrometers, for example, meaning the wall thickness t W The plate thickness t in the adjacent region is not compared. P Larger or smaller than 5 micrometers.

[0182] The mention of selectively thinning the area of ​​the metal sheet adjacent to the area selected to form the protrusion 106 does not mean that the metal sheet is thinned only in those adjacent areas.

[0183] In some embodiments, method 1200 may include the step of stacking multiple metal plates prior to forming the protrusion. In such embodiments, one of stamping, deep drawing, or ISF processes may be used to simultaneously form the protrusion in multiple metal plates. As described herein, the plate thickness t P The thickness can be significantly smaller than that of polymer components. This allows for the simultaneous formation of protrusions in multiple metal plates with only negligible deviations in the geometry of the protrusions between plates.

[0184] In some embodiments, method 1200 may include the step of forming a micro-surface texture (e.g., the micro-surface texture of surface configuration 1520 described herein) in a metal plate. In some embodiments, the step of forming the micro-surface texture may include a process selected from laser ablation, etching (e.g., chemical etching), and rolling.

[0185] Figure 13A -C shows a die 1300 for performing steps 1210 and / or 1220 of method 1200 according to some embodiments. For example, the die 1300 may be used for a stamping process.

[0186] The mold 1300 may include a first side 1310. In some embodiments, the first side 1310 may be a front side and include protrusions 1312 for forming protrusions 106 in the metal plate 101.

[0187] In some embodiments, mold 1300 may include a second side 1320. In some embodiments, the second side 1320 may be a negative side, including a receptacle 1322 for receiving the protrusion 106. In some embodiments, mold 1300 may not need to include a second side 1320 containing the receptacle 1322. Instead, the second side 1320 may include foam or other compressible material to receive the protrusion 106.

[0188] Although the first and second sides 1310, 1320 are described as "positive" and "negative" sides, in some embodiments, the first and / or second sides 1310, 1320 may include both one or more protrusions 1312 and one or more grooves 1322. In some embodiments, the protrusions 1312 and grooves 1322 of one side 1310, 1320 may be configured to shape and / or form other structural features on the metal plate 101 of the sole plate 100.

[0189] In some embodiments, the first side 1310 may include a groove 1322 having a protrusion 1312 at its bottom. Meanwhile, in some embodiments, the second side 1320 may include a protrusion 1312 having a groove 1322 on its surface facing the metal plate 101. This arrangement on the first and second sides 1310, 1320 can be used, for example, to form... Figure 6 The series 540 shown. The protrusion 1312 included on the first side 1310 of the bracket 1322 can be used to form Figure 6 The ridge 106b is shown, and the groove 1322 included on the second side 1320 by the protrusion 1312 can accommodate the ridge 106b. The protrusion 1312 on the second side 1320 allows the ridge 106b to... Figure 6 Plane P shown S A depression. Therefore, in some embodiments, from plane P S The recessed ridge 106b of the series 540 can be formed in a single stamping step.

[0190] In some embodiments, from plane P S The series 540 of recessed ridges 106b can be formed in multiple stamping steps, for example, first forming a protrusion on the top surface 102 in a first stamping step, and then stamping the protrusion in a second stamping step to form ridge 106b.

[0191] Figure 13A The metal sheet 101 may include—a sheet metal component comprising any metal and thickness described herein with respect to the metal sheet 101. In embodiments where stamping is performed, it may be as follows: Figure 13B -C shows the steps to form the metal sheet 101 into its final product: insert the sheet metal component into the mold 1300, press the first side 1310 and / or the second side 1320 to form the sheet metal component.

[0192] Although Figure 13A -C shows a cross-section of the metal plate 101 taken across five protrusions 106, but the mold 1300 can be configured to form any number and arrangement of protrusions 106 in the metal plate 101.

[0193] Although Figure 13A -C shows a single metal plate 101 in the mold 1300, but in some embodiments, multiple metal plates 101 may be stacked and inserted into the mold 1300 simultaneously to form protrusions 106 in multiple metal plates 101 at the same time.

[0194] Figure 14 A sheet material 1400 according to some embodiments is shown. For example... Figure 14As shown, in some embodiments, multiple metal plates 101 can be formed in a single sheet 1400. In some embodiments, the sheet 1400 can be inserted into a mold (such as mold 1300) to form multiple metal plates 101 simultaneously. In some embodiments, the metal plates 101 of the sheet 1400 can all be the same size and configured to fit the same shoe size. In some embodiments, two or more metal plates 101 of the sheet 1400 can be different sizes and configured to fit different shoe sizes.

[0195] The sheet material 1400 may include a frame 1410 that collectively holds multiple metal sheets 101. The metal sheets 101 may be cut from the frame 1410 before being integrated into the footwear.

[0196] Figure 15 Various surface configurations of the metal plate 101 are shown. For example, the metal plate 101 may include surface configuration 1510, surface configuration 1520, surface configuration 1530, surface configuration 1540, surface configuration 1550, or any combination thereof. The metal plate 101 may—in any region of the metal plate 101—include any one of surface configurations 1510, 1520, 1530, 1540, and / or 1550.

[0197] Surface configuration 1510 includes a flat plate. In surface configuration 1510, the top and bottom surfaces 102 and 104 of the metal plate 101 are substantially flat.

[0198] Surface configuration 1520 includes micro-surface textures on the top surface 102 and / or bottom surface 104. For example, in some embodiments, surface configuration 1520 may include grooves 1522 (with a plate thickness t). P First thickness t P1 (area) and beam 1524 (with plate thickness t) P The larger second thickness t P2 The grooves 1522 and the beams 1524 are micropatterned on the top surface 102 and / or the bottom surface 104. In some embodiments, the grooves 1522 may be spaced less than 2 mm (even as small as 0.01 mm) from each other, and the beams 1524 may be spaced less than 2 mm (even as small as 0.01 mm) from each other. In some embodiments, the depth of one or more grooves 1522 may be greater than or equal to the second thickness t. P2 1 / 4 and less than or equal to 1 / 2 of it. Figure 15 In the view, the longitudinal axes of the tooth groove 1522 and the beam 1524 extend into the paper.

[0199] The grooves 1522 and beams 1524 of the surface configuration 1520 are only composed of plate thickness t. PThe changes are formed not by bending the metal plate 101 as with anti-slip studs 106a and ridges 106b. In some embodiments, the plate thickness t in the surface configuration 1520 is... P The changes can be achieved through laser ablation, etching (e.g., chemical etching), or rolling. In some embodiments of the metal plate 101 including surface configuration 1520, the plate thickness t P The deviation can be any value disclosed herein—any percentage range across the area and / or region of the metal plate 101, excluding the deviation caused by the toothed groove 1522 in the calculation.

[0200] Surface configuration 1520 can provide increased stiffness (relative to a first thickness t of mating surface configuration 1520) along axis B1 parallel to its beam 1524. P1 The thickness of the plate (t) P Surface configuration 1510). Surface configuration 1520 can provide increased flexibility along axis B2 perpendicular to its beam 1524 (relative to a second thickness t of matching surface configuration 1520). P2 The thickness of the plate (t) P Surface configuration 1510).

[0201] Surface configuration 1530 may include micro-ripples. The micro-ripples may comprise a series (e.g., like series 410 and / or 540) of corrugated ridges 106b spaced apart by grooves 1532. In some embodiments, the maximum distance d between the peaks of adjacent ridges 106b in the "micro" ripples... P It can be less than or equal to 2mm.

[0202] Surface configuration 1530 can be along the longitudinal axis L parallel to its ridge 106b. R The direction provides increased stiffness (relative to surface configuration 1510). Surface configuration 1530 can be along the longitudinal axis L perpendicular to its ridge 106b. R The orientation provides increased flexibility (relative to surface configuration 1510).

[0203] Surface configuration 1540 may include macroscopic corrugations. Macroscopic corrugations may include a series (e.g., like series 410 and / or 540) of corrugated ridges 106b spaced apart by grooves 1542. However, the maximum depth d of the cavity defined by the ridges 106b of surface configuration 1540 is greater than that of surface configuration 1530. MAX and / or the distance d between the peaks of adjacent ridge 106b P It can be larger than that used for surface configuration 1530. In some embodiments, the maximum depth d of the cavity in the ridge 106b of the "macro" corrugation is... MAXIt can be greater than or equal to ##mm. However, the concepts of "micro" and "macro" ripples can more generally refer to smaller ripples (surface configuration 1530) embedded in larger ripples (surface configuration 1540) to form surface configuration 1550.

[0204] Surface configuration 1540 can be along the longitudinal axis L parallel to its ridge 106b. R The direction provides increased stiffness (relative to surface configuration 1510). Surface configuration 1540 can be positioned along its longitudinal axis L perpendicular to its ridge 106b. R The orientation provides increased flexibility (relative to surface configuration 1510).

[0205] Surface configuration 1550 may include a combination of surface configuration 1530 and surface configuration 1540. For example, surface configuration 1550 may include a series of corrugated ridges 106b-1 spaced apart by grooves 1542, wherein each ridge 106b-1 and groove 1542 in this series further includes a series of corrugated ridges 106b-2 spaced apart by grooves 1532. Figure 15 As shown, in surface configuration 1550, the maximum depth d of the cavity defined by ridge 106b-1 is... MAX and / or the distance d between the peaks of adjacent ridge 106b-1 P Significantly greater than the maximum cavity depth d defined by ridge 106b-2 MAX And / or the distance d between the peaks of adjacent ridge 106b-2 P .

[0206] Surface configuration 1550 can be along the longitudinal axis L parallel to its ridges 106b-1 and 106b-2. R The direction provides increased stiffness (relative to surface configurations 1510 and 1530, 1540). Surface configuration 1550 can be along the longitudinal axis L perpendicular to its ridges 106b-1, 106b-2. R The orientation provides increased flexibility (relative to surface configurations 1510 and 1530, 1540).

[0207] Any of the surface configurations 1510-1550 can be arranged in any area of ​​the metal plate 101 to affect the properties of the metal plate 101 in that area. For example, any of the surface configurations 1520-1550 can be arranged in any area of ​​the metal plate 101 to increase stiffness and flexibility along a particular axis / direction depending on its orientation.

[0208] Figure 16A metal plate 101 is shown, which includes different surface configurations (and / or different orientations of surface configurations) in different regions of the metal plate 101. For example, the metal plate 101 may include surface configuration 1610 in the foreleg portion 130 and surface configuration 1620 in the hind leg portion 140, and vice versa.

[0209] In some embodiments, surface configuration 1610 may include surface configuration 1520, which has a longitudinal axis L substantially perpendicular to the metal plate 101. P Arranged beams 1524. In some embodiments, surface configuration 1610 may include surface configuration 1530, which has a longitudinal axis L substantially perpendicular to the metal plate 101. P The arrangement is ridge 106b. In some embodiments, surface configuration 1610 may include surface configuration 1540, which has a longitudinal axis L substantially perpendicular to the metal plate 101. P The arrangement is ridge 106b. In some embodiments, surface configuration 1610 may include surface configuration 1550, which has a longitudinal axis L substantially perpendicular to the metal plate 101. P Arranged—ridges 106b-1 and 106b-2. Although Figure 16 The surface configuration 1610 shows that it covers almost the entire forefoot portion 130, but in some embodiments, the surface configuration 1610 may cover any subset of the forefoot portion 130.

[0210] In some embodiments, surface configuration 1620 may include surface configuration 1520, which has a longitudinal axis L substantially parallel to the metal plate 101. P Arranged beams 1524. In some embodiments, surface configuration 1620 may include surface configuration 1530, which has a longitudinal axis L substantially parallel to the metal plate 101. P The ridges 106b are arranged in a manner that, in some embodiments, may include a surface configuration 1540 having ridges 106b arranged substantially parallel to the longitudinal axis LP of the metal plate 101. In some embodiments, the surface configuration 1620 may include a surface configuration 1550 having ridges 106b arranged substantially parallel to the longitudinal axis L of the metal plate 101. P Arranged—ridges 106b-1 and 106b-2. Although Figure 16 The surface configuration 1620 shows that it covers the entire hind foot portion 140, but in some embodiments, the surface configuration 1620 may cover any subset of the hind foot portion 140.

[0211] In some embodiments, Figure 16 The configuration shown can be along the longitudinal axis L of the metal plate 101. P Increased stiffness is provided in the hindfoot portion 140 and increased flexibility in the forefoot portion 130, which can be used to allow flexion of the user's forefoot during exercise while supporting the user's midfoot and heel.

[0212] Figures 17A-17B One or more polymer segments 1710 coupled with a plurality of metal plates 101 are shown according to some embodiments. In some embodiments, the sole plate 100 may include a plurality of metal plates 101a, 101b, etc. For example, in some embodiments, the sole plate 100 may include a first metal plate 101a and a second metal plate 101b, such as... Figure 17A As shown. In some embodiments, the sole plate 100 may include a first metal plate 101a, a second metal plate 101b, and a third metal plate 101c disposed between the first and second metal plates 101a-b, as shown. Figure 17B As shown. The first, second, and / or third metal plates 101a-c may include components for use with respect to... Figure 1-16 The same or similar features (e.g., protrusions 106) described in the metal plate 101.

[0213] In some embodiments, the first metal plate 101a may be configured to occupy the footwear article (e.g., Figure 9 The footwear article 900 shown represents all or part of the rear half. In some embodiments, the second metal plate 101b and the third metal plate 101c may be configured to occupy all or part of the front half of the footwear article. Thus, in some embodiments, one or more polymer segments 1710 coupling the first and second metal plates 101a-b and optionally the third metal plate 101c may be disposed in the front half of the footwear article—which they constitute a part of. In some embodiments, the first metal plate 101a may extend to the heel end (e.g., heel end 904) of the footwear article—which it constitutes a part of. In some embodiments, the second metal plate 101b may extend to the forefoot end (e.g., forefoot end 902) of the footwear article—which it constitutes a part of the footwear article.

[0214] In some embodiments, the dimensions of one or more of the first, second, and third metal plates 101a-c may be set to extend from the body side (e.g., body side 910) of the footwear article, which constitutes part of the footwear article, to the mid-side.

[0215] In some embodiments, the dimensions of the first and second metal plates 101a-b may be set to collectively span more than 50% of the sole area of ​​the footwear article, for example, more than 60%, 70%, 80%, 90%, or 95% of the sole area of ​​the footwear article. In some embodiments, the first, second, and third metal plates 101a-c may be collectively sized in the same manner.

[0216] In some embodiments, the sole plate 100 may include one or more polymer segments 1710 coupling a plurality of metal plates 101. In some embodiments, the polymer segment 1710 may include a polymer plate. In some embodiments, the polymer segment 1710 coupling two metal plates 101 may comprise TPU, nylon, polypropylene (PP), rubber, and / or ethylene-vinyl acetate (EVA). In some embodiments, the polymer segment 1710 may be a 3D-printed part, for example, comprising a lattice structure.

[0217] In some embodiments, the polymer segment 1710 can couple the first metal plate 101a to the second metal plate 101b while leaving a gap 1720 between the first and second metal plates 101a-b, such as Figure 17A As shown.

[0218] In some embodiments, the sole plate 100 may include a plurality of polymer segments 1710, such as Figure 17B As shown. For example, the sole plate 100 may include a first polymer segment 1710a coupling a first metal plate 101a to a third metal plate 101c. Furthermore, the sole plate 100 may include a second polymer segment 1710b coupling a second metal plate 101b to the third metal plate 101c. In some embodiments, a gap 1720 may exist between the metal plates 101 coupled by the polymer segment 1710. In some embodiments, the gap 1720 may extend from the mesial side of adjacent metal plates 101 to the lateral side of the body, such as... Figure 17A -B is shown.

[0219] Figure 17A -B, as shown, can provide increased flexibility to specific areas of the sole plate 100. For example, Figure 17A The configuration shown in -B maintains the rigidity of the portion of the sole plate 100 that occupies the rear half of the footwear, while increasing the flexibility of the portion of the sole plate 100 that occupies the front half of the footwear. This allows for flexion in the user's forefoot during athletic activities while supporting the user's midfoot and heel.

[0220] Figure 18Various configurations for coupling a metal plate 101 to a polymer segment 1710, according to some embodiments, are shown. Figure 17A One or more polymer segments 1710 shown in -B can be linked to using any configuration described herein. Figures 17A-17B The multiple metal plates 101 shown.

[0221] In the first coupling configuration 1810, the polymer segment 1710 may overlap with the metal plate 101 on both the top surface 102 and the bottom surface 104 of the metal plate 101 (e.g., the first metal plate 101a and / or the third metal plate 101c). In some embodiments, the polymer segment 1710 may be fixed to the metal plate 101 by an adhesive. In some embodiments, the polymer segment 1710 may be fixed to the metal plate 101 by thermal bonding, such as heat staking, ultrasonic welding, induction welding, or laser welding. In some embodiments, the polymer segment 1710 may be fixed to the metal plate 101 by overmolding (e.g., injection molding) the polymer segment 1710 onto the metal plate 101.

[0222] In the second coupling configuration 1820, the polymer segment 1710 may be mechanically interlocked with a metal plate 101 (e.g., a first metal plate 101a). In such an embodiment, a slot 1822 may be formed in the metal plate 101. The polymer segment 1710 may include a flared locking protrusion 1824. In some embodiments, depending on preference, the locking protrusion 1824 may be compressed and inserted into the slot 1822 from either the bottom surface 104 side (as shown) or the top surface 102 side of the metal plate 101. The locking protrusion 1824 may extend through the slot 1822 and abut against the top surface 102 or the bottom surface 104 to lock the polymer segment 1710 to the metal plate 101. Alternatively or additionally, in some embodiments, the polymer segment 1710 may be secured to the metal plate 101 using any technique described for the first coupling configuration 1810.

[0223] In the third coupling configuration 1830, the metal plate 101 (e.g., the first metal plate 101a) may contain information about... Figure 15 The second surface configuration 1520 is described. Depending on preference, the second surface configuration 1520 can be on the top surface 102, the bottom surface 104, or both. The grooves 1522 and beams 1524 of the second surface configuration 1520 can provide a larger surface area to which polymer segments 1710 can be connected. The polymer segments 1710 can be fixed to the metal plate 101 using any technique described for the first coupling configuration 1810.

[0224] In the fourth coupling configuration 1840, the metal plate 101 (e.g., the first metal plate 101a) may include a hook-shaped portion 1826. The hook-shaped portion 1826 may be a part of the metal plate 101, and, depending on preference, this portion bends toward and extends over a top surface 102 or bottom surface 104 of an adjacent portion of the metal plate 101. In some embodiments, the hook-shaped portion 1826 may extend substantially parallel to the top surface 102 or bottom surface 104. In some embodiments, the hook-shaped portion 1826 may form a cavity 1828. Polymer segments 1710 may be secured to the metal plate 101 by overmolding (e.g., injection molding) the polymer segments 1710 onto the metal plate 101. A portion of the polymer segments 1710 may be disposed within the cavity 1828, thereby locking the polymer segments to the metal plate 101.

[0225] Figures 19A-19C Various configurations for the anti-slip stud 106a according to some embodiments are shown. While in some embodiments the anti-slip stud 106a may be formed solely of the metal plate 101, in some embodiments, polymer segments 1710 may at least partially form the anti-slip stud 106a, such as... Figures 19A-19C As shown. Therefore, protrusion 106 may include and / or be included by anti-slip stud 106a.

[0226] exist Figure 19A In the first anti-slip stud configuration 1910 shown, the metal plate 101 has a small curvature or no curvature at the coupling point with the polymer segment 1710. Therefore, the polymer segment 1710 can fully form the anti-slip stud 106a. The polymer segment 1710 can be used—with regard to... Figure 18 Any of the first to fourth coupling configurations 1810-1840 described are coupled to metal plate 101.

[0227] When the polymer segment 1710 at least partially forms the anti-slip stud 106a, it can be coupled to the metal plate 101 using various coupling means, in addition to the first to fourth coupling configurations 1810-1840, or alternatives to these configurations. For example, coupling can be performed using a threaded polymer segment 1710 that screws into the metal plate 101. As another example, coupling can be accomplished through a snap-fit ​​engagement between the polymer segment 1710 and the metal plate 101.

[0228] exist Figure 19BIn the second anti-slip stud configuration 1920 shown, the metal plate 101 may include a cavity 210 and a bump 220 at the coupling point with the polymer segment 1710. The polymer segment 1710 may be coupled to the bump 220. Therefore, the polymer segment 1710 can only partially form the anti-slip stud 106a. For example, the polymer segment 1710 may form the tip of the anti-slip stud 106a. In some embodiments, the bump 220 may include a slot 1822 for coupling the polymer segment 1710. The polymer segment 1710 can be used—with regard to Figure 18 Any of the first to fourth coupling configurations 1810-1840 described are coupled to metal plate 101.

[0229] In some embodiments of the second anti-slip stud configuration 1920, the polymer segment 1710 may extend a distance greater than or equal to the depth of the cavity 210 beyond the protrusion 220. In some embodiments, the polymer segment 1710 may extend a distance less than or equal to the depth of the cavity 210 beyond the protrusion 220.

[0230] exist Figure 19C In the third anti-slip stud configuration 1930 shown, the metal plate 101 may include a cavity 210 and a protrusion 220 at the coupling point with the polymer segment 1710. The polymer segment 1710 may be coupled to the protrusion 220. Therefore, the polymer segment 1710 can only partially form the anti-slip stud 106a. In some embodiments, the protrusion 220 does not include a slot for coupling the polymer segment 1710. Instead, the polymer segment 1710 may be fully coupled to the metal plate 101 on the protruding surface 222. In some embodiments, the polymer segment 1710 may be secured to the protrusion 220 by an adhesive. In some embodiments, the polymer segment 1710 may be secured to the protrusion 220 by thermal bonding, such as thermal positioning, ultrasonic welding, induction welding, or laser welding. In some embodiments, the polymer segment 1710 may be secured to the protrusion 220 by overmolding (e.g., injection molding) the polymer segment 1710 onto the metal plate 101. In some embodiments, polymer segment 1710 can be secured to bump 220 by immersing bump 220 in molten polymer. In some embodiments, polymer segment 1710 can be secured to bump 220 by the following steps: spraying or otherwise applying liquid polymer to bump 220, and then curing the liquid polymer into a solid.

[0231] In some embodiments of the third anti-slip stud configuration 1930, the polymer segment 1710 may conform to the shape of the protrusion 220. In some embodiments, the polymer segment 1710 may cover more than 50%, for example, more than 60%, more than 70%, or more than 80% of the area of ​​the protruding surface 222.

[0232] In some embodiments of the third anti-slip stud configuration 1930, the polymer segment 1710 may extend a distance less than the depth of the cavity 210 beyond the protrusion 220.

[0233] In some embodiments, the polymer segment 1710 that at least partially forms the anti-slip stud 106a may comprise TPU.

[0234] In addition to being a composite material of metal plate 101 and polymer segment 1710, Figures 19A-19C The anti-slip stud 106a shown may include, regarding Figure 1-16 The anti-slip studs described as having the same or similar features (e.g., dimensions) as the anti-slip studs 106a. Regarding Figures 19A-19C The configuration of the described anti-slip studs 106a can be implemented on any metal plate 101 described herein.

[0235] Figure 20 A sole plate 100 comprising stacked metal plates 101 is shown according to some embodiments. In some embodiments, the sole plate 100 may include a first metal plate 101a and a second metal plate 101b, the two metal plates being stacked in a vertical direction. Figure 20 The first metal plate 101a extends out of the paper in the view. In some embodiments, the first metal plate 101a may completely overlap the second metal plate 101b. In such an embodiment, no part of the second metal plate 101b extends beyond the peripheral edge 105 of the first metal plate 101a.

[0236] In some embodiments, the second metal plate 101b may be disposed on the bottom surface 104 of the first metal plate 101a. In some embodiments, the second metal plate 101b may be disposed on the rear foot portion 140 of the first metal plate 101a. In some embodiments, the rear foot portion 140 may overlap most of the second metal plate 101b. In some embodiments, the rear foot portion 140 may completely overlap the second metal plate 101b.

[0237] In some embodiments, the second metal plate 101b may be spaced apart from the heel end (e.g., heel end 904) of the footwear article (e.g., footwear article 900), which forms part of the footwear article, by a distance that is 15% or more of the length of the footwear article. In some embodiments, the second metal plate 101b may be spaced apart from the forefoot end (e.g., forefoot end 902) of the footwear article, which forms part of the footwear article, by a distance that is 30% or more of the length of the footwear article.

[0238] In some embodiments, the second metal plate 101b may be coupled to the first metal plate 101a at the first bonding region 2010a and the second bonding region 2010b. In some embodiments, the first and second bonding regions 2010a-b may be arranged along the longitudinal axis L of the first metal plate 101a. P Above. The second metal plate 101b may be coupled to the first metal plate 101a by means of welding (e.g., arc welding, resistance welding, energy beam welding, ultrasonic welding, friction stir welding, oxyacetylene welding, or magnetic pulse welding), brazing and copper welding, rivets, bolts, snap-fit, press fit, seam, adhesive, electroplating, electrobonding, interference fit (e.g., pre-tight fit), 3D printing (e.g., using laser sintering or electron beam melting), etc.

[0239] In some embodiments, the first and second metal plates 101a-b may contain the same material. In some embodiments, the first and second metal plates 101a-b may contain different materials. In some embodiments, the second metal plate 101b may contain a material that is more rigid than the first metal plate 101a.

[0240] The second metal plate 101b can provide increased stiffness to selected areas of the sole plate 100. For example, Figure 20 The configuration shown can increase the stiffness of the portion of the sole plate 100 that is configured to occupy the middle and / or rear half of the footwear.

[0241] Figure 21 It shows some embodiments Figure 20 A sectional view of the midsole plate 100 – taken along line 21'-21'. (See figure) Figure 21 As shown, in some embodiments, a gap 2110 may exist between the first and second metal plates 101a-b. The gap 2110 may be formed by the curvature of the first metal plate 101a—in the portion configured to support the wearer's arch. In some embodiments, the second metal plate 101b may be substantially planar.

[0242] Figure 22 It shows some embodiments Figure 20 A sectional view of the midsole plate 100 – taken along line 22'-22'. (See figure) Figure 22 As shown, in some embodiments, the second metal plate 101b may cover one or more ridges 106b. In some embodiments, the second metal plate 101b may cover the one or more ridges 106b, forming a plurality of gaps 2110 at adjacent ridges 106b.

[0243] Figure 23This illustration shows one or more metal segments 2310 coupled with multiple metal plates 101 according to some embodiments. In some embodiments, the sole plate 100 may include multiple metal plates 101a, 101b, etc. For example, in some embodiments, the sole plate 100 may include a first metal plate 101a and a second metal plate 101b, such as... Figure 17A As shown. In some embodiments, the sole plate 100 may include a first metal plate 101a, a second metal plate 101b, and a third metal plate 101c disposed between the first and second metal plates 101a-b, as shown. Figure 17B and Figure 23 As shown. The first, second, and / or third metal plates 101a-c may contain elements relating to... Figure 17A -B describes the same or similar features to the first to third metal plates 101a-c.

[0244] In some embodiments, the first metal plate 101a may be configured to occupy the footwear article (e.g., Figure 9 The footwear article 900 shown represents all or part of the rear half. In some embodiments, the second metal plate 101b and the third metal plate 101c may be configured to occupy all or part of the front half of the footwear article. Thus, in some embodiments, one or more metal segments 2310 coupling the first and second metal plates 101a-b and optionally the third metal plate 101c may be disposed in the front half of the footwear article—which they constitute a part of. In some embodiments, the first metal plate 101a may extend to the heel end (e.g., heel end 904) of the footwear article—which it constitutes a part of. In some embodiments, the second metal plate 101b may extend to the forefoot end (e.g., forefoot end 902) of the footwear article—which it constitutes a part of the footwear article.

[0245] In some embodiments, the sole plate 100 may include one or more metal segments 2310 coupled to a plurality of metal plates 101. The one or more metal segments 2310 may be configured to be more flexible than the first to third metal plates 101a-c by means of shape and / or material.

[0246] In some embodiments, the first to third metal plates 101a-c and the one or more metal segments 2310 may comprise the same material. In some embodiments, the first to third metal plates 101a-c and the one or more metal segments 2310 may comprise different materials. In some embodiments, the one or more metal segments 2310 may comprise a more flexible material than the first to third metal plates 101a-c. In some embodiments, the one or more metal segments 2310 may comprise a thinner material than the first to third metal plates 101a-c.

[0247] In some embodiments, the sole plate 100 may include a first metal segment 2310a coupling a first metal plate 101a to a third metal plate 101c. Additionally, the sole plate 100 may include a second metal segment 2310b coupling a second metal plate 101b to the third metal plate 101c.

[0248] In some embodiments, the one or more metal segments 2310 may be coupled to the metal plate 101 by welding (e.g., arc welding, resistance welding, energy beam welding, ultrasonic welding, friction stir welding, oxyacetylene welding, or magnetic pulse welding), brazing and copper welding, rivets, bolts, snap-fit, press fit, seam, adhesive, electroplating, electrobonding, interference fit (e.g., preload fit), 3D printing (e.g., using laser sintering or electron beam melting), etc.

[0249] Figure 24 It shows some embodiments Figure 23 A sectional view of the midsole plate 100 – taken along line 24'-24'. (See figure) Figure 24 As shown, in some embodiments, one or more metal segments 2310 may be arranged on the top surface 102 of the metal plate 101 to which they are coupled.

[0250] In some embodiments, a gap 2320 may exist between the metal plates 101 coupled to the metal segment 2310. In some embodiments, the gap 2320 may extend from the proximal side to the side of the adjacent metal plate 101, such as... Figure 23 As shown.

[0251] like Figure 24 and 25 As shown, one or more metal segments 2310 may include a shape configured to provide increased flexibility at the gap 2320—relative to the solid metal plate 101. For example, see reference... Figure 25 Metal segment 2310 (e.g., second metal segment 2310b) may include a first wall 2312a extending diagonally away from gap 2320, a second wall 2312b extending diagonally away from gap 2320, and a third wall 2312c joining the first and second walls 2312a-b. The third wall 2312c may close the entrance to gap 2320 on the top surface 102. The first wall 2312a may be coupled to a metal plate 101 (e.g., second metal plate 101b), while the second wall 2312b may be coupled to another metal plate 101 (e.g., third metal plate 101c). Although Figure 25 The first, second, and third walls 2312a-c are shown as basic planes, but in some embodiments, the metal segment 2310 may include curved surfaces such that the first, second, and third walls 2312a-c are connected at rounded corners.

[0252] like Figure 25 As shown, when a force F is applied to the metal plate 101 coupled to the metal segment 2310, the metal segment 2310 can cause the metal plate 101 to buckle in the direction of the force. For example, Figure 25 The combination of the second metal plate 101b and the third metal plate 101c shown can be buckled more easily than when the second and third metal plates 101b-c form a single metal plate 101.

[0253] therefore, Figure 23-25 One or more metal segments 2310 shown can provide increased flexibility to specific areas of the sole plate 100. For example, Figure 23-24 The configuration shown maintains rigidity in the portion of the sole plate 100 that occupies the rear half of the footwear, while increasing flexibility in the portion of the sole plate 100 that occupies the front half of the footwear. This allows for flexion in the user's forefoot during athletic activities while supporting the user's midfoot and heel.

[0254] Figures 17-25 have shown various polymer and metal components that can be coupled to the metal plate 101. However, additional components may be coupled to the metal plate 101, either together with or in place of the various components shown. For example, in some embodiments, the heel stabilizing portion (polymer and / or metal) may be coupled to the metal plate 101 using any technology described herein for coupling polymer or metal components to the metal plate 101. As another example, the upper cage (polymer and / or metal) may be coupled to the metal plate 101 using any technology described herein for coupling polymer or metal components to the metal plate 101. In some embodiments, the upper cage may provide lateral support. In embodiments where portions of the sole plate 100 (e.g., the lateral wings and / or mid-wings 710, 720) extend to the upper of the shoe containing the sole plate 100, lacing fasteners (polymer and / or metal) may be coupled to these portions using any technology described herein for coupling polymer or metal components to the metal plate 101.

[0255] Figure 26 A draping simulation 2600 according to some embodiments is shown. For example... Figure 26As shown, the overlay simulation can be performed on a computing device using a first virtual model 2610 and a second virtual model 2620. The first virtual model 2610 may contain flexible virtual materials, such as virtual fabric. The second virtual model 2620 may contain rigid virtual materials, such as virtual outsoles or shoe lasts. The overlay simulation performed on the computing device can be used to overlay the first virtual model 2610 onto the second virtual model 2620. Various computer-aided design (CAD) programs can be implemented to perform the overlay simulation, including CLO3D®, Rhinoceros® 3D (e.g., running Grasshopper®), Houdini®, etc.

[0256] In some embodiments, the second virtual model 2620 may include the general shape of the final outsole. For example, the second virtual model 2620 may include desired curvature and / or protrusions reflecting the shape of the cleats and / or ridges. However, the virtual model 2620 need not include the exact shape of the final outsole.

[0257] Figure 27A -B illustrates a metal sheet 2700 according to some embodiments. The metal sheet 2700 may be a three-dimensional (3D) metal sheet including bumps 2710 and cavities 2720. The metal sheet 2700 may be based on a first virtual model 2610 in a cladding configuration (e.g., Figure 26 The shape of the first virtual model 2610 in the covering configuration can be derived to a computer numerical control (CNC) machine tool that at least partially forms the sheet metal 2700 and / or components for forming the sheet metal 2700 (e.g., die head, mold, etc.). In some embodiments, the sheet metal 2700 can be formed by stamping (single-step or multi-step), deep drawing, progressive sheet forming (ISF) (e.g., single-point ISF) and / or other sheet metal forming processes.

[0258] like Figure 27A As shown, the metal sheet 101 described herein can then be formed from the metal sheet 2700 using any of the methods described (e.g., stamping, deep drawing, and ISF). Since a portion of the metal sheet 2700 has already been formed into the general shape of the final metal sheet 101, this second step of forming the metal sheet 101 can be performed more easily.

[0259] Figure 28 A method 2800 is shown for manufacturing a sole plate (e.g., sole plate 100) for footwear articles (e.g., footwear article 900) according to some embodiments.

[0260] Step 2810 includes performing a draping simulation (e.g., draping simulation 2600) using a first virtual model (e.g., first virtual model 2610) and a second virtual model (e.g., second virtual model 2620). The draping simulation may include virtually draping the first virtual model over the second virtual model.

[0261] Step 2820 includes: forming a three-dimensional (3D) metal sheet (e.g., metal sheet 2700) based on the shape of the first virtual model in the covering configuration. In some embodiments, step 2820 may include: exporting the shape of the first virtual model in the covering configuration to a CNC machine tool configured to form the 3D metal sheet and / or components for forming the 3D metal sheet.

[0262] Step 2830 includes forming and / or cutting the 3D metal sheet. For example, the 3D metal sheet may be formed and / or cut to form a metal sheet for a shoe sole (e.g., metal sheet 101). In some embodiments, step 2830 may include at least one process selected from stamping, deep drawing, and ISF.

[0263] Method 2800 allows the general shape of the metal plate used for the sole plate (e.g., metal plate 101) to be formed in a first stage (including steps 2810-2820). The final metal plate can then be formed by refining the general shape in a second stage (including step 2830).

[0264] While various embodiments have been described herein, they are presented by way of example and not limitation. Based on the teachings and guidance presented herein, it will be apparent that adaptations and adjustments are intended to fall within the meaning and scope of equivalents of the disclosed embodiments. Therefore, it will be apparent to those skilled in the art that various changes in form and detail may be made to the embodiments disclosed herein without departing from the spirit and scope of this disclosure. The elements of the embodiments presented herein are not necessarily mutually exclusive but are interchangeable to satisfy various situations, as will be understood by those skilled in the art.

[0265] When a range of numerical values ​​including upper and lower limits is listed herein, unless otherwise specified in the specific context, the range is intended to include its endpoints, as well as all integers and fractions within that range. When a range is defined, this disclosure or the claims are not intended to limit the specific values ​​listed. Furthermore, when a quantity, concentration, or other value or parameter is given as a range, one or more ranges, or a list of upper and lower limits, this should be understood as specifically disclosing all ranges formed by any pair of any upper or lower limit values ​​and any pair of lower or higher limits, regardless of whether such pairs are disclosed individually.

[0266] These examples in this disclosure are illustrative and not limiting. Other suitable adjustments and modifications to various conditions and parameters that are obvious to those skilled in the art and commonly encountered in the art are also within the spirit and scope of this disclosure.

[0267] It should be understood that the wording or terminology used herein is for descriptive purposes and not for limitation. The breadth and scope of this disclosure should not be limited by any of the exemplary embodiments described above, but should be defined by the appended claims and their equivalents.

Claims

1. A sole plate for footwear products, said sole plate comprising: A single, integrally formed metal sheet, comprising a top surface, a bottom surface, and a sheet thickness measured from the top surface to the bottom surface; as well as A protrusion formed in the metal plate defines a cavity on the top surface of the metal plate and a protrusion on the bottom surface of the metal plate, and the protrusion includes a cavity surface defined by the top surface of the metal plate, a protruding surface defined by the bottom surface of the metal plate, and a wall thickness measured from the cavity surface to the protruding surface. The plate thickness is greater than or equal to 0.01 mm and less than or equal to 0.5 mm, and The wall thickness is greater than or equal to 0.01 mm and less than or equal to 0.5 mm.

2. The sole plate according to claim 1, wherein, The cavity has a maximum depth of 0.5 mm or more and 22 mm or less.

3. The sole plate according to claim 1, wherein, The deviation of the plate thickness is ±200 micrometers over 50% or more of the area of ​​the metal plate.

4. The sole plate according to claim 1, wherein, The deviation of the wall thickness of the protrusion is ±100 micrometers over 50% or more of the protrusion area.

5. The sole plate according to claim 1, wherein, The wall thickness is substantially equal to the plate thickness in the region adjacent to the protrusion.

6. The sole plate according to claim 1, wherein, The protrusion is included by the anti-slip stud.

7. The sole plate according to claim 6, wherein: The sole plate includes multiple additional protrusions; Each additional protrusion is formed in the metal plate, defining a cavity on the top surface of the metal plate and a protrusion on the bottom surface of the metal plate, and includes a cavity surface defined by the top surface of the metal plate, a protruding surface defined by the bottom surface of the metal plate, and a wall thickness measured from the cavity surface to the protruding surface, the wall thickness being greater than or equal to 0.01 mm and less than or equal to 0.5 mm; and Each additional protrusion is enclosed by anti-slip studs.

8. The sole plate according to claim 1, wherein, The protrusion is a ridge.

9. The sole plate according to claim 8, wherein, The maximum width of the ridge is greater than or equal to 0.5 mm and less than or equal to 4 mm, and the maximum width is measured on the bottom surface between the edges of the protrusions and perpendicular to the longitudinal axis of the ridge.

10. The sole plate according to claim 9, wherein, The ratio of the maximum depth of the cavity to the maximum width of the ridge is greater than or equal to 1:2 and less than or equal to 10:

1.

11. The sole plate according to claim 8, wherein: The sole plate includes multiple additional protrusions; Each additional protrusion is formed in the metal plate, defining a cavity on the top surface of the metal plate and a protrusion on the bottom surface of the metal plate, and includes a cavity surface defined by the top surface of the metal plate, a protruding surface defined by the bottom surface of the metal plate, and a wall thickness measured from the cavity surface to the protruding surface, the wall thickness being greater than or equal to 0.01 mm and less than or equal to 0.5 mm; and Each additional ridge is an additional ridge in a series of corrugated ridges.

12. The sole plate according to claim 11, wherein, The distance between the peaks of adjacent ridges in the series of corrugated ridges is greater than or equal to 0.5 mm and less than or equal to 6 mm.

13. The sole plate according to claim 12, wherein, The ridges in the series of corrugated ridges are arranged substantially parallel to the longitudinal axis of the metal plate.

14. The sole plate according to claim 1, wherein, The metal plate is made of at least one metal selected from steel, titanium alloy, aluminum and brass.

15. The sole plate according to claim 1, wherein, The metal plate is made of a metal with a density greater than or equal to 4 g / cc and less than or equal to 8 g / cc.

16. The sole plate according to claim 1, wherein, The metal plate is sized to extend from the forefoot end to the heel end of the footwear and has a mass greater than or equal to 30 grams and less than or equal to 80 grams.

17. The sole plate according to claim 1, comprising: A body-side wing extending from the side of the metal plate and a near-center wing extending from the center of the metal plate, the body-side wing and the near-center wing being integrally formed with the metal plate.

18. The sole plate according to claim 17, wherein, The side wings are bent in a direction above the top surface of the metal plate, and the near-center wings are bent in a direction above the top surface of the metal plate.

19. A footwear product comprising: vamp; as well as The sole plate according to claim 1 is coupled to the upper.

20. A method for manufacturing a sole plate for footwear articles, the method comprising: A protrusion is formed in a metal plate, the metal plate including a top surface, a bottom surface, and a plate thickness measured from the top surface to the bottom surface, wherein the plate thickness is greater than or equal to 0.01 mm and less than or equal to 0.5 mm. The protrusion defines a cavity on the top surface of the metal plate and a protrusion on the bottom surface of the metal plate. It includes a cavity surface defined by the top surface of the metal plate, a protruding surface defined by the bottom surface of the metal plate, and a wall thickness measured from the cavity surface to the protruding surface, the wall thickness being greater than or equal to 0.01 mm and less than or equal to 0.5 mm. The forming process includes processes selected from stamping, deep drawing, and progressive sheet forming.

21. The method of claim 20, further comprising: The metal plate is formed while the protrusion is being formed.

22. The method according to claim 21, wherein, Forming the metal sheet includes: forming a concave curvature in the peripheral region of the top surface of the metal sheet.

23. The method of claim 20, wherein, The sole plate includes: a side wing extending from the side of the metal plate and a mid-wing extending from the mid-side of the metal plate; the side wing and the mid-wing are integrally formed with the metal plate, and the method further includes: bending the side wing in a direction above the top surface of the metal plate and bending the mid-wing in a direction above the top surface of the metal plate.

24. The method of claim 20, wherein, The protrusion is included by the anti-slip stud.

25. The method of claim 20, further comprising: A variable plate thickness is formed in the metal plate; The process of forming a variable plate thickness includes selectively thinning the region of the metal plate adjacent to the region selected for forming the protrusion.

Images